Sunbelt Rentals UK & Ireland operates one of the largest accommodation hire fleets in the country, supplying welfare and modular units across the construction sector. As demand continues to grow, the Accommodation division reviewed how its 32-foot cabins were being moved through workshops at nine depots.
The previous method relied on a diesel forklift at one end and a fixed-castor bogie at the other. In compact yards and single-door paint shops, this approach needed three to four people per move, which restricted load visibility, increased safety risks, and tied up a forklift that was needed elsewhere.
Sunbelt Rentals UK & Ireland set out a clear objective: make movements safer, reduce manpower, improve throughput, and maintain control.
Cabins weighing 3,000–6,500kg must be positioned accurately on stabilised bogies, moved across uneven yards, and up a 4° incline into paint ovens. With clearances as low as 12–18 inches either side, the team wanted operators to have full visibility while keeping people away from the load.
There was also a desire to remove diesel machinery from enclosed workshops to improve air quality and reduce unnecessary engine hours, protecting staff and decreasing environmental impact.
Sunbelt conducted trials at multiple locations to reflect different site layouts and ensure product suitability. Alternative products were also evaluated in like-for-like tests which, according to the team, "struggled with the weight and movement." Our MasterMover PS800+ LH, rated for 8,000kg of tractive power, out-performed consistently across the challenging surfaces and gradients at the Sunbelt depots.
Crucially, the ability to operate the machine remotely is what Sunbelt needed most – allowing a single trained operator to stand clear of the load and maintain line-of-sight to both sides of the cabin. "We liked the idea of the remote control... it gave much more visibility for the operator," the team notes. This is especially valuable where single-door ingress and egress require precise manoeuvring.
After deciding to move ahead with our PowerSteered tugs, we supported a structured rollout. Each depot received a tailored training package to suit their specific workflow and site layout. This transition removed the need to bring diesel forklifts into paint workshops and reduced the headcount for each move from three to four people down to a single operator.
Sunbelt's team have reported that the PS800+ LH easily handles the 4° inclines to paint ovens, taking on both indoor and outdoor conditions as well as challenging, uneven terrain throughout the sites.
The results for Sunbelt were instant. With the PS800+ LH, the process is now controlled by one person with full visibility, while forklifts and their licensed drivers are freed up to focus on other value-added work such as cabin preparation.
By reducing the process down from a 3–4 person task to a single operator, the team have been able to benefit from increased productivity with 75% of the team now able to focus on higher-value activities that get cabins moved through much quicker.
Additionally, the reduction in forklift time has significantly boosted safety for operators in these high-traffic areas as well as reducing the diesel emissions, further protecting staff throughout the site.
After such an impactful project result, our engineering team are already collaborating with Sunbelt on an additional attachment for the PS800+ LH to extend its capability to other modular buildings.
This project with Sunbelt Rentals highlights how a very simple equipment switch can turn operations around. Opting to introduce electric tugs into a site's fleet is a quick, effective way to create forklift-free zones that protect staff in pedestrianised areas and free-up licensed drivers to focus on tasks that deliver value.
Sunbelt has proven that taking a safety-first approach also delivers impressive productivity gains that compound to boost efficiency and sustainability efforts.
Want to learn more about this project? Check out the video below or explore our range of PowerSteered electric tugs capable or moving heavy loads up to 70,000kg.