16467 ALE Newsletter FEB AWLRsingle

IN THIS ISSUE

News in Brief

Branch Focus

Case Studies

Personnel Focus

new heightsTHE ALE NEWSLETTER • ISSUE 07

Welcome... ...to the March edition of the ALE biannual newsletter which takes a look at some of the latest projects and developments from the business around the world.

It is inspiring to see the changes and growth that ALE have made in the last decade, from a handful of branches worldwide to a company that now boasts more than thirty offices globally and leads the way in innovative equipment offering alternative solutions to the industry.

ALE is currently in its 30th year and along the way has had many notable highlights, acquisitions and more recently a number of joint ventures.

The R&D division, founded in 2006, has created a number of ground breaking innovations including the AL.SK 190, AL.SK 350, the Mega Jack, super capacity bolsters, and the Hydro Deck to name a few.

Another ALE innovation was recently deployed in Edinburgh on the Forth Bridge crossing project. ALE designed and built a barge which incorporates a bespoke mast that can be adjusted to various required lengths and capacities. It also has the ability to be rotated for the installation of equipment, and has the same properties as a floating crane with the added benefit of being tailor-made to serve clients individual requirements.

The barge was designed by our branch in Madrid and offers the client a cheaper alternative to a floating crane. The system incorporates two lifting points that can be utilised at variable distances depending on the project requirements. Another advantage is due to the lightweight design, the barge is able to operate in shallower waters than a floating crane.

It is exactly this innovative thinking that drives the success and growth of ALE, looking for intelligent solutions to clients’ requirements.

Javier Martinez Executive Director

WORLDWIDE HEAVY TRANSPORTATION AND LIFTING [email protected] WWW.ALE-HEAVYLIFT.cOm

IRAQ DEPOT ALE’s Iraq branch has recently expanded to include a purpose built depot within the current operational base; the depot includes a fully operational workshop to allow for maintenance work to be carried out on ALE’s equipment. The new depot will give the branch the facilities to enable a quick response on projects and a permanent base for the equipment.

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Company News

news in brief

WORLDWIDE HEAVY TRANSPORTATION AND LIFTING

ALE shORTLIsTED fOR EsTA AwARDs

ALE has recently been shortlisted for five prestigious ESTA awards including the safety award and innovation of the year. The awards ceremony will be held in Munich on 18th April.

ALE ECR hEAvyLIfT OPEN NEw PERTh OffICE This year ALE ECR has announced a new office in Australia. In addition to its current branches in Brisbane and Gladstone, and the operational bases in Western Australia and the Northern Territories, the Perth branch was opened in February 2013 to service the Western Australia market.

ALE OPEN NEw bRANCh IN CAsPIAN REgION ALE has recently announced the opening of a new branch in the Caspian region. The new office based in Baku, will service Azerbaijan, Kazakhstan and the wider Caspian/Central Asia area. This is the first ALE branch in this region and will offer ALE’s full range of heavylift and transportation services to clients in this part of the world.

Office News

ALE ANNOUNCE ROLL-LIfT JOINT vENTURE ALE and Roll-Lift have announced the formation of the joint venture ALE Roll-Lift Canada. The Edmond based venture has brought together the very best industry expertise and combined experience of over seventy five years to provide heavylift solutions to clients throughout Canada.

ALE Roll-Lift Canada offers heavylift and transportation solutions primarily within the oil, energy, mining and petrochemical markets. The company is currently investing in a fleet of heavylift cranes from 50te to over 1,000te capacity, lifting systems and specialized transport. This is in addition to the parent companies global resources, and their investments into new equipment.

ALE ANNOUNCE JOINT vENTURE wITh NORwEgIAN COMPANy NORDIC CRANE sTANgELAND ALE has formed another strategic partnership to expand the capabilities on offer to clients in new regions.

Nordic Crane Stangeland is based in Stavanger, Norway and is part of the Nordic Crane Group who operate a fleet of cranes ranging from 10te – 750te capacity and work mainly within the construction, oil, gas, petrochemical, renewable and offshore markets.

Both ALE and Nordic Crane work to ISO standard and by combining services will be able to offer the complete heavylifting and transportation solution to clients within the Scandinavian region.

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[email protected] WWW.ALE-HEAVYLIFT.cOm

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Ag&P ALE vENTUREs INTRODUCE ThE hyDRO DECK The AG&P ALE joint venture have announced the Hydro Deck. The transition pontoon will offer a solution to the challenges faced when loading-in modules under varying tidal conditions, and therefore offer clients a time and cost saving solution to their heavylift and transportation requirements. The Hydro Deck is currently in its fabrication stage and will start work on its first project early next year.

wORLDs hIghEsT CAPACITy LAND bAsED CRANE bUILD ON sChEDULE The latest innovation in the heavylift industry, the AL.SK350 5,000te capacity crane, is currently under construction. The build is on schedule for completion within the next quarter after which it will go through a testing period before starting its first project in Brazil. Included in the new build is a winch system with up to 4,000te capacity and an increased load moment to over 350,000 tonne meters. ALE ROLL-LIfT CANADA EXTENDs fLEET

The ALE Roll-Lift Canada joint venture has recently expanded its fleet to include:

• Two Terex CC2500-1 500te capacity crawler cranes

• One Liebherr LR1750 750te capacity crawler crane

• One Liebherr LR1350 350te capacity crawler crane

• 60 axles of Goldhofer THP/HL “Road Style” and THP/SL modular trailers

NEw EQUIPMENT fOR bRAZIL shIPyARD PROJECT ALE has recently purchased new equipment for its second contract at the Açu Shipyard in Brazil. The long term project will see ALE responsible for the supply of engineering, heavylift cranes and SPMT’s for the construction of FPSO’s, jackets, topsides and offshore support vessels. The new equipment includes three Liebherr LR1750 – 750te crawler cranes, and sixty four axles of Scheuerle SPMT’s.

ALE INCREAsE INvEsTMENT IN sPMT’s The latest investment in SPMT’s will see an increase of 248 axle lines of Scheuerle to be used on projects across the globe.

Equipment News

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NEw CRANEs fOR ALE’s IRAQ bRANCh ALE has now been working in Iraq for more than a year, to continue to grow the business and to meet demand in the area. ALE has invested in a number of new cranes due to high demand in the region, and to facilitate projects.

In total ALE have 37 new cranes specifically for the Iraq region including:

• 14 TEREX RT Cranes from 30 to 75 tonnes • 20 TEREX RT Cranes from 40 to 75 tonnes • 3 TEREX AC Cranes from 100 to 250 tonnes

ALE DEsIgNs NEw MODULAR bEAM sysTEM

ALE has designed a set of innovative transverse beams that can be utilised in a variety of arrangements. The beams are modular in lengths of 5.5m and 11m to provide multiple configuration options to our clients. The modular beam system was specifically designed for transportation and load-out operations of pieces including container cranes and oil and gas modules. The beams can also be utilised as grillage or lifting beams, thus providing several options and advantages to our clients’ needs and requirements.

Modular beam system during testing

Equipment News

The beams were fabricated and tested under the supervision and certification of Lloyds register.

The beams have already been used on the load-out of a FPSO Turret, in Johor, Malaysia.

The Turret weighed nearly 3000te and was loaded out using ALE SPMT’s. The beams were also used as grillage for the Turret for the short sail to Singapore prior to being lifted onto the FPSO.

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From the difficulties of working in the cold weather conditions and high altitude of the mountain ranges in Argentina, to the dust and severe heat in Australia, it demonstrates the dedication of the whole ALE team to be able to engineer and physically operate the plant and equipment in some of the most extreme, remote and difficult working environments in the world.

That being said, it is no surprise to see the increasing level of HSQE commitment being shown by staff when carrying out their work.

The organisational behaviour and culture of our employees is constantly improving which is being reflected in lower incident rates, increased customer satisfaction and repeat business.

Although we cannot allow complacency to creep in, we must also recognise the achievements and work that has been put into keeping safe, maintaining a high level quality of work and consideration for environmental management.

The 2013 hsQE award was presented to the Middle East team in recognition of their efforts for the past twelve months.

Haydn Hunt HSQE advisor for the Middle East region said “I feel that by achieving this award again shows that the safety culture has continued to surpass our already high standards in the Middle East over the past few years.”

“ALE’s senior personnel are present on site to oversee that projects are carried out in a safe and environmentally friendly manner, and that the quality that is put into the way ALE carry out duties is beyond the expectations of our client.

The new improved yard maintenance set up played a major factor to achieving certification to ISO 14001:2004 for Environmental Management and all who contributed to this being achieved must be praised and thanked.”

ThIs yEAR’s hsQE AwARD gOEs TO ThE MIDDLE EAsT

Left to right: Cameron Waugh, Haydn Hunt and Richard Peckover.

hsQE

2012 has seen some great improvements and achievements for ALE with regards to health, safety, Quality and Environmental Management.

To name a few examples, we have seen the following during 2012:

• The lowest lost time case, lost work day and total recordable incident rates since 2002

• Our Abu Dhabi office achieve ISO 14001:2004 certification for Environmental Management

• A maturing team of HSQE Advisors

• A maturing Integrated Management System available to all personnel across the world

• Confirmed LRQA certification audits for our offices in Madrid and Thailand.

new heights branch focus: Argentina


ALE began working in Argentina nearly twenty years ago, with the first project for the region being the transportation and installation of boilers. Since then ALE has rapidly expanded in the area and completed some notable projects including Pascua Lama, lifting of roofs, Stock Pile and Molienda Buildings, Argentina.

The current branch, which was opened in 2002, employs more than 40 members of staff and is ever expanding as the demand for heavylifting and transportation continues to grow. As ALE is a global company, the region benefits from the global resources available including the groups innovative equipment, in addition to its own dedicated fleet of equipment which completes the

majority of projects within the area. The branch equipment includes: SPMT trailers, conventional trailers, lifting systems of various capacities from 70 to 500te, strand jacks, skidding systems, steel structure beams and masts.

ALE’s ground breaking innovation – The Mega Jack System completed its first project at the end of last year. The scope of work included the jacking and installing of a stock pile building roof for use by a mining company, at 4,000 metres above sea level.

In each issue, New Heights takes an in-depth look at the service offering and recent projects of a different ALE branch. In this edition, we look at ALE’s Argentina’s branch.

MEgA JACK COMPLETEs ITs fIRsT PROJECT

The high altitude project within Argentina presented the team with challenging conditions including high wind speeds, temperatures ranging from -30 to +20, air pressure as little as 0.6 bar, and within an earthquake area.

The method used by ALE to construct the roof of the building was also a first; stock pile buildings are usually raised girder by girder, but due to the high altitude and harsh weather conditions it was decided that the girders would be preassembled at lower altitude and transported to the installation site. ALE would then use the Mega Jack System to raise the roof in three sections weighing 1,500te each.

Due to the unique way in which the roof was to be installed, ALE utilised four towers of the Mega Jack System –

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hMs QUEEN ELIZAbETh AIRCRAfT CARRIER PROJECTALE has been working on the high profile hMs Queen Elizabeth Aircraft carrier project. ALE has been contracted to complete the mammoth task of weighing, transporting, loading-out and loading-in sections of the Aircraft carrier for assembly at Roysth Dock, scotland.

with a total capacity of 20,000te and ten 90te capacity hydraulic skid shoes. With possible wind speeds of up to 150km/hr ALE took additional precautions by installing a guy wire system consisting of four 200te strand jacks at each end of the building to withstand high winds.

The roof of the building was positioned in three sections above the ground on temporary stands. ALE positioned the skid systems at each end of the building to enable the side sections of the roof to be skidded inward while the main inner section of the building was lifted 18 metres to the final position by the Mega Jack. Once complete the three sections created an A-frame shaped building.

Ronald Hoefmans Group Technical Director at ALE said: “This project shows not only the capabilities and reliability of our equipment but also that of our highly trained personnel on site who overcame extreme conditions to ensure the project was a success. We are also pleased that the Mega Jack has completed its first project and as such has illustrated its versatility in conditions and also market sectors.”

The Mega Jack System was launched in 2011 to meet growing needs within the offshore industry, primarily for the jacking of oil and gas platform modules and other large structures. The system which is currently designed to lift up to 60,000te to a height of 50 metres, is the first of its kind and was designed and built by ALE’s engineers at the Research and Development facility in Breda, The Netherlands.

The decision to build the HMS Queen Elizabeth and sister ship HMS Prince of Wales was announced in 2007 after a government strategic defence review. The new ships will be the largest ever warships to be built for the UK Royal Navy, and three times the size of the UK’s current aircraft carrier.

The sections weighing between 30te and 11,000te have been fabricated in five shipyards across the UK including Birkenhead, Portsmouth, Glasgow and Newcastle upon Tyne. The scope of work for ALE includes weighing, transporting, and loading-out each section onto barges for onward transport to Rosyth, Scotland where the sections will be assembled at number 1 dock.

Various configurations of up to 448 axles of SPMT, and up to 16 power packs are utilised for each load-out. After loading-out, the barge was moored to a bespoke mooring spread and submerged allowing the cargo to float clear. All operations covering barge arrival, load-out, towage and float-off had to be carefully timed to coincide with narrow tidal windows.

To provide the full service solution, ALE’s UK branch worked closely with the specialist skidding engineers based at its Netherlands office to assist with the two larger sections of the ship. The sections weighing 13,000te and 29,550te required a bespoke skidding system to complete the movement due to their weight and size.

Late last year the welded together midsection and bow was skidded over a length of 18 metres towards the stern section of the Queen Elizabeth; this piece weighed 29,550te and will required 69 skidshoes to complete the move.

Barney Mills Project Manager at ALE said: “The team here at ALE are very proud to be a part of such a historic project. We have been working on the project for a number of months now, and have invested a lot of time in the preplanning and engineering solution for the project. We look forward to watching the vessel take shape over the coming months.”

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case studies

SITE MOVE SOLUTION FOR LUXURY YACHTS IN POOLE, DORSET

OvERvIEw: During the first phase of an international project, ALE used its Lift ‘n’ Lock system to securely elevate a luxury yacht for moulding.

sERvICEs REQUIRED: ALE was commissioned to engineer and execute a lifting solution for one of the UK’s leading luxury yacht manufacturers.

The yacht’s moulding structure needed to be stripped, so ALE was engaged to lift the structure so that it could be transported to the fit-out bay.

To lift the yacht, ALE used the Lift ‘n’ Lock plus thirty axles of SPMT’s with saddles that had been fabricated specifically for this project and accurately positioned prior to loading.

This completed the first phase of what will be a six-phase project.

JACKET LOAD-OUT DURING FORTIES ALPHA SATELLITE PROJECT, WALLSEND

OvERvIEw: ALE performed the Forties Alpha Satellite Project Jacket site move and delivered mooring and ballasting in Wallsend.

sERvICEs REQUIRED: ALE recently oversaw a site move of the Forties Alpha Satellie Project (FASP) in Wallsend at evening tide.

A total of 284 lines of SPMT’s controlled by a single operator were used to move the Jacket weighing 7,500te.

Prior to loading the Jacket out onto the barge, construction stools were removed from the quayside. ALE also supplied a linkspan bridge as well as mooring and ballasting systems to ensure the success of the project.

TRANSPORTATION AND OFFLOADING OF CONTAINER CRANES IN ADEN, YEMEN

OVERVIEW: Two 1,000te container cranes were successfully offloaded and transported by ALE in Aden, Yemen.

SERVICES REQUIRED: ALE successfully completed the transportation and offloading of two large container cranes in Aden, Yemen, using 44-axle lines of SPMT.

Once the cranes had been offloaded, the steelwork and SPMT’s were removed. This took just one hour and meant port operations experienced minimal disruption.

KILN SECTIONS, RICHARDS BAY PORT, SOUTH AFRICA

OVERVIEW: Multi-axle trailers and heavy duty trucks were used for the reloading and transportation of abnormal pieces in Richards Bay, South Africa.

SERVICES REQUIRED: ALE was required to transport several kiln sections weighing up to 130te on a Ship in the port of Richards Bay.

The pieces were stored in ALE’s yard enabling a quick turnaround and prompt vessel discharge.

As per the installation requirement, the pieces were then reloaded and transported to site. ALE utilised a number of multi-axle trailers and heavy-duty trucks to execute the project.


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REPOSITIONING OF ELECTROSTATIC PRECIPITATOR IN VASILIKOS POWER STATION, CYPRUS

OvERvIEw: ALE assessed and restored an Electrostatic Precipitator displaced by a Cypriot naval base explosion at the Vasilikos Power Station in Cyprus.

sERvICEs REQUIRED: Following an explosion at a nearby Cypriot naval base, an Electrostatic Precipitator at the Vasilikos Power Station was displaced from its permanent steel columns.

ALE provided a prompt and restorative solution using skidding and jacking techniques, two independent frames and eight brackets to release the structure and assess the damage.

Two gantry frames with supporting towers connected by a main beam were utilised for the suspension.

Once the evaluation and recovery operations were completed and the ESP supports and foundations were ready for mating, the Precipitator was skidded back up to reach its final vertical position, then back down for mating its final support.

TRANSPORTATION OF CONTAINER CRANES IN MARSEILLE, FRANCE

OvERvIEw: ALE moved three container cranes at the Autonomic Port of Marseille, France.

sERvICEs REQUIRED: ALE transported the three container cranes weighing 1100te each over a distance of 2km at the Autonomic Port of Marseille, France.

The project utilised 48 lines of SPMT trailers with two transversal beams (composed of two double platforms of 12 axle lines) and moved the trailers from one dock to another.

RELOCATION OF SHIPLOADERS TO THE MOLINER DOCK, GIJON HARBOUR, SPAIN

OvERvIEw: ALE successfully transported two shiploaders weighing 230te to the Moliner dock at the Gijon harbour, Spain.

sERvICEs REQUIRED: A successful relocation of two 230te shiploaders has been completed by ALE using 20 axles of self-propelled modular trailers in two sets of ten lines. The shiploaders were moved from their original assembly position up to the first line of the Molinder dock at the Gijon harbour in the coastal city of Spain.

FLOAT-OVER AND BALLASTING AT THE GAJAH BARU GAS FIELD, INDONESIA

OvERvIEw: ALE provided ballasting and float-over installation of a topside complete with living quarters at the Gajah Baru gas field, Indonesia.

sERvICEs REQUIRED: ALE utilised fourteen 24 PS ballast pumps, fourteen 10 PS de-ballast pumps, ten 325 Hydraulic Power Units and a 154 x 36 meter barge to complete the ballasting and float-over of the 8700te topside.

Once ALE had completed the load-out ballasting and float-over the barge was positioned carefully at the installation site to meet the topside foundations, ALE then carried out the ‘rapid ballasting’ to lower the Gajah Baru topside onto the preinstalled jacket legs.

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case studies


POWER UPGRADE PROJECT IN TAWEELAH, ABU DHABI

OVERVIEW: ALE was contracted to lift and transport heavy goods in Taweelah, Abu Dhabi.

SERVICES REQUIRED: ALE was successful in transporting seven heavy goods items of Diverter Damper from engineering works to Hamriyah quayside.

The heavy goods to be lifted and transported included: diverter damper 80te, blanking plate 25te, round stack cans 40.3te, round stack can with support legs, lug can 26te, round stack cans 40.3te, horizontal transition duct 16.3te and a square to round duct 10te.

Once they reached the quayside, they were loaded onto a barge, transported to Port Khalifa, rolled off and stored. ALE’s conventional hydraulic trailers then took responsibility for delivering them to the project site.

TWO-STAGE TRANSPORTATION OF TRANSFORMERS IN DIELE, GERMANY

OVERVIEW: ALE successfully transported transformers from Nürnberg and Rotterdam to Diele, Germany.

SERVICES REQUIRED: ALE was contracted to transport two 280te transformers to a site in Diele, Germany.

ALE completed the project in two phases, firstly transporting transformer one from Nürnberg on a barge to Bingum. The second transformer was then transported from Rotterdam by the same process.

The transformers then made their journey from Bingum to Diele on SPMT’s

Once in Diele, the transformers were removed from their SPMT trailers and transferred onto climbing jacks. They were jacked down and railway wheels were installed. Lastly, pulling cylinders were used to move the transformers into the bays.

OLYMPIC PARK TRANSFORMATION PROJECT, UK

OVERVIEW: As part of the Olympic Park transformation, ALE completed the first bridge and portal removal on this project.

SERVICES REQUIRED: The Gottwald AK912-1 fitted with 77m Maxi Boom and 400te Maxi Lift Ballast removed the T12 bridge which was the main link between the Stratford Coach Park and drop off point, into the Olympic Park.

The bridge spanned across Stratford High Street, during a midnight road closure, the bridge was successfully removed using the AK912-1, 197te at 52m radius.

The bridge and portals were removed on three consecutive days. ALE engineered a solution to allow the portals which were erected in three sections to be removed as one piece using the AK912-1.

BRIDGE INSTALLATION FOR WEST COAST MAIN LINE IN LOCKERBIE, SCOTLAND

OvERvIEw: ALE installed a new bridge for the West Coast Main Line at the Land Farm Bridge site near Lockerbie, Scotland.

sERvICEs REQUIRED: Due to overhead power cables ALE had to engineer a solution that enabled the removal of the original bridge and the installation of the new bridge without the use of cranes.

SPMT’s at narrow configurations were instead used to navigate the narrow lanes and access the bridges remote location. Logistical issues including tight bends on the roads also meant that other equipment had to be transported in compact loads. Therefore precise choices were made regarding the steelwork for the trestling and bridge deck.

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Q: How long have you worked for ALE? A: I joined ALE in 2006 as a Student Engineer in the UK (‘year in industry’ as part of

my degree in Mechanical Engineering with Business Management). I found the ALE Student programme very well organised and that it introduces the student to a wide range of sectors in which ALE provide their services.

My first year was split in such a way that it covered a variety of disciplines: design and fabrication, working within the engineering office team, working alongside project managers and finally undertaking project engineering on site.

Q: Has your position within ALE changed since you joined?A: I enjoyed the first year so much that on attaining my degree I stayed with ALE, and

was soon appointed Project Engineer working all around Europe, predominantly in the power industry. I quickly became familiar with, and gained valuable experience of, a wide range of services including: transportation, load out operations, jacking, weighing, skidding, lifting, as well as installation.

In 2009 the opportunity arose to assist in the development and growth of ALE’s Far East Business (with an emphasis on the oil and gas markets). Although the market sector was very different from what I had experienced in Europe, the engineering practices that I had been taught were very similar making the transition from UK to Malaysia relatively smooth.

Q: What is your current role at ALE?A: Approximately one year ago I was promoted to the position of General Manager

of the ALE Malaysia Business which services South East Asia. My day to day responsibilities include ensuring that all departments in the Malaysian region are operating successfully, client relations, and sales.

Q: How has the team developed over the time you have been there?A: The team has had a constant growth over the years, bringing in both local staff

who are trained and developed within their roles, to specialists from ALE branches worldwide to work on both specific projects, and for permanent transfers. The team reacts, grows and develops to meet the requirements of clients’ and projects within the region. ALE has also strategically positioned offices together with a team of personnel to ensure that our clients’ are getting the best solution in the most time and cost efficient way.

Q: What do you enjoy most about working for ALE?A: What inspires me most is the buzz of winning new projects and seeing those projects

right through to completion. I like to make site visits during the actual operation as often as possible; however, as we are performing several multi-national operations at the same time and often on the same day, I cannot oversee them all, which is why I am grateful we have such a good team here in Malaysia.

Adam Ward General Manager, Malaysia

What inspires me most is the buzz of winning new projects and seeing those projects right through to completion.

personnel focus


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WORLDWIDE HEAVY TRANSPORTATION AND LIFTING [email protected] WWW.ALE-HEAVYLIFT.cOm

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16467 ALE Newsletter FEB AWLRsingle