Floating Dry Dock Specification

P246633 Marzo, 2005

FLOATING DOCK SPECIFICATION


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I N D I C E

1 General .................................................................................................................................... 3

1.1 Description....................................................................................................................... 3 1.2 Main characteristics ......................................................................................................... 6 1.3 Classification and Rules................................................................................................... 6 1.4 Stability............................................................................................................................ 6

2 Hull .......................................................................................................................................... 7

2.1 Structure ........................................................................................................................... 7 2.2 Pontoon ............................................................................................................................ 7 2.3 Wing walls ....................................................................................................................... 7 2.4 Umbrella structure............................................................................................................ 7 2.5 Connecting Towers between Umbrella and Dock. .......................................................... 8

3 Equipment ............................................................................................................................ 10

3.1 Umbrella hoisting system .............................................................................................. 10 3.2 Working forms ............................................................................................................... 11 3.3 Concrete booms.............................................................................................................. 13 3.4 Mooring.......................................................................................................................... 17 3.5 Towing ........................................................................................................................... 18 3.6 Platforms, Stairs & Ladders........................................................................................... 18 3.7 Cathodic Protection........................................................................................................ 19 3.8 Painting .......................................................................................................................... 20 3.9 Rails & Stanchions......................................................................................................... 22 3.10 Grating ........................................................................................................................... 22 3.11 Control room preparation............................................................................................... 22

4 Systems .................................................................................................................................. 23

4.1 Ballast system ................................................................................................................ 23 4.2 Sounding and Vents of tanks ......................................................................................... 24

5 Electricity .............................................................................................................................. 25

5.1 Shore connection............................................................................................................ 25 5.2 Main switchboard........................................................................................................... 25 5.3 Battery and battery charger. ........................................................................................... 25 5.4 24 V c.c. Switchboard. ................................................................................................... 25 5.5 Control panels ................................................................................................................ 25 5.6 Electrical consumers ...................................................................................................... 26 5.7 Generating set ................................................................................................................ 26


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1 General

1.1 Description

The aim of the present document is to define the main cha racteristics of a floating dock designed for construction of floating caissons, made of reinforced concrete.

The maximum dimensions of caissons to build are the following:

Length 58 m. Beam 37 m. Depth 35,5 m. Weight 45000 Tm approx.

There will be the possibility of building another kind of caissons, according to the design of dock.

The floating dock will operate in sheltered waters, protected from the sea, near a harbour. Occasionally the floating dock will be towed in open waters from harbour to harbour.

To see the composition and distribution of dock elements see the preliminary General arrangement drawing.

The floating dock comprises a central pontoon and two lateral walls having on top of each side, a metallic structure of seven (7) towers connected between them. From these towers a main horizontal frame (so-called umbrella) hangs on. This frame can slide using a motion controlled system (hydraulic jacks).

Over the pontoon deck is constructed the floating caisson. When the caisson is completed the caisson floats, after the dock have reached the necessary draught.


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2500

0

Figure 1.- Floating dock configuration (preliminary).

Basically the floating dock can be splitted in two different parts:

The dock

The sliding structure (umbrella)

The connecting towers between dock and umbrella

Umbrella

Dock


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Figure 2.- Umbrella and connecting towers.

The main equipment involved is:

o Forms and supporting elements

o Concrete mixing and pumping machines

o Pneumatic air system

o Hydraulic integrated system to lift and lower the so-called construction – umbrella that holds the block construction formers.

o Lighting system

o Ancillary hydraulic crane for handling material

There is an equipment for hydraulic lifting/lowering the umbrella for construction of high-rise concrete caisson structures.


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1.2 Main characteristics

Except otherwise specified, the metric system will be used through this specification.

The following characteristics and dimensions are provisional and could be changed after a final design is achieved.

Length b. p. 60 m. Beam moulded (exterior) 49 m. Beam (interior bulkheads of wing walls 39 m. Depth of pontoon deck 5 m. Depth of wing walls 31,1 m. Halfbreadth of sides 5 m. Scantling draught 29,1 m.

1.3 Classification and Rules

The dock is designed, classified and built to operate in sheltered waters. The classification notation will be I 3/3 + Service “Floating Dock” /NP “Sheltered Waters” and navigation “Deep Sea/Occasionally”.

This class notation is according Bureau Veritas rules, but a similar notation according to another Classification Society will be admitted.

The following international conventions are to be complied with:

International Convention for the Safety of Life at Sea (SOLAS) 1978 and Amendments in force. Consolidated edition 2001.

International convention on Load lines, 1966 including Protocol of 1988 and Amendments in force.

International Tonnage Measurement of Ships 1969 and Amendments International Convention of Prevention of Collision at Sea (1972) as amended by IMO Resolution A-464 (XII).

1.4 Stability

The dock will comply the stability criteria according to the Spanish requirement for this kind of ships as far as applicable, in particular the “Circular 12/90 de la Inspeccion General de Buques sobre estabilidad de buques de carga y pasaje menores de 100 m.”


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In all loading conditions GM, corrected by liquid surfaces, will be at least 1,0 m. as required by Lloyds Register for this kind of naval docks.

2 Hull

2.1 Structure

For the construction of both the pontoon and the wing walls mild steel, class “A” will be used, according to the Classification Society Rules. Minimum yielding stress to be 235 N/mm2.

Welding is to be approved by Classification Society. Continuous welding is to be adopted in the main structural elements and, always, inside ballast tanks.

There are two different zones by the structural point of view: the pontoon and the wing wall.

2.2 Pontoon

Both ye deck and the bottom are longitudinally framed, with transversal bulkheads being the boundaries of tanks. Every 2,50 m. there is a transversal girder, being this the span of longitudinal stiffeners.

All constructive details will follow the good naval construction practice, according with the Classification Society.

2.3 Wing walls

These are longitudinally reinforced in the upper part, where they collaborate to the longitudinal strength of the dock. In way of the window existing in the wing walls, the structure will be transversally framed, to stand up against the forces caused by the support, lifting and descend of umbrella.

2.4 Umbrella structure

The umbrella is a truss steel structure, shaped to form the blocks including the internal cells for stiffness.

It is a modular structure having 38.4 meters wide, 58 meters long and 3.3 m high. It has 24


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points to attach the climbing system (12 by side) and the estimated weight is about 420 ton.

This structure hangs from 24 points (12 by side). In addition and to avoid any excessive movement due to wind effect, the umbrella shall be guided at four points (one per corner) in both directions by means of shock absorbers.

Figure 3.- Umbrella structure.

There will have a central longitudinal platform to allow the installation of mobile concrete booms on the top floor of the “umbrella”.

There shall also be two longitudinal platforms at both ends to allow the installation of ancillary hydraulic cranes to manipulate steel bar for concrete caisson construction.

For both the booms and the cranes, it shall be required a system to allow the longitudinal displacement, using a guiderail and the needed equipment.

In addition several transversal platforms/footbridges shall be foreseen for personnel access.

2.5 Connecting Towers between Umbrella and Dock.

The floating dock has fourteen (14) steel structural towers (seven by side) connected between them by a master beam. There are two different types, four towers located at the ends of the dock (narrow towers) and ten between them (wide towers).

The structure of each wide tower is a truss type of 4.4 x 5 m at the base and a height of


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about 25 m. Its weight is about 17 ton.

The structure of each narrow tower is a truss type of 4.4 x 3 m at the base and a height of about 25 m. Its weight is about 16 ton.


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3 Equipment

3.1 Umbrella hoisting system

On both sides of the dock, 12 sets of stage- lifting hydraulic units operated by 3 high-flow power sources and controlled by a synchronized PLC system operate the umbrella.

• Controlled Movement

Due to the size of the concrete block and thus the umbrella, the risk of twisting and therefore locking the umbrella between both dock walls is a serious thread to the process. For that reason a fully PLC controlled synchronized hydraulic integrated system is required.

• Climbing elements

Along both sides of the dock huge but lightweight constructions hold the climbing stage lifting steel notched plates, while the climbing stage lifting hydraulic units are fastened to the umbrella deck. As mentioned before, 12 units along each side of the umbrella deck. Each unit exists of an advanced hydraulic system including stroke– and and proximity–sensoring technology.

• Climbing Units

All 24 climbing units comprise two long stroke hydraulic double acting cylinders of 70 tons capacity and two double acting hydraulic locking cylinders of 20 tons capacity. The long stroke cylinders, used for the actual lifting and lowering process, include a magnetic stroke sensoring system, which communicates the plunger’s position via a local manifold and valving unit to the central PLC-system. The locking cylinders also include stroke sensors that signal their position to the PLC-system where all data is processed and communicated back to the pumps and 2/2-way valves that control all cylinders (96 in total) in all 24 climbing units. The locking cylinders are used to fix the climbing units during the climbing process. The main PLC-system is operated via a touch screen with a graphical user interface, continuously showing the actual stage of the process, including all parameters. Overall lifting and lowing accuracy of the entire system is 0,01 mm.

• Ancillary crane Two hydraulic cranes type Palfinger or similar on top floor of “Umbrella”. Capacity 4 ton/12m, this crane shall be possible to use also as lifting appliance when lifting parts from deck or loading materials onboard ship.


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• Hydraulics Hydraulic system with electrically driven hydraulic pumps to be installed. Pumps to be installed top floor of “Umbrella”. Separate hydraulic system to be provided for ancillary cranes. All hydraulic piping on exposed decks to be made of acid resistant pipes and connections. System pressure preferably not to exceed 250 bar.

Final design of hydraulic system and components to be carried out in close co-operation with owner.

3.2 Working forms

Working forms will be supplied by the shipowner.

General dimensions and basic array is included for the selected form type.

o Height 1.20 m o Plate thickness 3 mm o Total weight : Forms +Hanging supports+Platform 225kg/ml o Strip (Tapering) 5-8 0/00 o Hanging supports length 1.50 m o Hanging support clearance (free height) 0.7 m

The floating dock (umbrella included) could be adapted in order to use different working forms as required.

The sliding speed shall be 20 cm/hour

The connecting elements between the “umbrella” and the working form shall be adjustable in order to guarantee the horizontal plane of the forms.

Working form array caisson dimensions Cell diameter

4,00 3,80 3,50 3,30 3,00 m

Outer cells cutting angle

111,06 0,00 64,70 119,68 108,90 Degrees

Length 57,30 56,60 56,10 56,60 56,60 m Width 36,00 35,98 36,00 36,00 36,00 m

Concrete caisson wall thickness (distance between forms):

Outer cells minimum distance to longitudinal edge (both sides): 0,50 m Outer cells minimum distance to transversal edge (both sides):: 0,40 m Minimum distance between round shaped cells: 0,20 m


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Minimum distance between round-oval shaped cells: 0,20 m

PLANT OF TYPICAL CONCRETE CAISSON


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Figure 4.- Typical dimensions for 3.8 m diameter cell.

3.3 Concrete booms

To supply the concrete, three (3) booms sha ll be installed on the top part of the “umbrella”, these booms shall be of stationary type, Putzmeister MXR-MX24-125 or equivalent and the total amount of concrete shall be at least 90 m3/h , this depends also in the human team to perform the activity.

See Annex for Technical data. • Main Characterístics:

The booms shall be easily separated from the interface, they can reach up to 23.8 m and its weight shall be less than 6.350 Kg without concrete, (6.800 kg with concrete on piping).

They shall have up to 4 articulated arms (Z deployment), swivel head and they must assure a controlled discharge of concrete.

The pipeline diameter shall be 5 1/2", and the discharge hose will have a length of 4 m.


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The boom shall have a device to connect with the hydraulic system. This hydraulic system shall comprise a tri-phase motor of 380V, 15 KW, 1480 rpm and a high pressure pump, 24 V control box, 160 lt oil tank with a filter acting on the High pressure pump. All the electric control shall comprise standard components located in a waterproof/watertight cabinet.

Figure 5.- Stationary boom MXR-(MX 24-T)

• Accessories: In addition to main components, each boom shall include the following accessories:

o Radio control

o 2 m length pillar with flanges to assembly, equipped to allow work.

o Working Platform with handrails, grid with required hole for stair access and four attachment bolts.

o Rigid Base

o 2 m length stair, with protection and pipeline supports.


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• Description of the system: 1) MXR-SYSTEM

Pos.1 4-section arm assembly with concrete line 125mm dia. and 4m end horse.

Pos.2.1 Boom pedestal with quick-separating device, mounted hydraulic unit 15 kW 400 V 50 Hz (on request special voltage) and integrated hydraulic oil tank (160lts).

Pos.2.2 Electric control cabinet.

Pos 2.3 Electro-hydraulic control for all boom functions including climbing device. Standard cable remote control with 40 cable. Special accessory-radio remote control.


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2) WORKING RANGE


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3.4 Mooring Following elements will be arranged for mooring procedure.


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3.4.1 Pontoon Deck

• Four double mooring bitts ( two Portside and two Starboard) installed at the window of the wing-wall.

• Four mooring points. Four forward points and two aft points. Two forward points for

main towing operation and two more ( forward and aft) for emergency towing operation.

3.4.2 Main Deck

• Four double bitts, one for every corner ( two in Portside and two in Starboard). • Four mooring electrical winches ( continuous duty pulls) according to the rules

satisfying the environmental conditions of the operation.

Approximate data: Continuous pull : 45 T. Wire: 120 m. Medium speed: 3 m/min.

3.5 Towing The forward structure will arrange four towing eye-bolts. Two of them like main towing operation and the other two like emergency towing operation. The eye-bolts will dimensioned by a unitary load work maxima of 200 T. The shipyard will develop the rest of the adjacent elements ( chains, cables, rings, shackles, etc.)

3.6 Platforms, Stairs & Ladders • Platforms Two braced platforms ( Portside & Starboard) on the top of the Lattice Columns. Wide: 0.90 m Weight: 150 Kg/m2 • Stairs


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Two stair access towers, aft & forward ( one for every side) from Pontoon Deck to the Main Deck. They will include rest intermediate platforms with their appropriate stanchions.

Wide (min): 0.75 m Inclination ( max): 60o

• Ladders The structure will have two protected ladders of emergency opposite to the regular stairs arranged mentioned.

All empty spaces and ballast tanks will be arranged vertical ladders.

Wide: 0.30 m Step distance: 0.30 m

In general, platforms, stairs & ladders will be built following the criteria of the Shipyard and satisfying all referring about security regulations.

3.7 Cathodic Protection Cathodic protection will be required for ballast tanks and hull ( outer shell) and special attention around Sea Chests. It will be considered sacrificial Zinc or Aluminium anode with a medium life of 4 or 5 years.


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3.8 Painting An appropriate painting schema will be applied to this kind of structures and work areas. Usually, first performance is a blast cleaning treatment for all steel material used on the lattice and main structure, ending this procedure with a final shop primer. Preliminary Painting Schema will be the next one.


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PRELIMINARY PAINTING SCHEMA

AREA No. OF COATS KIND OF PAINT THICKNESS (µ)

1 Polyamide Epoxi 50

Underwater Outside Hull 1 Epoxi ( 100%) 200

Immersed areas

1 Safeguard Epoxi Tar-Free 75

1 Antifouling SPC Tin-Free 100

1 Antifouling SPC Tin-Free 100


Outside Hull 1 Epoxi ( 100%) 150

Immersed / Non Immersed

areas 1 Epoxi ( 100%) 150

1 Polyurethane 50


Umbrella & Towers 1 Epoxi ( 100%) 125

Steel Structure

Non Immersed areas 1 Epoxi ( 100%) 125

1 Polyurethane 50


1 Epoxi ( 100%) 125

Deck

1 Epoxi ( 100%) 125

1 Non-Slip Polyamide Epoxi 120


Machinery & Deck Cabins 1 Epoxi ( 100%) 150

Pipe lines, etc.



Ballast Tanks 1 Epoxi ( 100%) 150

1 Epoxi ( 100%) 150

1 Antifouling Epoxi ( 100%) 150

Empty areas & Internals

1 Epoxi ( 100%) 150


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3.9 Rails & Stanchions Following the General Arrangement, Main deck, gangway, platforms in the towers and where are arranged any type of stairs in the structure, will have stanchions. Preliminary, 1 meter of height ( according to the rules). They will be compound for vertical flat bars ( 60X 20), handrails ( ND 42.2 X 3.5) and intermediate rods ( ND 20). Where in other areas are required, stairs dimensions could be modified.

3.10 Grating Where are arranged, shall be Thielco (type double serrated and double anti slip) or approved equivalent, thickness A5/30 above elevation +16 m and A5/50 30x5 (fully welded) DAS below +16 m. Grating to be fastened with clamps or weld studs for (A5/30) or continuous angle iron (A5/50), or approved equivalent. Grating floors shall have a 25 mm clearance from any vessel, sheeting, column, etc, and a clearance of 10 mm from hand railing, baseplates etc. Grating shall not be cut/adapted etc. after H.D. galvanizing.

3.11 Control room preparation The distribution of the Control House will be following the kind of equipments to mounting and Owner’s requirements in order to improve the control of the operations. The structural metallic closing will be completed with a tight exterior door and naval panoramic windows. Top and bulkheads of the Control House will arrange heat & acoustic insulation


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4 Systems

All the required systems will be installed, according to rules:

• Ballast • Vents of tanks • Bilge • Fire fighting • Life saving • Ventilations of stores and rooms • Tank sounding • Mooring • Towing • Electric equipment

4.1 Ballast system

For all the operational conditions of dock is necessary to load or unload ballast from the tanks showed in General Arrangement drawing. There are 16 tanks in pontoon and another 4 in wing walls.

The ballast system will allow maintaining the desired draught and stability conditions for a safe operation of dock

There will be four pump rooms in the pontoon, symmetrical. In each one a ballast pump to be installed and a sea chest, with all the necessary valves manometers, filters and accessories.

The pumps to be centrifugal, selfpriming, 1200 cubm/h capacity at 30 m. water column, electrically driven, with a common foundation for both the motor and the pump. The materials to be appropriated for sea water: casing and impeller of bronze, shaft of stainless steel. The motor will have

Each pump will connected to another pump of the same side, allowing to work with the tanks of this side in case of breakdown.

Valves of ballast system to be of butterfly type, hydraulically operated from control room, in general.

Ballast pipes to be of GRP or galvanized mild steel


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4.2 Sounding and Vents of tanks

Each tank to be provided with vent pipe, going from below the pontoon deck and through the wing wall up to the upper deck. The section of pipe to be 125 % of the corresponding pump discharging pipe. Piping to be of GRP or galvanized mild steel.

A sounding pipe for each tank will be fitted. Piping to be DN 50 ASTM A106 Gr B XS, galvanized., with the normal accessories fitted.


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5 Electricity

5.1 Shore connection

The dock shall be fitted with one Shore supply connection rated at 380 V, 1500 Kw, 50 Hz

5.2 Main switchboard.

The main switchboard will be located in the engine room, in the void spaces over the tower tanks. This switchboard shall provide the control and distribution of the electrical systems ( 380V 50 Hz. main consumers and 220V 50 Hz the low voltage)

5.3 Battery and battery charger. Two battery groups will be fitted on board, for emergency lighting system and remote operated valves The batteries will be charged from the exterior by a transformer.

5.4 24 V c.c. Switchboard. One 24 V continuous current shall be furnished and installed, shall provide emergency distribution services

5.5 Control panels The dock shall be fitted on board with the following control panels:

• Lighting control panel • Umbrella elevation/descend system control panel • Draft indication, forward and aft, port and starboard sides • GM indication, heel and trim situation. • Remote Monitoring and Control System for Ballast Handling.

All functions of ballast handling will be carried out from Control Room.

• Ballast monitoring from control room to be provided, with the following possibilities:

• Ballast pumps start, stop, and speed control • Ballast tank level/gauge indication: the four wing wall ballast tanks are

to be equipped with radar type sensing, Pontoon ballast tanks ullage


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(pressure sensing), with high and low level alarm. • Hydraulic remote valve control. • Ballast pumps running lights • Ballast pumps discharge pressure indicators. • Ballast remote controlled valves position (open/close)

5.6 Electrical consumers

Necessary lighting both for accommodation spaces as well as for deck spaces including working lights to be installed. All apparatus installed on exposed decks to be of non-corrosive material. Lighting equipment to be of approved type intended for use on board ships. All electrical equipment installed on exposed decks to be IP-56.

The electrical consumers are the following:

• Umbrella and its equipment. • Concrete distribution System • Lighting system • Ballast system • Mooring system • Signal and control system.

5.7 Generating set

One generating set, 1200 KW, shall be installed to supply the consumers.


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Annex A) TECHNICAL DATA SHEET MX 24Z

Mass (kg)

With concrete in pipeline: 6787 Out of order: 5898

Load moments (KNm)

Position of arm Arm-side arm-inclination

Pump operation with concrete en pipeline 446 0,0º

Boom operation without concrete in pipeline 19 90,0º

Boom not operation without concrete in pipeline, position for climbing 19 90,0º


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Torque moments (KNm)

With concrete in pipeline: 60 Out of order: 7


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Wind loads

Wind loads by pump operation

Pump operation is allowed only till wind force 8: (wind velocity 20 m/s preasure q – 0.250 KN/m2)

Wind loads boom not operation (high wind in accordance with DIN 1055

Wind load W (KN)

Q Impact pressure (KN/ m2)

A wind exposed area (m2) W= q * A * C

C Aerodynamic force factor for boom

Impact pressure q((KN/m2)

Absolute altitude 0-8 8-20 20-100 Above 100

q((KN/m2) 0,5 0,8 1,1 1,3

Wind exposed area (m2)

Position of arm Win exposed area Center of gravity distance xs of wind exposed surface

I Arm side 6,2 Xs I- 6.1

II Arm side 6,2 Xs II- 0.3

I/II Counterbalance side Xs I- -


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B) COLUMNS WITH QUICK-SEPARATING


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C) WORKING PLATFORM


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D) CRUCIFORM BASE


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MAIN EQUIPMENT AND MATERIAL LIST

Quantity Units Description Remarks

3350 ton Pontoon and lateral walls

units Ballast pumps

units Power unit

420 ton Steel NEN-EN 10025 Grade S355J2/J4G3 for the “Umbrella” tucture

234 ton Steel NEN-EN 10025 Grade S355J2/J4G3 for the towers structure

1800 m2

Grid (type double serrated and double anti slip) or approved equivalent, thickness A5/30 above elevation +16 m and A5/50 30x5 (fully welded) DAS below +16 m. Grating to be fastened with clamps or weld studs for (A5/30) or continuous angle iron (A5/50), or approved equivalent.

Handrails along the grating perimeter.

TBD Stairs

3 units

PUTZMEISTER MXR-MX24-125 or equivalent. This hydraulic system shall comprise a tri-phase motor of 380V, 15 KW, 1480 rpm and a high pressure pump, 24 V control box, 160 lt oil tank with a filter acting on the High pressure pump

Accessories to be included:

o Radio control

o 2 m length pillar with flanges to assembly, equipped to allow work.

o Working Platform with handrails, grid with required hole for stair access and four attachment bolts.

o Rigid Base

o 2 m length stair, with protection and pipeline supports

CONCRETE PUMPS AND THE PIPELINE TO THE BOOMS TO BE PROVIDED BY SHIPOWNER


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2 units PALFINGER or similar on top floor of “Umbrella”. Capacity 4 ton/12m

382 ton

5.7.1.1.1.1.1.1.1 Working forms o Height 1.20 m o Plate thickness 3 mm o Total weight : Forms +Hanging supports+Platform 225kg/ml o Strip (Tapering) 5-8 0/00 o Hanging supports length 1.50 m o Hanging support clearance (free height) 0.7 m

To be supplied by shipowner

24 set

Hoisting system for “Umbrella”. All 24 climbing units comprise two long stroke hydraulic double acting cylinders of 70 tons capacity and two double acting hydraulic locking cylinders of 20 tons capacity (or any other system of 140 tns capacity in each climbing unit)

72 ton Hoisting and guiding bars for hydraulic system. Steel NEN-EN 10025 Grade S355J2/J4G3

24 Units Rotary joints for hoisting bars

3 units Longitudinal displacement system for concrete booms

2 Units 5.7.1.1.1.1.1.1.10 Longitudinal displacement system for ancillary cranes

5.7.1.1.1.1.1.1.11

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