Heavy-duty gearboxes: built for the full load.
Heavy-duty gearboxes are used wherever high torques, shock loads, reversing operation or exceptional load spectra demand an individual design. We calculate every unit on the operating conditions of your plant — not on a catalogue value.
- > 2,500 kNm possible
- shock & reversing operation
- continuous 24/7 duty
- individual design
When a gearbox fails in a rolling stand or crusher, it is not one component that stops but the whole line — and every hour costs. The most frequent cause: the gearbox was bought by nominal torque, while real operation is governed by shock peaks, starting torques and reversing loads.
We design every heavy-duty gearbox for the real load spectrum: material, gearing geometry, bearings and lubrication are calculated for your toughest operating point — not for the average.
The key figures at a glance.
Series reference values — the final design is always based on your load profile.
How the Heavy-Duty Gearboxes works.
Real load spectrum
Shock peaks, reversing operation, starting torques and environment go into the calculation. The result is a drive built for your toughest operating point.
From specification to solution
We analyse the load profile, design the unit, simulate by FEA where required and support you through to commissioning — with dedicated contacts.
Built for service life
Generous safety margins at the critical points, high-grade materials and verified manufacturing — so the gearbox actually reaches its planned service life.
Where our drives work.
Wherever drives are pushed to their limits — and still have to keep running.
- Rolling stand and continuous casting drives
- Presses, shears and forging plants
- Ship lifts and locks
- Crusher, mill and grinding drives
- Converter and ladle tilting drives
- Large conveyors and heavy machinery
- Harbour cranes and straddle carriers
- Cement mills and rotary kilns
The knowledge behind the design.
A heavy-duty gearbox pays off when:
- shock and peak loads lie well above the nominal load,
- reversing operation or high starting torques occur,
- a catalogue gearbox repeatedly fails prematurely,
- downtime is expensive and operational reliability takes priority.
Designed for the worst case
We dimension against the real load spectrum including the shock factor — not against a smoothed nominal rating. The critical points (gearing, shafts, bearings) receive targeted reserves.
Materials & heat treatment
Case-hardened, ground gearing and appropriately selected materials secure flank pressure and tooth root strength precisely where the load is highest.
FEA verification where needed
For critical components we verify housings and shafts by FEA — creating reliable safety margins without blanket over-dimensioning.
Load spectrum
The time-based distribution of all occurring loads — continuous load, peaks, starting and shock torques. A serious design calculation works with the load spectrum, not with a single nominal rating.
Service factor KA
A safety margin that accounts for the shock and overload character of the application. Shock-loaded drives (e.g. crushers, shears) require a significantly higher factor than uniformly running machines.
Flank pressure (contact stress)
The contact stress on the meshing tooth flanks. It limits service life (pitting) and is verified during design against material strength and heat treatment.
Reversing operation
Frequent change of rotation direction. It stresses gearing and bearings particularly hard through load reversals and must be specifically accounted for in the design.
FEA simulation
Finite element analysis: computational strength and stiffness analysis of housing, shafts and gearing — for reliable safety margins instead of costly over-dimensioning.
Heavy-Duty Gearboxes by ATP — designed for your real load spectrum, not picked from a catalogue.
What sets us apart from off-the-shelf.
Designed for your load profile
We calculate every gearbox on the actual load spectrum and the real operating conditions of your plant — not merely on a theoretical nominal rating.
Brand-independent service
We maintain, repair and replace gearboxes from all manufacturers — including reverse engineering of legacy equipment and spare parts to original dimensions or with an improved design.
Fast support when it matters most
Downtime does not keep office hours. Our service hotline is staffed around the clock — we assess the situation, agree the next steps with you and dispatch our service technicians right away.
Engineering from Austria
Design, manufacturing and service from a single source in Marchtrenk — since 1995. Short paths, dedicated contacts, full responsibility for the result.
Frequently asked questions.
/ 01What distinguishes a heavy-duty gearbox from a standard gearbox?+
A standard gearbox is catalogued for a nominal rating. A heavy-duty gearbox from ATP is calculated on the real load spectrum of your plant — including shock peaks and reversing loads — and dimensioned accordingly at the critical points./ 02Do you also build replacements for a failed large gearbox?+
Yes. We survey existing gearboxes, reverse-engineer them when documentation is missing and deliver a fitting, frequently improved replacement — with emergency priority on request./ 03Can you assess the load profile if we do not know it precisely?+
Yes. From machine data, operational observation and experience with comparable plants, we derive a reliable load spectrum and base the design on it./ 04How quickly can you respond to a failure?+
Our emergency service is available around the clock; within the DACH region we are on site in under 24 hours. For the new design you receive a first assessment at short notice.
Where others have to pass, we design.
Describe your plant and load case — you will hear from our engineers within 24 hours, with a concrete design proposal.