WORLDWIDE HEAVY TRANSPORTATION AND LIFTING
Case Studies – Europe
INSTALLATION OF THE FREYBRÜCKE
BRIDGE IN BERLIN, GERMANY
WIKINGER PROJECT IN PUERTO REAL, CÁDIZ
OVERVIEW: ALE has successfully completed the transportation
and load-out of one jacket and one topside in Puerto Real, Cádiz.
OVERVIEW: ALE has installed the Freybrücke Bridge,
weighing 400t, in Berlin, Germany.
SERVICES REQUIRED: The topside was separated into two
parts: Topside I and II.
SERVICES REQUIRED: The 400t bridge deck was built
on supports, about 10m from the quayside.
Prior to the transport manoeuvres, ALE performed the
weighing of the three structures with 500t capacity load cells
and jacks. These weighed between 2,500t – 2,900t. The three
manoeuvres were performed following the same procedure and
consecutively.
To allow ALE to install their skidding system, the bridge deck
was jacked-up 400mm using climbing jacks. The barge, with
the skidding supports, was berthed and prepared for the
load-out operation of the bridge deck.
The strand jack construction, consisting of six unit beams,
an anchor head and a strand jack, was installed on the arc of
the bridge. Using this construction, ALE released the bridge
into the separate anchor heads which allowed ALE to remove
the strand jacks. The bridge deck could then be suspended in
the strand wires for a couple of months. In total, there were
eight constructions installed with a 70t strand jack, and four
constructions installed with a 500t strand jack.
The bridge deck was skidded 30m onto the barge within five
hours. During the skidding operation, the barge stability was
controlled using pumps with a total ballast capacity of 360m³
per hour.
After positioning the bridge deck onto the barge, the link beams
between the barge and quay were removed using an 80t crane.
To ensure that the bridge deck could cross the existing bridges,
the bridges were measured, the water level of the river was
studied and the barge was set to maximum draught.
The transport height of the bridge deck was decreased by
jacking-down the bridge deck using four 150t capacity climbing
jacks in order to transport the bridge deck under existing
bridges with a clearance of just 100mm.
Whilst the bridge deck was being transported 1km, it was
turned 180 degrees using two tugs and the mooring lines were
connected using a small tug.
After connecting the mooring lines, the barge was positioned
beneath the arc using six winches, with a total capacity of 40t,
and the strand jack anchors were connected. The bridge deck
was lifted off the barge by strand jacks, as the barge was
released and transported back to the quay side.
Whilst the bridge deck was lifted into its end position, a second
team was disassembling the barge and preparing it to be
transported back to the supplier.
All load-out operations were performed on schedule.
The operation is part of the Wikinger project and also it includes
loading 29 jackets by crane in the port of Ferrol, which is
currently still ongoing.
These pieces will eventually be part of Wikinger, the German
offshore wind farm. This substation will become the heart of
the offshore wind energy park based in the Baltic Sea. The
electricity produced by its wind turbines
offshore will power 350,000 German
households and CO2 emissions by almost
600,000t per year.
The client then welded the bridge deck and, once the curve
was checked, ALE tensioned the strands for the second time
when necessary so the pendants of the bridge could be
installed. After the pendants were installed, all of the strand jack
constructions were removed.
OVERVIEW: ALE has performed the transportation of
an STS crane, weighing 800t, within the terminal of
Port-Nou in Barcelona.
SERVICES REQUIRED: The crane was transported from
its original location to its new location and placed onto the
rails. Prior to the transportation, ALE welded the transport
brackets on-site. These were specifically designed by ALE
for that manoeuvre.
The transportation was performed using 40 axles lines
of SPMT and two cross beams, measuring 14m long.
The beams were previously assembled on temporary
supports which transferred the load from the crane
resistant areas to the transport platforms.
The transport was completed in just one day - as planned which minimised the impact on the traffic in the terminal.
TOGETHER, WE ARE SMARTER, SAFER, STRONGER
The jacket was loaded-out onto a single barge and both sides of
the topside were loaded-out onto a second barge.
The bridge deck was finally set down into the strand jack
construction. After the installation, ALE waited until they
received confirmation from the client that ALE could proceed
with the removal of the strand jacks. ALE tensioned the strands
separately upon client instruction to create the right curve into
the bridge deck.
TRANSPORTATION OF AN STS CRANE IN THE TERMINAL OF PORT-NOU
IN BARCELONA, SPAIN
1.
First, the jacket was transported from its fabrication yard until it
was in line with the barge using 120 axle lines of SPMT in
a configuration of 6 x 4 file 10 axles. ALE then loaded-out
the jacket in a vertical position using the same transport
configuration.
The delivery alongside the ship and load-out of the topside was
performed using the same method, equipment and sequence
of work used for the jacket. For topside I, ALE utilised 72 axle
lines of SPMT in a configuration of 2 x 4 file 18 and 48 axle lines
in a configuration of 2 x 4 file 12. For Topside II, ALE utilised 120
axle lines of SPMT in a configuration of 2 x 4 file 30.
LOAD-OUT AND LIFTING OF A 394T PILE
GRIPPER, BELGIUM AND THE NETHERLANDS
OVERVIEW: ALE performed the load-out of a 394t pile gripper
on quay 136 in Antwerp, Belgium. This was followed by the
mobilisation of the pile gripper in Flushing port, the Netherlands.
SERVICES REQUIRED: The pile gripper was used during the
Geoseas Race Bank project to install the monopiles.
The pile gripper was located on stools, approximately 30m
from the quayside, and was supported in the centre and at the
front. 20 axle lines of SPMT in a 2 x 10 axle configuration were
used to perform the load-out. Throughout the load-out, the barge
was ballasted.
In order to position the SPMTs, ALE needed to remove the stools
side by side to stabilise the pile gripper’s Centre of Gravity. Once
in position, ALE raised the SPMTs and lashed the pile gripper onto
the SPMTs.
The following morning, the pile gripper was transported to the
quay and loaded in steps onto the barge. The pile gripper was
placed on stools in the reverse way as during the lifting procedure.
ALE drove the SPMTs underneath the pile gripper, after which a
mobile crane was provided by the client to lift the SPMTs off the
barge and onto the trucks, which were located on the quayside.
The pile gripper was
then sea-fastened and
transported to Flushing Port
in the Netherlands, ready
for mobilisation on the ship,
Innovation.
The barge with the Pile
Gripper was positioned
at the aft side of the
Innovation. ALE chose a
special rigging configuration
which included strand jacks
so ALE could install the pile
gripper at its correct angle.
ALE configured the rigging
on the quayside and lifted
the rigging using the main hoist of the Innovation. The main hoist
was moved until above the pile gripper, after which the pile gripper
was connected to the rigging, lifted and positioned above its final
position.
Finally, the pile gripper was adjusted to the correct angle using
a lifting computer connected to the strand jacks, before being
lowered and connected to the ship.
TOGETHER, WE ARE SMARTER, SAFER, STRONGER
2.
WORLDWIDE HEAVY TRANSPORTATION AND LIFTING
Case Studies – Europe
TRANSPORTATION AND STORAGE OF A REACTOR HEAD, SPAIN
RICKMANSWORTH BRIDGE REPLACEMENT, UK
OVERVIEW: ALE has performed the onsite transportation of a
60t reactor head from its temporary storage area, the fuel building,
to the storage building at the Vandellos nuclear power plant.
The transportation also involved skidding and lifting manoeuvres.
OVERVIEW: ALE has carried out the successful removal and installation of
overbridge MR88 in Rickmansworth in North West London, UK.
SERVICES REQUIRED: In order to transport the reactor head
between both buildings, 6 axle lines of SPMT were used. The
head was loaded onto the SPMTs at the fuel building using an
overhead crane.
All manoeuvres were carefully and precisely coordinated,
performed to a strict schedule without any significant deviation
or impact to other activities inside the plant. Because of this,
the client and all other parties involved considered the project
a complete success.
The new bridge weighed approximately 150t and was installed using
another 16 axle lines of SPMT in a 4 file 8 configuration. Again, the SPMTs’
packing consisted of a jacking frame and climbing jacks. The new bridge had
to be driven in below the services and above the new
cill units, which were at various levels.
Once at the entrance of the storage building, the reactor head
was offloaded by means of a 500t hydraulic crane and positioned
onto the skidding system.
A modular skidding steel structure was previously installed so
the head could fit through the entrance at a height of 4.3m above
ground level. The head was skidded inside the building and, once
inside, was lowered into position using a 500t hydraulic crane.
The crane was operated from outside the building, through a hole
made in the roof in order to allow the use of the long sling during
the crane manoeuvre. Once the head was at ground level, it was
skidded into its final position.
The bearings were attached to the underside of the bridge prior to the
bridge move. The bridge was lowered down utilising the climbing jacks on
the SPMTs and the bearings were lined up with pre-formed pockets in the
cill units by incorporating alignment gear into the scheme.
There were several major challenges that ALE needed to overcome to
ensure that the scheme was a success. Due to space restrictions in the
site compound, it was necessary to rig the SPMTs during planned night
time road closures and prior to the possession, as well as de-rig the SPMTs
during the planned night time road closures during the possession.
The operation also included the transportation and storage of
10 vessels containing Control Rod Drive Mechanisms (CRDMs),
weighing 10t each. All of these containers were transported and
installed using a similar method.
Another challenge ALE faced was moving the old bridge into the site
compound up a steep ramp. ALE used a tractor unit to assist with
pulling the SPMTs and old bridge off the road and into the compound.
This operation had to take place within a one-hour window due to traffic
management restrictions.
TRANSPORTATION OF A SHIP SECTION, ROMANIA
OVERVIEW: ALE has successfully performed the transportation
of a 2,400t ship section in Constanta, Romania.
then done on the load and all steering functions in the SPMT
configuration was checked.
SERVICES REQUIRED: The ship’s stern was built by the
client onto a frame in a dry-dock behind an intermediate wall.
A dock crane was used to lift the SPMTs into the dry dock.
The frame allowed for 112 axle lines of SPMT positioned in a
5 file configuration under the ship section.
ALE then transported the ship’s stern until it was 5m from the
front ship section, where the alignment of the two pieces was
checked. The ship’s stern was then transported until 50mm
from the other ship section so the levelness of the pieces was
corrected. The ship’s stern was cut to the required dimensions
before both pieces were joined.
Each line of SPMT had its own power pack, which enabled them
to be installed under the frame separately. Once positioned,
all lines were pressurised to a minimal load and all trailers were
hydraulically and electrically connected. Further testing was
3.
TOGETHER, WE ARE SMARTER, SAFER, STRONGER
SERVICES REQUIRED: The existing bridge weighed approximately 80t
and was removed utilising 16 axle lines of SPMT in a 4 file 8 configuration.
The SPMTs steelwork packing consisted of a jacking frame and climbing
jacks. The climbing jacks enabled the old bridge to be lifted from its bearings
and clear of all obstacles on the abutment before being driven back to the
compound ready for demolition.
The ship section was transported against the front part of the ship.
Once the pieces were together the frame from the ship’s stern
was removed and the SPMTs were driven out from below the
frame and disassembled.
LOAD-OUT OF AN 800T SHIP SECTION, THE NETHERLANDS
OVERVIEW: ALE performed the load-out of an 800t ship section
in Hardinxveld-Giessendam, the Netherlands.
SERVICES REQUIRED: Prior to the load-out, ALE jacked-up the
ship section using 13 climbing jacks. 40 axle lines of SPMT in
a configuration of 2 x 4 file 10 were placed underneath the ship
section and in between the climbing jacks.
The ship section was transferred by lifting the SPMTs and
transported onto the barge during the rising tide to minimise the
ballasting. Once on the barge, the ship section was lowered on its
supports. The SPMTs were then lowered and removed.
The barge was then towed to a suitable location, where the barge
was submerged and the float-off of the ship section performed.
TOGETHER, WE ARE SMARTER, SAFER, STRONGER
4.