Shiploaders Are Built for Decades of Heavy-Duty Operation
Shiploaders are large, rail-mounted steel conveyor systems used to load bulk materials onto cargo vessels in port terminals. But what needs to be considered when designing these complex technical systems that must operate reliably for decades in harsh conditions? ROXON’s Senior Product Manager Jutta Kettunen and Head of Projects Mikko Järvinen share their insights.
Moving Bulk Cargo from Storage to Ship Holds
When talking about cargo handling, people often first think of the colorful containers and cranes dominating modern ports. However, ships also carry bulk materials such as ore, sulfur pellets, urea pellets, various industrial process products, and concentrates from mining operations. This type of bulk material is typically delivered to ports by rail before being loaded onto ships using ship loaders.
“When handling large vessels that need to be loaded quickly to minimize time spent at berth. To reach this, the material is normally unloaded from intermediate storage facilities at the port to shiploader. In practice, the material is dumped or discharged from for example the railcars into receiving hoppers, and from there it’s conveyed into storage until it’s time to load the vessel,” explains Jutta Kettunen.
When the ship is ready for loading, the ship loader moves along rails on the quay under operator control, positioning itself longitudinally alongside the vessel. From storage, the material travels via conveyor belts into the ship loader. The loader then transports the cargo along its conveyor systems towards the vessel. The boom that extends over the vessel can be adjusted both vertically and horizontally, allowing even distribution of cargo within the ship’s holds without repositioning the entire loader. A telescopic loading spout guides the cargo precisely into the desired location inside the hold. Loading chute also has a big role in dust control when dealing with dusting materials. Once the vessel arrives, loading continues non-stop until the ship is fully loaded.
Designing Shiploaders Requires Multidisciplinary Expertise
ROXON is currently completing a shiploader delivery for a port in Australia. For Mikko Järvinen, these demanding projects make the work especially interesting:
“Designing these solutions constantly challenges us. Every delivery is a complex, tailored system built to meet the customer’s specific requirements. Delivering a high-quality and durable system requires extensive engineering skills and experience.”
Typically, a shiploader delivery takes about two years, with the first year dedicated to design. ROXON’s project department employs 50 people, and subcontractors are used as needed for both design and construction.
“The manufacturing location depends on the delivery destination, since shipping such large and complex equipment would otherwise become too expensive. Our engineers identify and select local subcontractors, lead the construction process, and supervise the quality of subcontractor work throughout the project,” Mikko explains.
Every shiploader is a custom solution, as factors like quay width, sea level, vessel size, and rail gauge vary from port to port. Additionally, the loader must integrate into the port’s overall operations.
“For example, trucks and heavy equipment must be able to pass underneath the shiploader. When not in operation, the boom is swung or lifted into a parked position and locked, freeing up 200 meters of quay length for other port activities,” Jutta adds.To give a sense of scale, Jutta shares specifications for one of ROXON’s shiploader deliveries: “The rail gauge is 12 meters wide, allowing clearance for trucks and equipment beneath. The loader’s height is 30 meters, and its boom extends 25 meters from the main structure. The total weight of the machine is 500 tons. Electrical automation plays a significant role, and the system includes numerous components across various subsystems.
The mechanical parts list alone includes over 13,000 individual line items.”
Designed for Long Service Life in Harsh Environments
ROXON designs its shiploaders in accordance with crane standards, and all equipment is CE-certified. The steel structures are dimensioned for a 25-year service life, which can be extended through regular maintenance — a critical factor for ensuring operational safety.
“Seaside conditions can be extreme. The salty air causes significant corrosion, many ports experience severe storm winds, and some are located in seismic zones. Reliability across different conditions and serviceability must both be considered in design. These are massive machines with long booms, so it’s essential to be able to inspect even internal structures for corrosion damage. We design the loaders so that internal inspections and access to support steel structures are possible,” Jutta and Mikko emphasize.
Maintaining durability requires strict maintenance and inspection routines. After each vessel is loaded, the equipment undergoes a cleaning inspection. More extensive service inspections and maintenance are carried out while the machine is parked while the intermediate storage is being replenished. The delivery process of ship loaders includes training for the customer’s personnel on operation, maintenance, and inspections.
Even under heavy use, well-maintained shiploaders remain operational and can be modernized. Mikko provides an example:
“We perform numerous modernization projects that extend service life. For example, we recently helped a customer whose loader dates back to the 1960s. It was modernized once in the late 1980s to early 1990s. And a few years ago we replaced the undercarriage structure running on the rails and, the following year, the boom conveyor.”
Customers appreciate ROXON’s ability to support investment decisions through detailed calculations. “We investigate production challenges and map out different solution options along with their schedules. We don’t offer standard solutions, but rather customized systems based on strong process know-how and customer-specific requirements,” Mikko summarizes ROXON’s approach.