Designed, built, and commissioned a remote-operated constant tension winch system to replace unreliable air-powered units during offshore lifting operations. Engineered for heavy-duty taglining with automated tension control and operator safety in mind—delivered in just 45 days.
The challenge
A first-time offshore client needed a safer, more reliable solution for taglining during complex marine lifting operations. Their previous reliance on conventional air-operated winches had led to repeated reliability issues and required operators to work dangerously close to tensioned wire lines.
The client needed:
- A robust hydraulic winch system to handle taglining during 1300-tonne offshore lifts.
- Fully remotely operated for improved safety by removing the operator away from the winches
- A system that could maintain constant line tension in a dynamic offshore environment.
The client discovered I&M Solutions online after researching similar systems, and chose us based on our technical capabilities, responsiveness, and ability to custom-engineer a high-capacity solution from the ground up.
The solution
I&M Solutions designed a complete constant tension winch package tailored for offshore use. The system included:
- Two 10-tonne hydraulic winches with constant tension functionality.
- Custom operator console with remote controls and manual override capabilities.
- Power pack and fairlead system for reliable deployment and rope handling.
- Factory Acceptance Testing (FAT) with a simulated load and on-site client approval.
- Commissioning and training support, including load testing, commissioning and handover
Every component was built for offshore resilience and precise control—enabling safe handling of extreme loads without placing operators in the line of fire.
Project delivery & execution
The full system was designed and built in just 45 days and deployed offshore for a 3-month hire period.
One of the key challenges was making sure the system could perform consistently in harsh offshore conditions while remaining easy to control from a safe distance. I&M addressed this by developing adjustable tension settings, a remote console, and intuitive controls that allowed operators to respond to changing conditions.
The project went smoothly from start to finish. With full in-house design, fabrication, and testing, We controlled every step, ensuring performance, safety, and timely delivery.
Results & outcomes
The impact was immediate and measurable:
- Enhanced operator safety: Remote operation removed the need to work near live wire lines.
- Flawless offshore performance: The system operated seamlessly under load.
- Time and labour savings: the constant tension console allows one operator to control both winches simultaneously.
- High client satisfaction: The client reported the system worked exactly as intended and praised I&M’s delivery and support.
Why it matters
This project highlights our ability to engineer and deliver complex offshore systems with speed, precision, and safety at the forefront.
Instead of relying on outdated or underperforming equipment, this client now has a high-performing constant tension solution tailored to their environment, and built to protect personnel and increase operational efficiency during high-stakes marine lifts.
If you’re looking for a custom-built, high-capacity system that performs where it counts, get in touch with I&M Solutions—we’re ready to design, build and deliver exactly what you need.