Heavy Duty

40 years' experience

igus® is a specialist in the area of plastic research and can look back on 40 years of experience here. Specially developed high-performance plastics enable the use of igus® e-chains® in almost all application areas. Whether it be damp, dirt, chips, heat or cold, we have the solution for every requirement and completely avoid the use of steel or other metals in our e-chains® materials. In an increasing number of heavy duty areas, steel systems are being successfully replaced by igus® plastic e-chains® due to their exceptional suitability.

 

State your requirements and we fulfil them:

Corrosion-free

Cost-efficient, modular design

Long life at minimum maintenance costs

Resistance against dirt, chemicals and high temperatutres

Proven, tested material with igus® system garantee

Low weight with high stability

TÜV certified



That is only a few points that we consider when selecting and designing your "heavy-duty system". See all the things for yourself that are possible in the heavy-duty area with igus® - plastics for longer life®.

2015 Updates for heavy-duty areas

Quiet, fast, low wear, durable …

Reduce drive power for moving energy chains® - with the E4.1 standard kit – E4.1 rol e-chain®

Quiet, fast, low wear, durable …    

4240AX

Special e-chain® for applications with fine dust

4240AX    

divisible separators

To fill the e-chains® more easily and more effectively,

divisible separators    

36-month guarantee … for chainflex®

With our unique igus® guarantee for ALL chainflex® cables we are providing predictable security for 36 full months

36-month guarantee … for chainflex®    

… 40 % lighter …

High energy efficiency thanks to low driving forcesand use of lighter e-chains® Conductor cable made of special material CCA

… 40 % lighter …    

… CAT7 Ethernet cables for all movements …

Bus cables in the Ethernet area are becoming increasinglyimportant.

… CAT7 Ethernet cables for all movements …    

... 400 x new.

Now choose from 7 quality levels and over 3200 drive cables with guaranteed service life

... 400 x new.    

… good to shafts … in case of heavy duty

iglidur® Q 290 shows outstanding service life in robust swivel applications, as they are frequently found in some agricultural machinery, especially on "soft" waves (eg galvanized). The duty of the shafts is minimal.

… good to shafts … in case of heavy duty    

... iglidur® TX1 ... stable ...

Heavy duty: iglidur® bearings up to 200 Mpa

... iglidur® TX1 ... stable ...    

DryLin® R linear plain bearing

Open, enclosed, split and self-aligning

DryLin® R linear plain bearing    
iglidur® G  

iglidur® G

the jack of all trades: the globally best selling iglidur® plain bearing

Energy chain in open-air storage facility for alumina production

Design and installation of a roller energy chain for outdoor use on a bauxite stockpile - an environment with extremely harsh ambient conditions.

Energy chain in open-air storage facility for alumina production    

Assembly robot

This robot lifts heavy work pieces weighing up to 1.7 tons.

Assembly robot    

Tunnel building crane

Tunnel construction is generally space constrained, thus requiring compact components.

Tunnel building crane    

Coal transport system

The motors in this system need a large number of cables.

Coal transport system    

Working platform

This new design permits a variety of multiple tunnel construction processing steps to be performed by one machine.

Working platform    

Transporter for steel coils

Heavy steel coils are transported here. The energy supply is recessed into the floor.

Transporter for steel coils    

Casting implements for car rims

Automotive wheels are manufactured here using the gravity die casting process.

Casting implements for car rims    

Zinc electrolysis, bathing halls

The sulfur fumes generated by the electrolysis are highly corrosive and corrode the customer's system. igus® products withstand these extreme conditions.

Zinc electrolysis, bathing halls    

Rocket launch site

The igus® products used are designed for mobile applications in such a way that it features a long life and functions absolutely reliably.

Rocket launch site    

Heavy load transporter

Rugged Energy Chains® are technically and economically the first choice in the construction of an extendable heavy load transporter.

Heavy load transporter    

The longest travel with plastic energy chain

The complete length of the E-Chain®'s travel at 615m clearly exceeds the previous record holder at the Singapore harbor.

The longest travel with plastic energy chain    

Taconite mine

The next long distance with a plastic chain: 550 m.

Taconite mine    

Tile factories

Extreme stressing from tile dus in the building material industry.

Tile factories    

Road construction

An asphalt finisher applies hot and cold bitumen mixtures. The E-Chain® supplies the front area of the vehicle and is exposed to extreme dirt.

Road construction    

Heavy fillings

E-Chains® for heavy-duty uses: Guiding of the supply cables of a quenching chamber, which moves toward the linked vacuum ovens.

Heavy fillings    

Power plants

Safe function despite extreme dirt accumulation: Parallel facility in the waste-to-energy plant

Power plants    

Waste incineration plant

Safe application of E-Chains® in waste incineration plant

Waste incineration plant    

Tunnel construction

Tunnel boring in defined sections with the assistance of an igus® E-ChainSystem®, which guides the essential hose cables section by section.

Tunnel construction    

Steel mills

Temperatures up to 1200°C or lashing blaze from the oven pose high demands on the plant.

Steel mills    

Waste incineration plant

Application of E-Chains® in waste incineration plants: Strong dirt with high metal content and 300,000 t waste every year.

Waste incineration plant    

Thermal application

igus® roller chain in power plant application: Strong dust, application of the chains in trolley and crane, the crane drive arranged in the opposite direction.

Thermal application    

Coal-fired power plant

Operation in severe dust. The energy chains are employed in trolley and crane, the crane drive arranged in the opposite direction.

Coal-fired power plant    

Offshore industry

High pressure hydraulic hoses + power cables. Extreme weather environment but this chain delivers and delivers.

Offshore industry    

Coal-fired power plant

E-ChainSystem® for a coal unloader. Operating since three years without any problem.

Coal-fired power plant    

Ship unloading crane

Application of E-Chain® systems in ship unloader

Ship unloading crane    

Offshore industry

Tube handling plant provides an igus® plastic E-Chain®. E-Chain® ensures high stability and reliability in pipehandling.

Offshore industry    

Steel works

Extremely difficult conditions: Dirt and dust, heavy filling, long travel and high temperatures. The system functions since 2003.

Steel works    

Mining industry

The E-Chain® is located in the area of the rotating assembly in a bucket-wheel excavator.

Mining industry    

Lignite quarrying

The wagon makes a 180° turn and empties into the coal bunker. The energy chain secures the energy supply of the rotating device.

Lignite quarrying    

Composting plant

Heat, abrasive dirt, high atmospheric moisture: These are only some of the ambient conditions in a composting plant.

Composting plant    

Sewage treatment plant

Energy chain system instead of cable drum - Smooth operation at the sewage treatment plant since 2000

Sewage treatment plant    

Excavator

The plain bearings run without lubrication and without significant wear and tear
in the very harsh environmental conditions of construction machinery.

Excavator    

Concrete pipe cutter

Concrete cutting machine in extremely heavy-duty operation since three years free of maintenance.

Concrete pipe cutter    

Ship unloader

441m travel with E-ChainSystem® in Malaysia: Reduction of tensile strengths by about 75%, E-Chains® with weight up to 2.5 tons.

Ship unloader    

Sewage treatment plant

The used igus® products prove themselves till today and drastically reduce the maintenance input.

Sewage treatment plant    

Sewage treatment plant

The existing system with a motor cable drum proved to be not resistant enough in the difficult outdoor environmental conditions, and was replaced by a flizz® system.

Sewage treatment plant    

Piling and drilling rigs

The driven boring machine produces extremevibrations and heavy soiling duringthe work process.

Piling and drilling rigs    

Dismantling tool

During the removal of a nuclear power plant, 14 metre-high steel tanks are milled into small metal chips. At the same time, a milling cutter, which is used as a dismantling tool, must be inserted precisely into the tank from above.

Dismantling tool    

Maintenance-free operation for 8 years

The energy chain employed in 2000 runs smoothly.

Maintenance-free operation for 8 years    

Indoor and outdoor cranes

Outdoor cranes must withstand severe weather conditions. Even indoor cranes work under ever-changing humidity conditions together with very high temperatures.

Indoor and outdoor cranes    
More examples for difficult and extreme applications
 

Norway. Standing application for Aker Kværner Maritime Hydraulics AS.
Assembled for the half-immersible platform West Edrill.

 

Germany. Dismantling of research reactor Karlsruhe. The dismantling of a nuclear power plant with a zigzag chain.

 

Czech Republic. Lhoist a.s. Modular steel design in lime works.

 

Czech Republic. Fully enclosed E-Chain System® right on the coal conveyor.

 

Czech Republic. Porici company CEZ a.s. Energy supply for coal carriage.

 

Czech Republic. Ventilating machine in the Bunker of a power plant.

 

Midland Bricks in Australia is the largest brick manufacturer worldwide! Three energy chains have been in operation round the clock since three years and still looks the same as it was on the first day.

 

Maanshan steel- and ironworks: High temperatures, large loads, heavy dust and high tempo.

 

voestalpine Stahl Donawitz: High dirt accumulation during scaling of the rails to be milled.

 

Slovakia, aluminum factory. Error-free operation since 9 years. Travel 62 m, Speed 0.3 m/s.

 

Czech Republic. Ventilating machine in lime works.

 

Germany. BASF in Ludwigshafen, premises for fertilizer, since 1998, E-Chain®: 4040.32.250.0

 

Austria, Niklasdorf, ABV, district heating plant

 

RTG in India, travel: 22 m, E-Chain®: 5050.30.550.0, customer: Kalmar, for ATM

 

Plaster dust

 

Quayside crane with igus® E-ChainSystem®. Long travels up to 800 m are possible.

 

Norway: E-Chain® with Chainflex® in a truck wash. In contact daily with street dust and mud. Chainflex® cables perform exceedingly well.

 

Shagang, steel- and ironworks in China. High temperatures, high speeds, heavy dust.

 

Czech Republic. CEZ a.s. Modular design for the energy supply of a coal excavator.

 

Long travel in a bulk goods storage

 

Crane builder Noell in Panama. Application: RTG; Travel: 19.5 m; up to 60 m/min.

 

Czech Republic. Shipyard Kresice-Loubi; Refueling point for cargo ships.

 

Compost mud

 

Meishan steel and ironworks, Nanjing in China. Crane, heavy dust, high speed.

Further interesting applications from extremely diverse areas can be found here.

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