Turnkey ropeways
We specialize in the realization of turnkey ropeway systems, managing every phase from project planning and design to production, assembly, and final testing. Our comprehensive approach includes obtaining all necessary approvals from relevant authorities, ensuring that each installation is delivered ready for operation, fully compliant with safety and regulatory standards.
Design
Each project begins with a tailored design phase where our in-house engineering team works closely with the client to define specific needs. We conduct detailed analyses to determine the ideal transport capacity, line length, vertical elevation, and operating speed, all based on terrain, environmental conditions, and user flows.
Line calculation
Once parameters are established, we select the most appropriate system — ski lift, chairlift, jig-back, funicular, or custom ropeway — always optimizing for functionality, safety, and cost-efficiency.
Graffer engineers calculate the ropeway geometry using advanced simulation tools, ensuring smooth performance and compliance with national and international regulations (including ANSFISA and EU Reg. 2016/424).
Key subsystems — including in this phase
steel cables
grip assemblies
drive units
braking mechanisms
electrical systems
Structural load calculations for supports and anchorage points are also developed to meet seismic and wind resistance criteria.
Production
The production phase focuses on fabricating the primary mechanical structures:
- Towers and supports, manufactured from high-grade steel with protective coatings
- Cabins, chairs, or carriers, often custom-built with options for bicycle racks, disabled access, or panoramic features
- Drive systems, which include motor bases, gear reducers, tensioning assemblies, and braking units
Depending on the project scope, parts are manufactured in-house or by qualified external partners, all subject to Graffer’s strict quality controls.
Additional components — such as sheave assemblies, hydraulic power units, and safety sensors — are sourced from certified suppliers to ensure full compatibility and durability.
Electric & Control system
Graffer designs and installs complete electrical architectures for its ropeway systems.
This includes
Main control panels with programmable logic controllers (PLCs)
Redundant safety circuits for emergency and service braking
Frequency inverters for motor speed regulation
Remote monitoring systems, allowing real-time diagnostics and status reporting
UPS (Uninterruptible Power Supply) for blackout protection
Passenger communication systems, such as intercoms and public address (PA) setups
CCTV systems for visual control across stations and lines
All systems are designed according to CE marking standards and meet the latest electrical safety norms (e.g., IEC 60204-1).
Assembly & Integration
Once all components are ready, our team performs full pre-assembly checks and coordinates on-site assembly. This includes the mechanical integration of supports, stations, carriers, rope installations, and tensioning systems.
Mechanical, electrical, and hydraulic elements are all integrated into a single operational framework.
This ensures that the ropeway system is not just functional, but optimized for performance, safety, and user comfort.
Installation
The installation phase involves the transport of components to the site, often in challenging terrain. Graffer has extensive experience operating in alpine and remote environments, using specialized vehicles and air-lifting techniques when necessary.
Our field teams handle
Foundation anchoring
Tower erection
Station placement and alignment
Rope stringing and tensioning
Cable splicing and lubrication
Commissioning
Once installation is complete, we perform comprehensive functionality tests. This includes verifying operational parameters, load simulation, brake tests, system responsiveness, and safety drills.
We calibrate sensors, fine-tune motor responses, and confirm line tension to deliver optimal performance.
Testing & Certification
Graffer conducts all required certification procedures, coordinating with relevant authorities such as ANSFISA, USTIF, or equivalent international bodies.
We carry out
Load tests
Magnetic rope inspections
Structural integrity assessments
Electrical conformity verifications
Safety function validations
All documentation, schematics, and test reports are compiled and submitted for official approval.
Training & Documentation
Post-commissioning, Graffer provides comprehensive training for both operational and maintenance staff.
This includes
System operation and emergency procedures
Daily and seasonal maintenance routines
Troubleshooting and diagnostics
Use of spare parts and maintenance kits
Each project is delivered with complete as-built documentation, user manuals, and maintenance logs, ensuring long-term independence and operational excellence.
Conclusion
Our turnkey ropeway systems include all essential subsystems for complete functionality and safety.
These comprise mechanical drive and return stations, hydraulic tensioning systems, and carrier vehicles such as chairs, cabins, or baskets. We provide support towers equipped with sheave trains, along with fully integrated electrical power and control systems.
The package also includes communication and surveillance equipment, safety devices, evacuation tools, and operator interfaces with remote access software for seamless management and monitoring.
We’ll bring your ropeway project to life,
smartly, and sustainably.
Request a free assessment