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Land & Water
Land and Water are the UK’s largest independent marine civil engineering specialist, operating in the complex environment where land and water meet. The company is dedicated to delivering effective solutions for maintaining and managing the UK’s costal, canal, and river networks. The company reached out to organise a meeting at our workshop in Llandovery to discuss an idea they wished to explore further. We were eager to learn more as we couldn’t see any forestry connection, and it is always exciting to face new challenges. Land and Water had viewed our social media posts on the CE approved M3 Innovations Winches that we design and manufacture. The company thought that this could offer an effective solution for their dredging operations.
Dredging
Dredging is by no means a new technology, it can be traced back to ancient civilisations, such as the Egyptians, who used simple tools like buckets and baskets, to remove sediment from rivers and canals. Evidence shows that the Romans also practiced dredging to build ports and canals, further developing the techniques used at that time.
The 18th and 19th centuries marked a crucial turning point in dredging history, with the introduction of steam powered machines and mechanical excavators. These innovations enabled more efficient removal of sediment and materials from waterways, supporting the expansion of ports, the building of canals, and land reclamation. Important projects, like the construction of the Suez Canal, depended heavily on advanced dredging techniques.
In the 20th century, dredging technology continued to progress, with the introduction of suction dredgers that facilitated large-scale projects, including coastal defences and land reclamation. Dredging remains essential for trade, flood defences, and environmental management, addressing challenges such as sedimentation and maintaining navigable waterways.
Vision
Land and Water ‘s proposal was that a M3 Winch would be mounted in place of a digging bucket on an excavator and would be used to pull the 10m³ dredge box on a winch line between two floating pontoons. The excavator would be on one pontoon, with the pulley on the other. This system is similar to a high-lead system used in forestry, featuring a main line and a haul-back line that work together to move the dredge box backwards and forwards between the two pontoons. Based on a traditional dredge box design, similar to what was operated by mechanical winches on traction engines in the past, the dredge box had an ingenious system, a swinging plate that remained closed during collection, and opened when being hauled back, which reduced water resistance on the empty journey home.
As nothing like this had been attempted before, several hours of discussions took place. The system at the time, used two winches on either side to pull the dredge box backwards and forwards. John suggested compiling some drawings with information, but several of the Land and Water team were so convinced by the concept, that John was encouraged to build it. Shortly after the team had departed, John was in the workshop meticulously sketching designs and preforming calculations; the M3 dredging winch project was officially underway.
The design was agreed upon, but unfortunately Covid hit, supply chains were disrupted, and the build took longer than expected. In real time, it took around seven months from design to completion. John has been involved in designing and manufacturing winches for over 25 years, so he has a clear understanding of what is required for a successful dredging operation.
The double drum M3 winch was built with a pulling force of 16 tonnes. The main line uses an 18mm cable with a drum capacity of 400 metres. The haul-back winch was restricted to an 8 tonne pull because it required double the cable length and used a smaller diameter cable. The CE approved M3 winch is a non-invasive modification to a base machine, in this case a Hitachi ZAXIS 250LC 25 tonne excavator. A secondary Magard sheet was installed over the front window for added operator protection. The monitor for the camera system on the winch drums and electronic winch controls, were integrated into the existing joysticks and switches.
Prototyping
The concept worked, but after initial testing, John thought it was probably about 80-90% what he wanted and would have liked to have taken it back to the workshop for modifications. Land and Water just wanted to keep using it. A real plus for John was having Richard Waters, Land and Water’s engineer, there, as he is a hands-on person and genuinely knowledgeable, and could keep John updated with helpful feedback on the winch’s performance.
Fukes’s winches are constantly evolving, which allows them to update customers existing winches. John comments “one of our latest innovations was designing our own hydraulic valve control block, which maintains optimal tension on both drums when operating in opposite directions. This prevents any slack in the winch cables during use, although both winches can be controlled separately if needed.”
Although the M3 winch was preforming well, the addition of the control unit last year, has taken it to the next level and exceeded all expectations. The modern use of a M3 winch, mounted to a hydraulic excavator in conjunction with the dredge box that had an adjustable blade is currently expected to be granted a full UK patent by the end of 2025.
Ecosystems
Land and Water are currently working just off the coast of Lymington, and it is a twenty-minute boat trip from the harbour to the location where a delicate saltwater marsh restoration project is underway.
Saltwater marshes are rapidly disappearing, yet they are a vital part of the ecosystem as they protect shorelines from erosion and storm flooding by buffering waves and trapping sediment. The marshes help to reduce flooding by absorbing rainwater and slowing the spread. They act as a natural pollution filter and metabolise excess nutrients, thereby improving water quality. The saltwater marshes support biodiverse wildlife populations, including migratory birds and specialist plants. They are natural carbon capture zones, storing carbon both in the plants and in the sediment.
Fish also inhabit saltwater marshes. These habitats support a variety of species, including juvenile fish, and serve as nurseries for many fish species. The dense vegetation provides shelter from predators and offer food for fish, waterfowl, crabs and oysters. The intricate root systems of marsh plants help to sustain water quality, supporting a diverse ecosystem which is crucial for the health of coastal environments and the overall wellbeing of marine life.
There are many constraints to working in this environment, all equipment must use bio-oils and grease to prevent pollution. Effective dredging work can only take place during low tides, therefore working hours are dictated by the natural tides. Wind is another factor, strong winds can create large waves that can halt progress. This means as much work as possible must be done quickly and safely within working windows. This approach ensures that contracts can be completed within tight timeframes.
Good teamwork is essential for an operation like this, and it is clear that this team enjoy working together and have the upmost respect for each other. Many of the equipment operators are able to cover each other’s machine if required. Equipment is only as good as the people who use it, having a professional team at Land and Water that keep excellent maintenance schedules and operate within the equipment’s working parameters, is an asset to both the company they work for and the equipment manufacturer.
“When integrating our M3 winch controls onto the base machine, we keep them as simple as possible,” said John. “A single joystick handles all the functions, making them user friendly. Because the winches position can sometimes be hidden from the operator, the camera and monitor system is essential for the operator to see what is happening.”
On the pontoon, alongside the winch, is another Hitachi long-reach excavator, which removes the debris collected by the dredging bucket. Two smaller amphibious CAT 307.5 excavators work in tandem to move it further back, re-establishing and stabilising the saltwater marsh. This is a productive operation, capable of dredging up to 600m³ per day, when working in optimal conditions. The winch is so effective that the excavators occasionally struggle to keep up with moving the debris away fast enough.
Initially John and his team approached this project with some apprehension. However, they have successfully navigated every challenge and developed and exemplary, productive, and reliable solution for Land and Water.
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