100 kN Barge Loader Winches
100 kN Barge Loader Winches
A complete set of 100 kN electric barge loader winches built in Yatala for coal barge loading, covering main luffing, shuttle, take-up and chute tilting duties on three-phase power with heavy-duty steel construction.
Barge Loader Winches Project Overview
Custom-built 100 kN electric winches for coal barge loader hoisting and positioning
A complete set of winches for a pair of coal barge loaders, covering the main luffing winch that raises and lowers the loading boom, the shuttle winch that traverses the conveyor, the belt take-up winch and the chute tilting winches. Each machine was rated around a 100 kN duty with 100 m of rope and matched to the speeds and travel of the loader it drives. The full set was designed and built together so the motions work as one system, then packed into shipping containers at Yatala with wire rope drums, rigging kits and spares for delivery to the client port.
Key Project Highlights
Exceptional performance, precision and reliability
This set of 100 kN barge loader winches was engineered for continuous coal loading duty on a bulk export terminal. Headline specifications:
100 kN
Rated Capacity
100 m
Rope Storage
Mining
Industry
Hoisting
Application
Design & Manufacturing Considerations
Built for durability and efficiency in demanding environments
Specified with the loader designer for every motion on the machine and assembled in-house at Yatala. Key design considerations:
Heavy-Duty
Steel Frame
Material Choice
Electric
3-phase
Power System
100 kN
Rated Line Pull
Drive System
Manual
Standard control
Control / Brake
Operational & Technical Breakdown
An in-depth look at the 100 kN barge loader winches' performance and technical capabilities
Every winch in the set shares the same design approach: a fabricated steel frame with machined drum, gearbox and brake mounting faces, a grooved drum sized for the rope length and layers of its motion, and a spring-applied fail-safe brake that holds the boom, shuttle or chute whenever power is removed. Grease points, inspection covers and rope anchors are positioned so maintenance crews can service each winch from the loader walkways.
Drive selection was matched to each motion. The luffing winch carries the heaviest static load and the tightest speed control, the shuttle winch runs the longest travel, and the take-up winch has to keep constant tension on the belt as it stretches. Motors, gearing and drum diameters were chosen for those duty cycles, the whole set was load tested at Yatala, and each winch was crated into a container with its rope drum and lifting gear for the sea freight leg.
Other Winch Applications
Versatile winching solutions across multiple industries.
Beyond mining, a coordinated set of luffing, shuttle and take-up winches suits ship loaders, stackers and conveyor booms in any bulk handling terminal.
Ship loader, conveyor boom and gantry winches at ports and bulk terminals – heavy-duty electric drives sized for continuous loading cycles.
Luffing and positioning winches for intake screens, gates and material handling at water and power plants – three-phase electric drive with fail-safe braking.
Project Conclusion
The 100 kN barge loader winch set shows ACW delivering a complete, export-packed winch package rather than a single machine, with every motion engineered to work with the others. Designed, built and tested in Yatala by Australian Certified Winches.
Like every winch we build, it was designed to AS 1418, the Australian Standard for cranes, hoists and winches, and signed off by our RPEQ-registered engineers before load testing in Yatala.
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- 2/14 Freight Street, Yatala, QLD 4207
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Frequently Asked Questions
Common questions about winch sets for barge loaders and bulk loading equipment.
Which motions on a barge loader need a winch?
On these loaders the boom luffing, the shuttle conveyor traverse, the belt take-up and the chute tilt are all winch driven. ACW supplied a purpose-built winch for each motion so the loads, speeds and brake ratings suit that job rather than using one generic unit everywhere.
Why is the luffing winch treated differently from the others?
The luffing winch holds the weight of the boom and conveyor at all times and has to lower under full control. It received the largest drum and gearbox in the set and a brake rated well above the maximum boom load, with speed control tuned for smooth starts and stops.
How does a take-up winch keep the belt tensioned?
The take-up winch pays rope in or out to move the take-up pulley as the belt stretches and relaxes, holding a constant tension so the belt does not slip on the drive drum. Its brake and gearing are chosen for holding duty rather than speed.
How were the winches shipped to site?
Each winch was mounted in a transport frame, packed into a shipping container with its wire rope drum, rigging kit and spares, and secured for sea freight. Lifting slings and shackles were supplied so the loader crew could install the winches on arrival.
Can ACW supply winches for an existing loader upgrade?
Yes. ACW can survey the existing machine, match drum sizes, rope speeds and mounting footprints to what is already there and supply one winch or the complete set, load tested and certified before dispatch from Yatala.
Loading Barges?
Tell us the loader geometry, the duty cycle and the loads on each motion. Our RPEQ engineers will size a certified set of winches for it.