new heights THE ALE NEWSLETTER June 2018 • ISSUE 14
Welcome... ...to the June edition of the ALE newsletter, with the latest news to keep you informed of our activities around the world.
RECORD BREAKING 3,000T CRANE LIFT WITH NEW JIB
“The global shift in energy production to renewable sources has provided an opportunity for ALE to demonstrate innovation to developers, contractors and wind turbine manufacturers. The ALE-Wind Services division is led by a team of experts and can offer enhanced balance of plant (BoP), electro-mechanical installation and maintenance services. This highly specialised team can be deployed globally and can complement our local teams to better service our clients who routinely transport, commission and install wind turbines. We have also invested in new equipment and the latest technologies, not only for this sector, but across the business as we continue to look for innovative solutions to save costs and time for our clients. As we approach our 10-year anniversary of the AL.SK cranes, it marks a massive milestone, not only for ALE but also for heavylifting showing how the industry continues to break records and how ALE continue to lead the way when it comes to challenging the conventional. We are really proud of everything our teams within the ALE Group have achieved and continue to work towards our goal of being smarter, safer, stronger together.” Kees Kompier Regional Director – Australia, Asia and South East Asia
ALE LAUNCHES TRIO OF NEW TECHNOLOGIES
ALE ENHANCES PRESENCE IN NORTH AMERICA AND AFRICA
IN THIS ISSUE ALE News Project Focus Division Focus HSQE ALE People Case Studies
I N F O @ A L E -H E A VY L I F T. CO M
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WORLDWIDE HEAVY TRANSPORTATION AND LIFTING
RECORD BREAKING 3,000T LIFT IN NIGERIA WITH NEW JIB
ALE LAUNCHES TRIO OF NEW TECHNOLOGIES
ALE has broken another industry record when performing the heaviest ever land based crane lift using a jib whilst working on Total’s Egina FPSO module integration project in Nigeria.
INNOVATION IN HEAVY TRANSPORT
The FPSO module ‘S2’ has a total load weight of 2,810t and was lifted using ALE’s unique AL.SK350 crane and heavy duty jib for the project in Lagos, Nigeria. INVESTMENT IN ASSETS The world’s largest capacity land based crane was rigged with a 124m a-frame main boom, 49m ballast radius and the 38m jib for additional outreach, along with a heavy winch system and 4,000t ballast. For Total’s Egina project, ALE was contracted to lift and install six modules from the yard onto their final position on the FPSO. The lift weights were between 335t and almost 3,000t.
“The project really showcases the capabilities of the AL.SK350 and the jib to perform some of the world’s heaviest ever crane lifts in a congested site. When combined with the unique heavy duty jib and the largest crane configuration, this represents another record-breaking achievement for ALE,” explained Carlito Alberto, ALE Project Engineer. EXCELLENT CUSTOMER REFERENCES The client has praised ALE’s work to date: “I want to thank the ALE crew on behalf of SHI-MCI for their outstanding efforts that allowed us to complete 100% of the expected lifts before the first shipment. Despite challenges on site, ALE has been able to complete the lifts on time,” commented the SHI-MCI Egina Project Manager.
In November 2017, ALE successfully launched three new innovative technology systems: the AL600 girder frame, the Telescopic Lifting Gantry (TLG1000), and the Route Survey Tool. All three were designed in-house by ALE’s award-winning Research and Development team, and unveiled for the first time at an exclusive client event in Breda, the Netherlands. The systems provide increased capacity, improved safety and more advanced features, enabling ALE to take on even greater challenges.
The AL600 girder frame can carry loads up to 600t - 100t more than ALE’s previous largest frame (the AL500), using up to 80 axle lines. One of the AL600’s most noteworthy features means it can travel more easily on challenging routes. The AL600’s necks narrow in from the load carrying beams to the tower on the trailer. The ends of the necks are narrower than the trailer width. As a result, the convoy can drive around narrow curves in the road without taking up as much space or needing to remove lamp posts and other obstacles while providing the lowest axle weight possible.
The lifting operations took place throughout March and April.
“I want to thank the ALE crew on behalf of SHI-MCI for their outstanding efforts that allowed us to complete 100% of the expected lifts before the first shipment.”
INTRODUCE GREATER SAFETY
AWARD-WINNING SAFE SOLUTIONS
The TLG1000 is the first in a new fleet of high capacity hydraulic gantries. It has a capacity of 1,000t and its increased stability gives it a huge advantage over existing systems. The gantry system has four towers and a variable track width, which means it can run on standard 915mm wide tracks to 1,750mm wide tracks – adding more stability. This stability enables the TLG1000 to maintain its 1,000t capacity across all three of its stages, up to 12m high.
ALE’s most revolutionary new technology is the Route Survey Tool. ALE designed it as a computerised system that automatically logs accurate route descriptions on digital maps. Critical sections of the route are measured and photos, video footage and drawings are generated for more in-depth analysis. The system has a scanning range of a 100m radius around the car and, at 100m, it can scan to an accuracy of 20mm. The system also has a GPS accuracy of ± 0.5m. Safety has been improved and project efficiency optimised as the separate Driver Assist tool helps on the actual route by instructing drivers of the route ahead. By providing them with automatic data, they can prepare for complex parts of the route beforehand and improve the overall time and cost efficiency of the project. In fact, the Route Survey Tool won the ‘Safety’ award at the ESTAs for its safer and more reliable functionality. INNOVATION AVAILABLE GLOBALLY The AL600’s first project is in Chile and the TLG1000 is also destined for South America, while the Route Survey Tool’s inaugural project was in Indonesia with more being deployed throughout ALE.
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THE AL.SK CRANE ANNIVERSARY: A DECADE OF CONTINUED INNOVATION ALE is celebrating the 10-year anniversary since the launch of the AL.SK crane series, which have performed some exceptional and record-breaking lifts previously thought impossible.
DEDICATED CANADIAN OFFICES ENHANCES PRESENCE IN NORTH AMERICA
In 2006, ALE’s Research and Development (R&D) division, based in Breda, the Netherlands, began developing concepts for a new crane. ALE wanted the new design to have the highest capacity on the market, be capable of being configured in different sizes, to maintain speed and efficiency for smaller lifts, and have enhanced safety, accuracy and performance.
ALE has announced that it is now operating as a single business entity in Canada. ALE set-up a joint venture in 2012. During this time, the company worked on some high-profile projects in both western and eastern Canada. Following on from the restructure and demerger, ALE will be applying its core principles as the leading provider of integrated and innovative engineering solutions to focus more on large, long-term projects throughout Canada, with a specialist team of experts and project managers.
NOT JUST BIGGER, BUT BETTER This became the first AL.SK crane, the AL.SK190, which was launched in 2008. It was the first crane to be designed and built by ALE and, at 4,300t, was then the world’s largest capacity land-based crane. This was not just a new crane but a new type of crane altogether. ALE developed a solution to enable the crane to rotate around its ballast. It was this that helped to give it such a high capacity as well as an improved outreach. AVAILABLE GLOBALLY From its first job installing petrochemical columns in Saudi Arabia, to replacing coke drums in the USA and performing over 150 lifts on the STAR Project in Turkey, the AL.SK cranes have travelled around the world, delivering effective solutions to complex challenges. Cees Segeren, Technical Adviser, explained, “The AL.SK fleet has revolutionised the way the industry perceives crane lifting and has had many notable achievements in the last 10 years. One of the great advantages of the cranes is that they can operate in a small space and this was showcased recently during renovation works at Earls Court in London, UK. Other demolition works could continue, which pleased the clients as they saved time and costs.” THE INNOVATION The AL.SK cranes were later included in ALE’s Innovation Series of equipment. Over the last 10 years ALE has continued to innovate and build more AL.SK cranes. The AL.SK350 was launched in 2013. It can lift up to 5,000t and took its place as the world’s largest capacity land-based crane.
Company News
RECORD BREAKING The AL.SK cranes have performed some exceptional and record-breaking lifts never believed possible. ALE performed a remarkable achievement when, in 2016, the AL.SK350 completed a 3,000t lift, the largest commercial lift by a land based crane. In 2016 ALE enhanced their capabilities further by fabricating a new heavy duty jib for the cranes and also announced plans to combine two AL.SK cranes into one system, the AL.SK700, which will be able to lift loads up to 8,000t. Roger Harries, who founded ALE, said, “ALE’s Innovation Series demonstrates our commitment to developing and the Series is still growing because there is a great demand for this specialist equipment. As a company, we are always looking forward to anticipating future challenges and innovation is at the heart of that. The AL.SK cranes were just the beginning for the Innovation Series and they will remain an important part of it as we continue to enhance our current systems and develop new solutions.”
“The AL.SK cranes were just the beginning for the Innovation Series and they will remain an important part of it.”
“We recognise the potential opportunities within the country and are excited to offer ALE’s services. With dedicated offices across Canada, we can not only increase our presence nationwide, but demonstrate our continued commitment and enhance our overall service offering to our local clients in the region.” As a global business, ALE has the ability to work world-wide and draw on its group resources as well as its local expertise. ALE will operate from branches in Edmonton, Calgary, Toronto and Montreal, with the regional head office in Edmonton, Alberta.
Bas Bronder, President for ALE in Canada said: “Over the last five years the joint venture played a strategic role in establishing the ALE name in the competitive Canadian heavylift market.
ROUTE SURVEY TOOL CROWNED BEST SAFETY INNOVATION ALE has won an ESTA (European Association of Abnormal Road Transport and Mobile Cranes) award for Best Safety Innovation of the Year for the Route Survey Tool, a computerised system that automatically logs accurate route descriptions on digital maps. The tool attaches to the roof of a car, measuring the route and minimising the need to step out of the vehicle. The Route Survey Tool also alerts drivers to any points of interest on the route so they can prepare in advance.
ALE WINS SC&RA HAULAGE AWARD FOR COMPLEX VENEZUELAN PROJECT ALE’s landmark transportation project in Venezuela has won the Haulage Job of The Year Award, for loads over 500,000 lbs at the Specialized Carriers, and Rigging Association (SC&RA) Awards 2018. DELIVERING COMPLEX ENGINEERING ALE secured the prize for their transportation of six 22MW power plant engines, weighing a combined total of 1,891 US tonnes, from Italy to the Santa Ines Refinery Development in Barinas State, Venezuela. As the distance was so vast, covering almost 1,000 combined land and nautical river miles, the project was split into three phases over three years. ALE faced routing and logistics challenges that required complex engineering studies, co-ordination with different authorities, and significant preparations with an experienced team.
ALE WINS ACCLAIMED BUSINESS AWARD FOR INNOVATION IN EXPORT ALE has been awarded the Golden Bridge Trade & Investment Award for Best Innovation in Export. The British Ambassador to Belgium, Alison Rose, presented the award to ALE at a ceremony in Brussels, Belgium. SIMPLIFYING COMPLEX SOLUTIONS The jury was impressed with ALE’s innovative approach to securing, managing and delivering the Yamal LNG Project at the Modular Intermediate Storage Yard in Zeebrugge, Belgium. ALE provided a fully integrated solution to the client, which also led to increased traffic for the Port of Zeebrugge, resulting in the port’s expansion. Yannick Sel, Sales Director – Global Sales Division, said: “This award is dedicated to all of the ALE staff working on the project. Receiving this recognition, not from within our own industry but from the Chambers of Commerce, shows that ALE has achieved something remarkable.”
The award was collected by Javier Martinez Gutierrez, Executive Director for ALE. He said: “We are really proud of the hard work by everyone involved across the ALE Group worldwide. This project was a huge achievement which demonstrated our capability to handle many challenges and deliver the engines safely and successfully across a route that was incredibly varied, involving different terrains and environments.”
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ALE INCREASES LOCAL SERVICES IN AUSTRALIA
Office News ALE TOPS CRANE LIST IN AUSTRALIA AND NEW ZEALAND ALE has emerged as number one in a list of the top 100 crane owning companies in Australia and New Zealand. The list was compiled by Cranes and Lifting magazine and follows up on a previous list of top 50 crane owning companies in the region, which ALE also topped. ALE’s Australian branch has a number of both mobile and crawler cranes, as well as being able to draw on the group’s global fleet of equipment. This gives ALE’s Australian branch a total maximum load capacity of 39,960t – over 13,000t more than their regional competitors.
ALE has opened a new branch in Melbourne to optimise their service offering. The Melbourne office can provide clients with ALE’s full range of services, with a specific focus on civil works as well as wind services. The increased presence in Australia means ALE is closer to their clients in the Melbourne area and can offer greater localised services throughout Victoria. This is the first branch to open in Victoria and will join ALE’s well-established Brisbane and Gladstone branches.
Algeria
BUSINESS EXPANSION IN AFRICA ALE has expanded its business operations in Africa and opened new offices in Nigeria and Ghana.
MIDDLE EAST EXPERTISE SHARED AT INDUSTRY EXHIBITION Two ALE employees participated in discussion panels at this year’s Breakbulk Middle East 2018 conference and exhibition, UAE. Both employees shared their knowledge, based on their experiences of working across the region. Alberto Pittaluga, Director of ALE’s Iraq and Italy branches, spoke on the subject of Risk Management: Handling Projects in Post-Conflict Regions. Alberto discussed how to succeed when faced with challenges such as destroyed infrastructure, scarce equipment, banking and personal safety.
Environment – a country which has large growth plans. He gave his thoughts on the common heavylifting and transportation challenges in Kuwait, which has required barges to make beach landings and other complex manoeuvres, and how ALE has overcome them. He also discussed how to deal with limited port space and power cables, as well as delays because of road modifications.
DELIVERING COMPLEX SOLUTION ACROSS ALL GEOGRAPHIES Edward Talbot, General Manager of ALE’s Abu Dhabi and regional head office branch, discussed a case study on Kuwait’s Project
TRANSPORT CAPABILITIES INCREASE ACROSS SOUTH AMERICA ALE has significantly increased their overall transportation offering with the purchase of eight new Iveco Trakker trucks for use in Argentina and Chile. The new trucks have been delivered to the regional base in Argentina, to be used across Argentina and Chile. These new trucks will be added to the current fleet of enhanced transportation equipment, such as conventional, semi-trailers and extendables, as part of the new transportation division. This division will be based in the regional head office in Argentina and will enable ALE to cater for their client’s transportation requirements. EQUIPMENT SUITABLE TO SPECIFIC MARKETS “We wanted to increase our transport capabilities as we often have to negotiate terrain that has unprepared roads. The decision was made to purchase these trucks because of their off-road characteristics. This makes them particularly suitable for the region’s roads and the specific routes we take,” explained Walter Rago, General Manager of ALE’s Argentina branch.
The new Iveco Trakkers are the latest addition to ALE’s South American transportation fleet, which includes 42 axle lines of conventional trailer and two extendable semi-trailers.
“Along with the new division, the trucks will be used to strengthen ALE’s service offering across the region.”
Egypt
With two established offices in South Africa and a sales presence in Algeria, Ethiopia and Egypt, the Nigeria and Ghana offices means ALE has seven branches in Africa and an indication of the company’s drive to expand its footprint across the continent.
Ghana
“The new partnership is the result of ALE’s response to the increasing demand for heavy road haulage that the country is experiencing,” explained Jose Luis Salamanca Garcia, Sales Manager for ALE. “We are committed to providing our engineering and operational expertise to our clients in Ghana. With a dedicated business development manager, local partners and transport equipment, we can optimise any potential future opportunities in the country.” Recognised as one of the leading economies in Africa, the Nigeria office will be focused on business development for oil and gas, petrochemical, offshore, power generation and shipyards projects taking place within the country and West Africa. The Lagos branch in Nigeria will hold commercial, operations and engineering teams to deliver efficient relationships with the potential to develop a fully functioning office to carry out full project execution.
Ethiopia
Nigeria
In Accra, Ghana, ALE has established a joint venture with Jacob Lawren Ltd, complete with a dedicated business development manager and a fleet of heavy transport modular trailers and prime movers to focus on providing transport and installation services to the local power generation market.
Johannesburg
Cape Town
Adrian Jordaan, General Manager in Nigeria, said: “We have established an extensive reputation for our heavylifting capabilities within the oil and gas industry all over the globe. We want to bring the same levels of engineering and service excellence that our clients are accustomed to across the world, such as compliance with ISO 9001 and 14001, as well as OHSAS18001. As part of our concerted drive and strategy, we made the decision to expand our business opportunities within this market and position ourselves within closer reach to local clients in West Africa.”
CONBIT EDUCATES TOTAL’S LIFTING EXPERTS Conbit, who is part of the ALE group, was invited to showcase its offshore lifting expertise at the Lifting and Handling Seminar by Total E&P. The seminar, which takes place every two years at the company’s training complex in Paris, France, was attended by many of Total’s clients, including CPLOs (Competent Person Lifting Operators) and SLSs (Site Lifting Supervisors) from all over the world.
Bram van Oirschot, Bart Steerneman and Joop de Fouw from Conbit gave a presentation on ‘temporary offshore lifting solutions’, as well as encouraging constructive discussions on the topic and coordinating a practical exercise to work on. “The seminar was well-received and we hope that we contributed to an increased safety awareness for the global lifting teams that were present,” explained Bram van Oirschot, Sales Manager for Conbit.
“Their sturdy features, including the chassis, suspension and engine capabilities, will help when negotiating the difficult Patagonian roads. Along with the new division, the trucks will be used to strengthen ALE’s service offering across the region and their presence in the region’s wind energy market specifically.”
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Equipment News
Project News
LATEST TOWER CRANE INVESTMENT BRINGS TIME AND COST SAVINGS
ALE REACHES MILESTONE IN OFFSHORE WIND TURBINE INSTALLATION
ALE has added three new tower cranes to their extensive global fleet that are expected to make cost and time savings for clients in the wind sector.
ALE has completed a major project milestone and lifted the two sections (T1 and T2) of a telescopic tower - the first self-installing telescopic offshore wind turbine in Arinaga, Gran Canaria. The T2 section, weighing 240t, and the T1 section, weighing 360t, both measured 31.5m high.
The innovative K1650L crane has lifting capabilities like no other free-standing tower crane on the wind energy market, with an increased lifting height, and the ability to work at high wind speeds and with uneven or small hardstands. The compactness of this free-standing pedestal crane means that civil works and costs are ultimately reduced, without the need to be tied-in to the turbine tower. The low counterweight, increased visibility and quick assembly functionality optimises overall project efficiency. Thanks to the short 70m boom, the area to boom up and down can be significantly shortened, when compared to any equivalent lattice boom crane. This, together with the very short minimum boom radius, allows the developer to reduce the portion of land to be acquired and cleared, significantly reducing costs and environmental impact. The crane can be transported and even partially rigged, reducing the relocation time and schedule.
Due to the complexity of the project, ALE started planning in January 2016, before performing the tower section test lifts in December 2017. In March 2018, ALE completed the lifting test of the T2 section with nacelle, weighing a total of 490t.
“As ALE secure more complex scopes of balance of plant (BoP) within the wind markets, we wanted to invest in the most suitable equipment for these operations,” explains Danilo Viappiani, Regional Engineering Manager.
During the project, ALE’s R&D department was responsible for developing a unique Wi-Fi system enabling the manoeuvres to be performed with wireless equipment. Furthermore, it was in charge of managing the manoeuvres from a boat located away from the tower.
“We work closely with our clients to understand potential challenges in the future, such as increased hub heights or heavier components, and where there is the opportunity to make time and cost savings. The tower crane solution has lifting capabilities like no other on the market, and by investing in these cranes, it represents a further ground-breaking advancement in our step to become world leaders in the renewable wind industry.”
INAUGURAL PROJECT FOR INNOVATIVE TOWER CRANES
The cranes are currently being deployed at Wind Energy Holding’s Thepharak T5 wind farms in Thailand, where ALE has been contracted to provide the full-service TCI and BoP scopes.
JACKING CAPACITY INCREASES TO OVER 100,000T ALE has increased its jacking capacity to over 100,000t with the introduction of new jacking systems and enhancements to existing technologies. In order to fill a gap in the market and satisfy client demand to perform the jacking operations on three jobs at the same time, ALE has built four new towers for the Mega Jack. ALE’s R&D team designed and fabricated the new towers in Breda, the Netherlands. Now with 16 towers, each with 5,200t capacity, the original Mega Jack has over 83,000t capacity. In addition, when combined with the other jacking systems in the fleet, like the Mega Jack 800 and the new Mega Jack 300, this brings ALE’s total jacking capacity to a huge 100,000t. “We are always looking at developing new solutions to upcoming challenges and work closely with our clients to find out how we can help them. We have seen an increase in demand for the Mega Jack and, as such, we decided to build additional towers to satisfy three projects that are taking place at a similar time,” explained Technical Director Ronald Hoefmans. “This huge increase in capacity for ALE demonstrates our continuing commitment to growing not only our abilities to lift greater amounts and weights, but also our range and variation of jacking equipment. These new developments represent a huge milestone for both ALE and the heavylifting industry.”
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This is part of the H2020 ELICAN project lead by ESTEYCO, where ALE is part of the Consortium who aim to build the first self-installing telescopic offshore wind turbine for a Siemens-Gamesa 5MW turbine in the Canary Islands. ALE is responsible for the tower lifting operations and the coupling between the tower and the Auxiliary Floating System, as well as the final offshore installation.
The Mega Jack’s towers were utilised for the first time in Mexico in March, while other existing towers are operational on other projects in both Australia and the UAE.
“These new developments represent a huge milestone for both ALE and the heavylifting industry.”
Cecilio Barahona, Project Engineer for ALE, said: “It is fantastic to be involved in such a unique project that will revolutionise renewable energy production. We are really happy with the achievements so far, with the successful assembly of the two sections.” The connection of the Auxiliary Floating System and final offshore installation is expected to take place in May 2018. In this final lifting manoeuvre, the sections, comprising of blades and nacelle weighing 540t and 900t, will be lifted using strand jacks and a new horizontal guidance system. Finally, the 5MW turbine will be connected to the electrical cable and the energy production is expected to start by second part of 2018.
ALE is utilising two innovative tower cranes on Wind Energy Holding’s Thepharak wind farms, Thailand, to handle and install over 700 wind components. ALE was contracted to perform both the craneage and installation of 60 wind turbine generators (WTGs), with the components weighing up to 120t each and a hub height of 157m. Commencing in December, ALE used two of the new K1650L tower cranes, as well as crawler and mobile cranes to lift and install the WTG components. The K1650L cranes were chosen as the low counterweight, increased visibility, quick assembly functionality, ability to work in high winds and with uneven or small hardstands optimises overall project efficiency. “We pride ourselves on our extensive and innovative equipment fleet, investing in the latest technologies for the sector and the challenges posed. For this project, we are using the most time and cost-effective method to install WTGs at this hub height. By using these compact pedestal cranes, the civil works and costs have been significantly reduced for our client. The crane has lifting capabilities like no other tower crane on the market and we are pleased with the good results in lifting and installation activities on the project so far,” explained Tommy Quik, Project Manager for ALE. The project is expected to complete in June 2018.
“We are using the most time and cost-effective method to install WTGs at this hub height.” WWW.ALE-HEAVYLIFT.COM
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THAMES TIDEWAY MILESTONE REACHED USING BESPOKE LIFTING SYSTEM ALE has completed the second phase of work on the Thames Tideway project in London, UK, with the use of a time and cost-saving lifting system. ALE successfully loaded-in and transported 72 components, weighing between 9t-119t, for two Tunnel Boring Machines (TBMs). INNOVATION TO COMBAT CIVIL AND RAIL CHALLENGES The work was completed on behalf of FLO – the joint venture, comprised of Ferrovial Agroman and Laing O’Rourke, which is delivering the central segment of the project. ALE secured the contract due to the confidence the client had in their R&D division’s innovative methodology that could complete the scope quickly and cost-effectively. ALE designed a bespoke lifting solution and cradles to hold the fully-constructed TBMs. ALE’s first phase of work on the project began in November 2017, with the construction of two TBM cradles in Tideway Central’s laydown area. BESPOKE ENGINEERING SOLUTION In January 2018, the second phase commenced with the delivery of components to the site, using a specially designed sheerleg system
to unload the heaviest items and a crawler crane for the remaining components. Both methods were chosen as the best equipment to maximise the lifting schedule within the available tidal window and optimised cost savings. “By designing the sheerleg to specifically fit within the capacity of the jetty, we could provide the most cost-effective method to the client. The bespoke equipment we designed for the Thames Tideway project has enabled us to complete the first two phases swiftly and safely,” explained Chris Horan, ALE’s Project Manager.
ALE USES FLOATOVER JACKS TO INSTALL ONE OF THE WORLD’S LONGEST LINKSPAN BRIDGES ALE has installed one of the world’s longest linkspan bridges using the innovative hydraulic floatover jacks in Gujarat, India. Measuring 100m long and weighing 950t, the linkspan bridge needed to be installed onto the Dahej-Gogha Ro-Pax ferry using jacking, mooring and ballasting techniques.
“This part of India witnesses massive tidal variations; in fact, some of the highest tidal variation in the world. Therefore, the operation required a timely and synchronised solution with little room for error,” explained Matthew Hodgson, Engineering Manager for ALE – Offshore Services. GLOBAL EXPERTISE DELIVERED LOCALLY
TRUSTED ADVISOR
“There are so many stakeholders involved across the whole project, so we are delighted to have successfully coordinated the transportation of so many components within the tight project schedule. We are looking forward to progressing to the next phase of the Thames Tideway project.”
In January, ALE deployed its specialist ALE-Offshore Services division to perform the necessary calculations, engineering designs and testing, and offshore operations, including mooring and ballasting. ALE used one of its latest pieces of technology, the 3m stroke floatover jacks, to install the bridge.
The next phase will involve the assembly of the components onto he cradles by the client, where ALE will then complete their scope by transporting the two TBMs on site and lowering them down a 65m deep shaft.
This is the inaugural job for the hydraulic floatover jacks and they were ideally suited to perform the quick floatovers that can counterbalance the fast currents and the high tidal range of over 10m – within some of the highest variations in the world.
The Thames Tideway project involves the construction of a 25km underground tunnel, up to 66m deep, which will help to expand London’s sewerage system.
The quay side part of the link span had to be positioned onto a fixed support, with the opposite end of the support fixed to a floating pontoon. As the weight of the link span was gradually taken by the floating pontoon, the buoyancy constantly changed and the jacks were used to incline and lower the link span into place.
Dan Kempin, Business Development Manager for ALE-Offshore Services, said: “We needed to navigate the bureaucratic complexities and drew on our group resources as the foundation of our expertise. Unlike other installation methods that would have required up to 11m of dredging, we only needed 2m, which was the ideal solution as it saved time and money for the client. This is a great milestone for the client and ALE – Offshore Services and shows the jack’s unique capabilities for projects like this.” This new Ro-Ro bridge will reduce travel time to 1 hour 30 minutes compared to 7 hours travelling by road around the Gulf of Cambay, as sea transport connections are opened from Dahej and Gogha via ferry. A video of the operations can be viewed here: https://www.youtube.com/watch?v=yeg5y9rzqvI
“The operation required a timely and synchronised solution with little room for error.”
“By designing the sheerleg to specifically fit within the capacity of the jetty, we could provide the most cost-effective method to the client.”
RECORD-BREAKING EVAPORATOR MOVE IN SAUDI ARABIA ALE has broken another world record to transport the world’s heaviest evaporator, weighing 5,134t, in Saudi Arabia. ALE was contracted to perform the full delivery scope of the evaporator as well as the steam transformers, lime filters and brine manifold to the Shoaiba Desalination Plant Project in Shoaiba, 100km south of the port city, Jeddah. COMPLEXITY MADE SIMPLE Commencing in April, ALE first received and handled the items at the plant’s jetty. The evaporator was loaded-in using 186 axle line of Generation 3 SPMT in a 3 x 2 file 62 configuration. Smaller, different configurations were used for the other items. These were then transported 1km to the Shoaiba Desalination Plant Project site. Once on site, ALE had to negotiate the challenging route within the plant. To avoid the unnecessary removal of obstacles and pass over fences, aspects of the cargo structure were modified. Andrew Spink, General Manager for ALE’s Saudi Arabia branch, commented: “It is fantastic to be involved in transporting cargo of this sheer size and scale that makes it such a landmark move. This was a complex operation, not only in terms of the pieces involved, but also the logistics of receiving almost 200 axle lines of SPMT and mobilising an experienced transport crew. It was completed successfully and sailed away within the time constraints all thanks to our team’s flexibility, local expertise and effective co-ordination between ALE’s Middle East branches.”
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WORLDWIDE HEAVY TRANSPORTATION AND LIFTING
Division Focus In 2017 ALE set up a new global division providing specialist services in the wind energy sector: ALE – Wind Services. CENTRE OF EXCELLENCE This division acts as a ‘centre of excellence’, comprising a dedicated team of experts with over 40 years’ specialist combined experience in wind farm construction across the globe. The division focuses primarily on the developing regions for the mechanical and electrical installation, Balance of Plant (BoP), maintenance and project management, with one simplified interface for optimised cost, contract and project management. The division operates world-wide to compliment the core transportation and heavylifting services of ALE’s local branches, whilst providing an enhanced level of specialist expertise. Based in strategic global locations, our people also have the expertise to understand the localised market conditions, challenges and regulations in line with international project management. ALE’s dedicated Wind Services division works with major suppliers, developers, and engineering, procurement and construction contractors (EPCs) to deliver specialised project engineering that can be fully customised to client requirements. As a result, ALE has opened a new office in Melbourne, Australia, as well as Alicante, Spain, with proficient new teams who are experienced within the field and have the necessary civils and wind-energy knowledge to oversee the client requirements. FULL SCOPE OF SERVICES FOR WTG DELIVERY “Having grown a good reputation within the wind industry, the requirements of our clients are changing and we identified a gap in the market for a heavylifting company that can provide a BoP package, including the flexibility of bespoke crane, transport and installation solutions from one single point,” explained Matthias Breu, General Manager for ALE - Wind Services.
“This team will maximise our current localised offering and position ALE on a truly global level for these specialist wind services that is unparalleled within the industry.”
ALE DEMONSTRATES FULL-SERVICE WIND SCOPE FOR EL LLANO WIND FARM, ARGENTINA
ALE has invested in the latest technology, such as the K1650L tower crane, to ensure that we can meet our clients’ demands and the next generation of turbines. Selecting the most suitable equipment and main crane specifications is fundamental in optimising the logistics, health and safety, and installation sequence as well as fundamental to the build rate and the overall success of the project.
Overview: ALE has successfully provided the full-service package for the El Llano wind farm, including the discharging and port handling, transportation, assembly and electro-mechanical installation of 14 wind turbines.
Sectors: Renewables. Equipment: In co-operation with the local branches, divisional projects utilise the ALE group’s specialist equipment for the renewable energy sector. This includes an extensive range of blade, low bed and extendable trailers, as well as tower clamps and low profile wind tower adaptors which enable tower sectors to be transported under standard bridges. ALE has some of the largest wind energy-specific mobile and tower cranes with minimal civil footprints and high-wind compatibility.
Services Required: The 14 wind turbines comprised 154 components. ALE received the wind components at Puerto Madryn, in Patagonia. They were then transported to site using a variety of trailers suited to the job at hand. ALE utilised 36 conventional axle lines and two spacers, three extendable semi-trailers plus two trailers of different capabilities.
Services: Port handling and storage, inland transportation and lifting, BoP (civil and electrical works), electrical and mechanical installation, and maintenance support of wind components.
For the discharge on site, ALE provided several cranes, ranging from 95t capacity to 250t capacity.
“We identified a gap in the market for a heavylifting company that can provide a BoP package, including the flexibility of bespoke crane, transport and installation solutions from one single point.”
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For the installation and assembly scope, ALE positioned an LR1600 W/2 crawler as the main crane, an LTM1500 mobile crane, an LTM1250 mobile crane as well as an LTM1095 mobile crane for the assembly of the T1 and T2 sections and supporting activities. The project is ongoing and is currently at the assembly and electromechanical installation phase, where ALE has an experienced team of 45 to carry out the rigging and operations for the installation and transportation.
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WORLDWIDE HEAVY TRANSPORTATION AND LIFTING
ALE FOCUSES ON RISK MANAGEMENT WITH CLIENT WORKSHOPS
HSQE
ALE has focused on its risk management and increased client engagement by conducting workshops with clients in the Middle East. The sessions have been part of a collaboration between ALE’s Commercial and HSQE teams to provide greater engagement with clients in order to create the safest possible work environment. They enable ALE and their clients to agree best practice on sites, as well as share ideas and previous lessons that have been learnt.
SAFETY COMMUNICATION AND TIME MANAGEMENT AWARD WIN ALE has won an award for outstanding safety awareness, after impressing a client with their communication and time management whilst performing three load-outs in South Korea as part of the Johan Sverdrup project.
ALE has run numerous risk management sessions over the last year with companies including DHL, ABB, GE and Lamprell, and ALE has been able to adapt the sessions to each client. Knowing that every client has different needs, some sessions have been held within large groups, while others have been more intimate.
There were numerous contractors working on the project and the client was particularly impressed with ALE’s levels of communication, which kept the client regularly updated about any safety issues. The client also praised how ALE had managed the tight schedule and site deadlines without compromising on safety.
Jeff Dean, Technical Sales Manager for ALE’s Middle East branch, said, “We have chosen to take the initiative with our clients and
An extra crew ensured that employees could be guaranteed enough rest during the two-week operation. This also enabled the operation to be carried out at a steady pace. ALE held daily meetings to discuss any safety issues onsite, which ensured they could be handled and communicated across all parties consistently.
differentiate ourselves by conducting more mature and diligent risk management. Ultimately, this translates to lower risks and costs across all of our projects.” “The early client engagement ensures we can gain a clear understanding of a client’s requirements. It also saves time that might otherwise be lost due to a lack of or breakdown in communications.” Working alongside others in the industry has enabled ALE to identify methods to increase efficiency and the company plans to continue driving risk engagement by conducting more sessions in the future.
“They enable ALE and their clients to agree best practice on sites.”
SAFETY INITIATIVE PROVES A SUCCESS
The operation consisted of the weighing and load-out of three modules, weighing 6,223t, 9,239t and 9,766t respectively, and measuring approximately 80m x 20m x 30m.
ALE’s in-house safety initiative has proved a real success for gaining insight and making improvements in the business, with several employees in ALE’s Global Projects Division (GPD) recognised for their contributions.
act on a ladder and ensuring that the ladder could be secured for future use, demonstrating the use of appropriate personal, protective equipment (PPE) at all times on site, taking responsibility to survey site ground and providing positive HSQE improvement suggestions.
The modules form part of the Riser platform. This will be the first of four platforms to be installed as part of the Johan Sverdrup oil field project in the North Sea, near Stavanger, Norway.
Every month, GPD recognises employees who have demonstrated or encouraged excellent HSQE behaviours. Each recipient receives a recognition certificate and is also awarded with a small prize.
Employees were also recognised for proactive actions like demonstrating the use of appropriate Personal Protective Equipment at all times on site and taking up responsibility to survey a site ground. The latter ensured cranes were prevented from toppling during base-levelling and assembly for the operation.
GPD work on specialist long-term projects across the globe, including high profile operations like the recent award-winning Yamal LNG and Sakhalin projects. The safety awards have been running since 2015 and anyone working on a GPD project is eligible.
CORPORATE SOCIAL RESPONSIBILITY EXPERTISE INCREASES
To date, awards have been presented on projects in several countries, including Brazil, Belgium, Russia, Nigeria, and the UK.
Awards can be given for positive and reactive initiatives, such as initiating a procedure for reporting defective tools, reporting an unsafe
ALE has boosted its Corporate Social Responsibility expertise and plans to be more proactive with the support of Eva Merino, HSQE Manager for ALE’s Spanish branch, who has completed a Master’s degree in Corporate Social Responsibility (CSR) at the University of Alcalá, Spain. The CSR degree examined the various consequences of corporate activities, including the social, economic, ethical and HSE impact. Eva studied numerous areas, including public policy, ethics, law, and HSE. Eva has already begun to put her knowledge into practice and is currently analysing the types of action ALE can take as part of ALE’s CSR policy. “This is an important step in Eva’s personal development and will also help prepare ALE for the future,” said Gary Hewitt, Group HSQE Manager. “With the knowledge and skills this qualification has provided, Eva will be able to help take ALE to the forefront, working towards sustainable operations and resilient environments.” Eva will be advising other HSQE managers around the globe, as well as helping to shape the ALE Group Key Performance Indicators in 2018.
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WORLDWIDE HEAVY TRANSPORTATION AND LIFTING
Q&A – KIMBERLY MYERS, PROJECT ASSISTANT FOR ALE’S USA BRANCH
ALE People
travel arrangements, to managing accounts and processing invoices. One of my main responsibilities is supporting the sales team in the US. This could include adding information into our client database (CRM) and arranging employee training on the system. I also manage all the company licensing, obtaining any permits that ALE may need to work in a different state or county.
ALE INVESTS IN THE NEXT GENERATION OF ENGINEERING TALENT As part of ALE’s hunt for the next generation of engineering talent, the leadership team from ALE’s UK branch hosted a dynamic assessment event in January 2018. A total of 24 engineering undergraduates took part across two separate assessment days, completing a total of 11 exercises and tasks which tested their problem solving, communication, presentation, time management, drawing and technical capabilities. The five successful students were invited to join the engineering teams within the Hixon, Middlesbrough and Breda branches on a 12-month industrial placement, starting in the Summer of 2018.
More than 200 candidates applied from various universities across Europe. During their 12-month placements, the students will be involved in a range of tasks, both office and site-based. “In addition to providing valuable support to our engineering functions, the objective of this programme is to spot and engage people who will fit with, and be able to add to the company’s unique engineering capability once they have completed their degree studies. This opportunity could be in the UK or in any of ALE’s global locations,” explained Chris Hines, Group Recruitment, Learning and Development Manager.
Q: When did you join ALE? A: I joined the company in January 2016. When I started, I was supporting the Sakhalin project in Russia, as I had previously worked on the project. My job has grown into a huge office managementtype role and it’s been an enormous learning experience because of how much ALE is growing in the US. Q: Describe your role and what it involves? A: I cover a lot of different things and get involved in a variety of tasks, from co-ordinating the health insurance and
As the Houston office is growing, I’m also providing more HR and recruitment support. I set up the new starters, making sure all their computer software needs are set up, cell phones and business cards ready upon the first day of work.
Q: What is a typical day like? A: I never know how my day is going to be. I arrive, sort out the office facilities and emails, address any accounts, process invoices and handle any insurance issues. After that, it’s mainly following up on outstanding issues. I assist the sales team with CRM, proposals and non-disclosure agreements, as needed. After my routine is done, everything varies afterwards.
Q: How has the branch changed since you have worked here? A: Yes, in the beginning this office was only a sales office for the ALE – Global Projects Divison. Now we have more employees and have acquired equipment, including 60 axle lines of SPMTs and 2 PPUs. We are working on securing more heavy haul transportation work. Business in the US has really been picking up and we are currently bidding on lots of work across the US and Canada. Q: What do you enjoy most about working for ALE? A:
I like staying busy, learning new things and I enjoy working with people from different parts of the world. Every day is something new so I’m constantly learning – not just about equipment, but also how ALE functions internally. Also, I really enjoy working exhibitions because I get to assist in the coordination of the booth, meet clients face-to-face and watch our ALE sales team at work. It’s exciting.
Going forward, I hope to learn and grow more in my role with ALE.
“It’s been an enormous learning experience because of how much ALE is growing in the US.” SUPERVISOR EXPERTISE IS ENHANCED WITH LAUNCH OF DEVELOPMENT PROGRAMME ALE has enhanced their Supervisor expertise with the introduction of a dedicated internal course: The Supervisor Development Programme. VALUE IS TO ADDED TO OUR CUSTOMERS Recognising the crucial role that Supervisors play in ensuring that projects are carried out safely, on time, within budget, to a high standard, ALE’s Board of Directors have put their full support behind a series of initiatives. A ‘Supervisors Round Table’ has been established which comprises 12 Supervisors from across the ALE Group, along with Board members and contributors from internal HSQE and Learning and Development teams, to lead these initiatives that will benefit and support their colleagues. The programme is being delivered by ALE’s in-house training team, using a mix of face-to-face workshops as well as practical sessions. A pilot took place at ALE’s Spanish office in April, with a view to roll-out the programme across the ALE Group throughout the remainder of 2018. The programme has been designed by Charles Green, Regional Training Manager for ALE’s Abu Dhabi branch. Charles commented: “Our operational teams are at the heart of everything we do, and we designed this programme to ensure we are giving the team all the tools they need to succeed. The aim is to enhance their expertise with management and interpersonal skills, whilst giving them the empowerment necessary to ensure operations are executed safely.”
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“We designed this programme to ensure we are giving the team all the tools they need to succeed.” WWW.ALE-HEAVYLIFT.COM
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Case studies – Africa, Caspian and Middle East
WORLDWIDE HEAVY HEAVY TRANSPORTATION TRANSPORTATION AND AND LIFTING LIFTING WORLDWIDE
Case studies – Europe PRE-ASSEMBLY OF OFFSHORE WIND COMPONENTS, NORTHERN IRELAND
BESPOKE METHODOLOGY FOR HULL ROTATION, SOUTH AFRICA
OVERVIEW: ALE has successfully completed the pre-assembly works for 51 offshore wind turbines, for the Walney Extension offshore wind farm in Belfast.
OVERVIEW: ALE has successfully performed the loading, transportation and rotation of a ship hull, weighing 100t, in Table Bay Harbour, South Africa.
SERVICES REQUIRED: ALE utilised one 750t capacity, two 300t capacity and one 1,200t capacity cranes to discharge and assemble the 51 wind turbines at Belfast Harbour.
SERVICES REQUIRED: The hull was first loaded onto 24 axle lines of SPT in a configuration of 3 file 16. These were chosen as they were the best transport solution, suitable for the dimensions of the hull.
The wind turbine components comprised of nacelles and towers sections. The components were discharged from a delivery vessel and then transported to a temporary storage area on a variety of trailers, suited to each specific component. ALE used 8 axle lines of SPMT, 12 axle lines of SPT for site movements of the tower sections and nacelles.
The hull was then transported from the fabrication warehouse to the rotation area within the harbour. The hull, which was built upside down to reduce the man hours spent on fabrication work, then needed to be rotated. Considering the hull’s asymmetrical shape, it could not be rotated using the normal cradle method and ALE was tasked with finding an alternative solution.
The blades were moved around site on ALE’s blade transportation system which was specially designed in-house by ALE to carry the blades. This was the first time this transport system has been utilised. As part of ALE’s four-year crane framework agreement, ALE has been continuously lifting and moving on site and has now completed the full scope for the shore operation, ready for the offshore installation.
Instead, ALE utilised three 220t cranes to rotate the hull 90 degrees, detach the third crane, relocate it to the opposite side, reattach it and completing the rotation. This methodology was favourable to the client as it saved costs as only three, not four, cranes were required. The hull was then transported back on the SPTs to the fabrication warehouse and offloaded using the trailers’ hydraulics.
THE MEGA JACK 800 USED IN QUICK AND MULTI-SERVICE BRIDGE INSTALLATION, BELGIUM
The project was completed in three days.
OVERVIEW: ALE has successfully demonstrated its multi-service capabilities when performing the load-out and installation of the arc bridge, weighing 1,200t, using the Mega Jack 800 in Antwerp, Belgium, for De Vlaamse Waterweg. ALE had only one weekend to complete the operations; this was only possible by using the Mega Jack 800 as operation time is reduced. SERVICES REQUIRED: In order to complete the different techniques and operations, ALE ensured logistics were optimised to work with the limited room available on the barge. The bridge deck and arches were transferred from the construction supports onto 40 axle lines of SPMT with 4 PPUs in a configuration of 4 x 4 file 4/6 row. ALE then loaded-out the bridge deck, longitudinally from the fabrication site at Gent. The bridge was then transported 75km with the SPMTs by barge to Antwerp on the Scheldt River. In order to pass under the low bridges on route, the arches of the bridge were positioned in pieces on top of the bridge deck with a restricted height. Once in Antwerp, the bridge was loaded-in transversally at the site near the final location. Here, the arches were fully assembled over three months and then the entire bridge structure was jacked-up using four 500t climbing jacks and loaded-out using 28 axle lines of SPMT in a configuration of 2 x 4 file 14. It was transported by barge 2.5km under high voltage lines to the final installation site. The bridge was then installed into its final position. To position the bridge higher than the abutments, the bridge was jacked-up 8m using ALE’s Mega Jack 800 and strand lashing was installed to protect the bridge against the wind and float-in forces. The Mega Jack 800 is one of the most stable jacking solutions on the market, making it the ideal solution that also increased safety. ALE used tugboats to float-in the bridge into its position, the bridge was then lowered by 3m in between the abutments, with a clearance of 160mm. The bridge was then set-down onto the temporary bearings.
LIFTING OF HEAVY FERTILISER PLANT EQUIPMENT IN ASWAN, EGYPT OVERVIEW: ALE has completed the lifting of 11 heavy items, weighing up to 494t, at a fertiliser plant in Aswan, Egypt. SERVICES REQUIRED: The largest and heaviest items were the ammonia converter, weighing, 494t, and the pool reactor and absorber, each weighing 347t. ALE transported the pieces using conventional trailers, until they were close to the foundation and within the radius of the crane. ALE lifted the items into position using 400t and 800t capacity cranes. The LR1800 was the main crane while the LR1400 assisted with most of the lifts by lifting in tandem, followed by the erection and the subsequent installation. The lifting system included a 700t capacity rocker beam, consisting of different sections that, together with the choice of hoisting gear, enabled ALE to adjust the length depending on the characteristics and hoisting points of each piece.
A video of the operations can be viewed here: https://www.youtube.com/watch?v=5tMqRpGuSGE&t=291s
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WORLDWIDE HEAVY TRANSPORTATION AND LIFTING
Case studies – Americas COST-EFFECTIVE INSTALLATION OF THE OLYMPIC STADIUM ROOF SECTIONS, ARGENTINA OVERVIEW: ALE has completed the installation of six roof sections, weighing 50t each, for the Parque Roca Olympic swimming pool in Buenos Aires, Argentina.
which is slightly smaller than other crane options, ALE delivered a more efficient configuration and was ultimately a more cost-effective method for the client.
SERVICES REQUIRED: ALE installed the six roof sections, as well as a springboard and steel structure.
ALE completed the roof lifts in two months.
ALE used a 600t capacity crawler crane with a luffing jib at a 48m radius and 30.5m mast to lift each section. By deploying this crane,
The roof forms part of the Parque Roca stadium that will host the Youth Olympic Games later in the year.
PORTAINER CRANE MOVE SHOWCASING MULTI-SERVICE EXPERTISE, CHILE OVERVIEW: ALE has performed the jacking and skidding of a portainer crane, weighing 1,400t, at the Terminal Pacifico Sur Valparaiso port in Valparaiso, Chile. SERVICES REQUIRED: The crane was skidded away from a set of railway tracks so that the port could increase the quay efficiency and four cranes could be relocated.
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ALE used eight 150t skid shoes with four 22t jacks and four 300t skid shoes with four 43t jacks to move the crane 60m. The total length skidded during the operation was 120m. ALE completed the manoeuvre in 40 hours.
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WORLDWIDE HEAVY TRANSPORTATION AND LIFTING
Case studies – Australasia and Asia Pacific FULL TCI PACKAGE OF WIND TURBINES FOR THE TOLO 1 PROJECT, INDONESIA OVERVIEW: ALE is currently performing the transport, craneage and installation of 20 Siemens Gamesa wind turbine components for Vena Energy’s Tolo 1 project site in Jeneponto, in South Sulawesi province.
specialist clamp tower trailers had been used in Indonesia and they were ideally suited when negotiating the overhead restrictions on the challenging route as the driving height could be reduced.
SERVICES REQUIRED: As part of the whole contract, ALE has been tasked to provide the full TCI package of 20 Siemens Gamesa wind turbines comprising five tower sections to make up a total of 220 abnormal loads.
For the 64m-long blades, 12 axle lines of specialist extendable blade trailers were utilised in a configuration of 3 x 2 file 4 axles.
The components were received at the Makassar Port, where they were unloaded and stored. The generators, weighing 74t each, and the tower sections, the heaviest weighing 86t, were loaded onto 11 axle lines of conventional trailers in a configuration of 3 x 2 file 5 as well as 6 axle lines of clamp tower trailers. This was the first time these
So far, ALE has transported 40% of the components almost 100km to the site. The craneage recently started with the completion of pre-population on two turbine foundations using a 450t mobile crane.
WEIGHING AND LOAD-OUT OF 20,000T MODULES, SOUTH KOREA OVERVIEW: ALE has successfully weighed and loaded-out two modules for the Martin Linge project in South Korea. SERVICES REQUIRED: ALE first performed the weighings of the utility module, using 24 600t capacity weightors, and the process module, using 32 600t capacity weightors, with ALE’s centrally-controlled synchronised weighing system. This system allowed the client to receive the results of the module weights and centre of gravity positions in real time. The utility module weighed in at 9,580t and the process module weighed 10,850t.
The modules were then loaded-out onto the same vessel in two separate operations. As the modules had a high centre of gravity, it was extremely challenging to load them out onto the same vessel and control the vessel’s stability. For this, ALE utilised a computerised skidding system to overcome this, as well as quay jacks to monitor the load. The operations were completed within three months. A video of the operations can be viewed here: https://www.youtube.com/watch?v=GDFQU3VFUlo&t=1s
The main-build operation will commence soon using a specialist 750t crane.
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