DROMEC Winches develops ingenious winch system

Cordeel Netherlands is involved in a wide range of construction projects, from residential to commercial. They work in various sectors, focusing on sustainable building and customized solutions for new constructions. For the Clubhouse Boompjes project in Rotterdam, WVH Facade Technology approached DROMEC Winches to develop an ingenious winch system for the construction of the residential towers.

Winch System for Residential Towers

Cordeel Netherlands, in collaboration with WVH Facade Technology, is constructing two residential towers in Rotterdam, with heights of 100 and 70 meters. The bare concrete structures are being further developed using finished facade elements. These 1200 kg facade elements are lifted into place using a DROMEC winch system. What sets this system apart is the bottom-up assembly of the residential tower, with each floor being progressively expanded in 5 steps.

Electric Drive

WVH designed the residential towers with floor grooves to facilitate the lifting of facade elements. On each floor, two winch systems with a combined lifting capacity of 2 tons are installed in lifting frames. These lifting frames can extend up to 1.5 meters and are stabilized. On the ground floor, two tagline winches are in place to maintain Constant Tension on the element in the correct position. As the element reaches its destination, it is slid into place using the lifting frames. DROMEC Winches also integrated a third lifting frame into this design, providing the ability to lift ceiling elements. All winch systems are electrically driven, which is of significant environmental importance in cities like Rotterdam.

Constant Tension

In this ingenious winch system, the control system plays a pivotal role, as all components must work in harmony to ensure a safe working environment. The three lifting frames can be operated simultaneously with a single joystick, and they can also be controlled individually for fine-tuning the lifting operation. The Constant Tension tagline winches on the ground floor can be operated remotely through the control system.

Gijs, the engineer, states,
“The winch systems working together allow for very precise positioning of facade or ceiling elements through Constant Tension. This is especially significant in urban areas with high-rise buildings.”

Compact and Safe

The winch system is designed to be highly compact and can be placed in the construction elevator. Each lifting frame, weighing 1000 kg, is equipped with wheels for easy mobility. The winch system has a cable storage capacity of 110 meters and is secured with a Dyneema chain. In case of cable breakage, the Dyneema chain serves as a safety measure. With this winch system, DROMEC Winches has once again elevated the bar for their projects.

DROMEC Constant Tension machines

DROMEC Constant Tension machines are known for their multifunctional spooling capabilities. These machines find applications in various market sectors, ranging from spooling and unspooling electrical cables to winding heavy tow wires for offshore vessels. Over the years, DROMEC has developed a diverse range of winches in terms of power and size.

Electric Drive

What makes DROMEC special is the deliberate transition to exclusively using electrically powered systems a few years ago.

According to Cees Drost,
“This transition has brought DROMEC two significant advantages. Firstly, we have reduced environmental impact by eliminating diesel emissions. Secondly, our machines can be controlled with much greater precision, allowing even highly sensitive umbilical wires to be spooled without risk, thanks to integrated data logging. Furthermore, our system offers the capability to generate electricity during the project itself. These machines are often employed in opposite position to other winches or reels, where customers require specific tension requirements. During spooling, we can switch the motor to act as a braking dynamo. This not only results in emissions savings but also energy savings, especially in situations where work is predominantly carried out indoors. In the absence of a power source at a project site, there is always the option to activate a small and energy-efficient generator, a requirement in less than 5% of projects.”

Tensioning

DROMEC primarily sees these machines being used in markets such as rigging companies, where long lengths are converted into customer-specific lengths for both steel and fiber ropes. Another application involves replacing steel cables on cranes and pile drivers, where old wires are first spooled onto an empty reel before the new or clean cable is wound under tension on the machine. DROMEC spooling machines are also widely used for wire inspection. In this process, wires are degreased, inspected, re-greased, and immediately spooled under tension on the winch, all in a single back-and-forth motion.

Customization

Upon request, DROMEC Winches can offer more extensive customer-specific features, such as Active Heave, line measurement, high-speed capabilities, or specific pulling forces. DROMEC spooling machines vary in pulling force, with the smallest machine having a pulling force of 60 kg, and the largest machine exerting a pulling force of 42 tons (at the core). For newly developed spooling machines, two essential parameters are always considered: the maximum weight of the reel within the machine and the desired pulling force. At DROMEC we are always up for this challenge!

DROMEC Winches develops winch systems

Kooiman Marine Group is an independent group of multi-disciplinary shipbuilders in the maritime sector. On behalf of Kooiman Marine Group, DROMEC Winches has developed specialized winch systems for the dredgers Maas and Mursy operated by Van Oord.

Active heave

On both sides of the dredgers, there are 25-meter-long injection pipes used to dislodge the seabed with water jets, allowing it to be carried away by the water’s flow. The pipes are lowered into the water at an angle using the winch system. The winches are equipped with active heave, which ensures that the pipe remains at the same height above the seabed, compensating for wave motion. Both the Maas and the Mursy are equipped with two winches.

Absolute encoder

The electric hoist winches each have a 110 kWh electric motor. The working load for lowering the pipes is 30 tons, with a peak load of up to 40 tons. The holding force of the winch system is 45 tons. In the event of a cable breakage, the ship can pull the winch up to the waterline and proceed to repair. What makes this system unique is the interconnection of the winches through an absolute encoder that records the motor positions. This synchronization allows the pipes to be lifted in parallel. When combined with active heave, this means that the system is constantly in motion. The active heave capacity is 20 tons, with a wave height of 400 mm amplitude within 7 seconds.

Jan Willem, engineer: “The control of the winch system is truly exceptional for these Van Oord vessels. We have had a positive collaboration with Kooiman Marine Group, with clear agreements in place. They entrusted us with the development of this system, and as DROMEC Winches, we have delivered on our promises. It’s satisfying to know that we are now building a series of 4 winches for 2 new vessels once again.”

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Team DROMEC

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Dynamic and Innovative in winches, winchsystems, controls and software. With our enthousiastic team, we develop  from small till  very big & complex systems with the highest demands in terms of safety and ease of use. We also work very closely with certified body’s as DNVGL, BV, ABS, Lloyds so your winches and systems can be completely certified at our own company together with you.

It often starts with a good idea, preferably on a piece of scrap paper. After an initial consultation, we prepare one or more proposals, including a target price and preliminary drawing. Your idea or problem, always remains central in this. If the feeling on both sides is good, we start. Thanks to our own inhouse developed and written project software, your project stays in the picture and under control from start to finish, including the planning and delivery time. We are LloydsRegister ISO 9001 certified.