News

New Crawler CranesNew Crawler CranesIncreasing our heavy lifting capabilitiesIncreasing our heavy lifting capabilities

Baosteel ProjectBaosteel ProjectFagioli’s Elevator SystemFagioli’s Elevator System

PalermoPalermoAnother Magnificent InstallationAnother Magnificent Installation

Issue 09Spring 2009

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Big Changes in Fagioli’s

Lifting Capabilities!!!To extend our lifting capabilities and tocomplement our existing range oflifting equipment, Fagioli haveinvested in heavy duty cranes.

After detailed investigations andcomparisons of the products availableon the market, Fagioli purchased twoLiebherr crawler cranes. A 750 tonnecapacity crane, the LR 1750 and the1350 tonne capacity crane. In orderto cover as many different operationsas possible, the cranes were orderedwith a wide range of equipment:

� The LR 1750, with a 91m main boom, 84m luffing jib, derrick, and ballast trailer

� The LR 11350 equipped with a 114m main boom, 84m luffing jib and derrick with suspended ballast.

At the beginning of October tocelebrate the purchase of these twocranes, Fagioli hosted an informationday for its international customers,held at the Liebherr plant in Ehingen.

This provided an early opportunity topresent the capabilities of the LR1750 and to explain the importance ofthe purchases of these two crawlercranes, which enables us to offer "fullservice package" to our clients whenit comes to transportation and liftingof heavy loads, a range which willnow be extended further by theprocurement of the new giant cranes.

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Since the delivery of the LR 1750, thecrane has been used on two projects.In November the crane was deliveredto Italy for the first official liftingoperation, a roll-up of a jacketweighing 180 tonne, performed at“Marina di Ravenna port”. The projectwent well. (see pictures left and right)

In Cremona Fagioli was called toperform the installation of a reactorweighing 160 tonnes. The generatorwas lifted from its original foundationsand laid on in a horizontal position.The item was then positioned onto a 6axle SPMT and moved close to thenew installation area where the LR1750 was re-positioned. (see picturebelow).

The main advantage of a crawler crane isthat it can move on site and performseveral erections as well as being able totravel fully loaded. It offers a highstandard of safety with its “wheeled”counterweights and on-boardcomputerised control system.

The versatility and strength of thismachine as well as the “gigantic” LR11350 crane (which will be in operation atthe end of this year) adds to our vast rangeof lifting equipment and enables us to offera full lifting package to our clients !!

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Fagioli were awarded a project in Chinaby one of the biggest steel companies inthe world to replace an old blast furnace!

This project was particularly interestingand challenging for Fagioli because theclient wanted to replace its entire blastfurnace in less than two weeks instead ofsix months. The operation, the first of itskind, included the complete substitutionof the entire top section in one operationwithout dismantling it. In order to do this,Fagioli used a skidding system, and aspecially made elevator system withSPMT’s.

Both furnaces (old and new) were dividedin two parts:

� top boiler� bottom boiler

The base (old and new) was divided inthe following items:

� lower section� mid section� top section.

The old top boiler section weighing 2,533tonnes was replaced with a new oneweighing 2,111 tonnes using a skiddingsystem and SPMT’s to transport all theold and new base sections.

The weight of the old base sectionsranged from 1,800 to 4,000 tonnes whilethe new ones ranged from 1,400 to 2,600tonnes.

The old top boiler was skidded from itsoriginal position onto the Fagioli elevatorsystem using 8 Fagioli skid shoes. It wasthen lowered down and skidded onto the108 SPMT axle lines. After this operationthe SPMT’s moved the huge item into thestorage area and using skid shoes placedit onto temporary stools. The same skidshoes were used to skid the new topboiler from its temporary stools inside thestorage area onto SPMT’s where it wastransported to the installation area. Thenew top boiler was then transferred ontothe Elevator System, lifted, skidded andpositioned in its final location. It was thefirst time that the top section of a blast

A Unique Project in a Mystical La

storage area. At the end of the wholeoperation, a new concrete beamweighing 700 tonnes was installed toreplace the old one.

The old bottom boiler sections werelowered one by one by the client andpositioned onto Fagioli SPMT’s they werethen transported into the storage area

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furnace was replaced without dividing itinto smaller parts or dismantled intosections.

The old top boiler section 22m long, 22mwide and 60 m high, weighed anincredible 2,583 tonnes. The new Topboiler section 22m long, 22m wide and54m high weighed 2,111 tonnes. Thesubstitution of this top section waspossible thanks to the innovation shownby Fagioli which allowed this project to becompleted in a few days rather than sixmonths which is the standard time tocomplete an operation of this kind.

Before substituting the bottom boilersection Fagioli had to remove theconcrete beam (approx. 1,000 tonnes)that was positioned in front of the bottomboiler. This allowed the skidding of thebottom boiler items to and from the

where the client skidded the items ontotemporary supports. One by one, the newbottom boiler items were moved from thestorage area to the furnace area ready forthe final installation by the client.

The project was organised perfectlybetween Fagioli and the Chinese clientwhich allowed the project to becompleted on time but more importantlywithout any incidents.

This project highlights the innovativesolutions that Fagioli can provide for thelifting, transport and installation of heavyitems anywhere in the world.

The elevator system was the key to thisparticular operation, the same system wassuccessfully utilised in Spain for theinstallation of the large modules for theAdriatic LNG project and in Palermo for thefinal positioning of a huge drilling Rig towerfor the offshore industry (see page 6).

If you would like a copy of the DVD for theChina project, please ask our marketingdepartment - contact details are on theback cover.

and ‘China’

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Another impressive project performed byour engineering and operational teams!!!

Fagioli’s new elevator system was theideal solution for positioning andinstalling two living quarters and agigantic drilling rig tower on top of a 50mhigh offshore platform. The offshoreplatform “Scarabeo 8” was anchored atthe port of Palermo in the MediterraneanSea.

The semi-submersible offshore platform,owned by Saipem, is composed of twofloating hulls with facilities supported onsix columns. The lower part of theplatform was built in Russia while the topsection was manufactured in Italy. Fagioliwas awarded by Fincantieri to installapproximately 80 small modulesweighing 100 to 300 tonnes, two livingquarters each weighing 600 tonnes and ahuge drilling tower weighing 2,400tonnes which was to be placed 50m inheight.

Fagioli performed the load-out operationsof the two living quarters onto a barge inGenova and the load-in operations inPalermo by means of SPMT’s.

Palermo...........Another Magnificent Installation!!!

The two living quarters werepositioned close to theinstallation area by SPMT’s andinstalled using the new elevatorand skidding system above. Butit was the second part of theproject, performed two monthslater that was the mostextraordinary, the installation ofthe huge drilling rig tower (seepicture below and right) whichwas an impressive 90m highand weighing 2,400 tonnes.

The new elevator system wassuccessfully used on the Adriatic LNGproject and the blast furnace replacementproject in China, but the Scarabeo 8project was the most challenging,positioning a 90m item on top of a 50mhigh platform…in the sea!!!

Detailed engineering studies, and perfectcontrol of the system and ideal weatherconditions allowed the success of thewhole operation. The Tower waspositioned using more than 100 axle linesof SPMT’s onto 8 skid shoes, running ontwo girders. The piece was than lifted andskidded to its final position.

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Fagioli SpA was awarded thetransportation and erection of a vessel‘D324’ It was to be installed as part of theexpansion works within a UK refinery.

The essential features of the reactor in itshorizontal transportation attitude are:

� length:16.9 metres� transportation width: 5.7 metres� erection weight: 167 tonnes, excluding

saddles

On 29th November 2008, the vessel wasloaded onto Fagioli’s trailers andtransported to the docks at Porto Nogarowhere it was lifted and sea-fastened to theMV Phantom for a 12 day sea-voyage.

On arrival in the UK the vessel wasoffloaded onto Fagioli’s transporter in itsStage 1 configuration - comprising adoublewide 14 axles SPMT powered bytwo 350kW diesel hydraulic power packs.

From the quayside, the vessel wasmoved through the Associated BritishPorts area, across the port rail tracks andover a series of main oil pipelines, via abridge fabricated specially for thepassage of heavy transport, into thefabrication yard of Fabricom Suez.Working closely with local police, road,rail authorities and public utilities, a routeto the refinery was approved – the onlyrestraint being that the transport had totake place early Sunday morning. The3km journey via the public roads into therefinery was achieved as planned in lessthan three hours.

The erection method selected was theFagioli Towerlift System, this offeredmany benefits over conventional crane –particularly, the effects on the operationof the refinery which remained livethroughout the whole process. TheTowerlift System comprised of 2triangular towers, 24m high, supportedon a specially fabricated steel grillagefoundation.

The lifting force in the Towerlift system wasprovided by one L300 jack mounted on apurpose built crosshead beam and L300fixed anchor which allowed rotation of thevessel once in the fully vertical position.

In order to negotiate the extremely tightheadroom restraints under pipe-racks inthe refinery, it was necessary toreconfigure the transport so that thereactor was suspended by purpose-builtframes on two double-wide SPMT carrierswith the transportation saddles nominally50mm clear of the road surface.

Once the assembly of the Towerlift systemwas completed, the reactor was transportedthrough the first part of the route, under theexisting pipe-racks, with only 10mmclearance, the operators proved theiroutstanding ability to move large, heavyloads with machine-like precision.

Having negotiated the initial part of theroute, where vertical headroom wascritical, the next challenge was anextremely tight “pinch-point” where lateralclearances became critical. The SPMTswere reconfigured on a single wide 14axle to allow the client to leave in placesome operational equipment at low level.This stage was again executed withmaximum precision, having to actually tiltthe vessel to achieve the clearancesstipulated. The vessel was eventuallypositioned under the towers and theclosure head lifting lug connected to thelifting swivel of the Towerlift System.

Due to a congested site, Fagioli electedto use a specially fabricated tilting-frame,attached to the skirt of the reactor fortailing. When the strand jack systemstarted to lift, the SPMT was movedforward under power to maintainverticality of the lifting strands within 1%.

Once the reactor reached the verticalposition, the tailing frame was detached,the SPMTs removed, and the reactor waslowered close to the foundation. The finaloperation was to rotate the vessel into itsfinal orientation and bolting it down in itspermanent position.

UK RefineryTransport and Erection Package

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The joint venture formed betweenFagioli and Almajdouie Group in SaudiArabia enjoyed a record growth in2008.

Load-out of Rig Hull UnitLast September they completed a4,800 tonne hull loadout in the UAE.This involved the transportation fromMIS to Sharjah Port and loadout of thehull onto a barge. The dimensions ofthe hull were 72m long, 63m wide and28m in height.

The Middle East ....

Load-out of Sea Jacks UnitIn November 2008 a Load out of SeaJacks unit weighing 5,177 tonnes wascarried out in the UAE, this involved thetransport from Lamprell to Jebel Ali Portand load out on to a Barge. Thedimensions were 75m long, 55m wideand 25m high.

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The biggest achievement was thesuccessful transportation of several1,600 tonne evaporators for the marafiqindependent water and power plant inJubail. This project carried out BifalHeavy Industries was described as alandmark project and involved thetransportation of nine evaporators in all.Each evaporator, which was 62m long,21m wide and 18m high, was moved fromthe Bifal module yard near King FahadIndustrial Port to the work site over adistance of 9 km.

Marafiq ProjectThe route involved the use of the regularMP-111/101 module path but then carriedon across the busy TS-1 Highway into aresidential area leading to the site. Thearrangements required the co-ordinationand support of several agencies includingthe Royal Commission and police as wellas several subcontractors who had toremove and replace more than 100 lightposts for each move and installtemporary traffic islands over severalmonths of the project.

For the same project the Bahrain-basedoffice transported an additional five unitsto the site that had arrived from abroad.

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FPU 5500 – Thunderhawk HullLoadoutFagioli Asia successfully completed theside loadout of FPU 5500 – ThunderhawkHull in July 2008. The loadout operationwas award to Fagioli Asia by Dyna-MacEngineering Services Pte Ltd. The totalweight of the Hull is 13,000tonnes and theloadout operation was performed with 4 xL750 jacks and 2 x L4/50D power packscontrolled by our computerised system.

CASL Hangar, Hong KongAirportFagioli Asia was contracted to lift the 900tonne hangar roof at Hong Kong airport.The Roof was lifted by fifteen L180 strandjacks to a height of 32m. All jacks weresynchronised and controlled by a singlecomputerised lifting system.

The Far East ....

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Muarakarang Power plant –On base with T1400TelegantriesFagioli Asia carried out the lift andinstallation of 6 units of gas turbines,generators and transformers inIndonesia. The above operation showsthe on base of a gas turbine generatorweighing 280 tonnes at a height of 4mwith our T1400 telegantries.

Lifting of HRSG Modules inNorth Bangkok, Thailand Fagioli Asia was contracted to carry outlifting of modules for 2 units of CMIdesign HRSG.. Due to extremely tighttolerance set by the client, Fagiolicomputers control system was used forthe lifting. This allow for precisesynchronisation during lifting andlowering. A total of 30 nos of L100 jackscoupled to 3 nos of L12/8E powerpacks were used for this lift.

The NBCC project has the significanceof being the first project using Fagioli'scomputer control jacking system forthe lifting of CMI's modules. The liftingworks were completed effectively inexcellent time, to the greatsatisfactions of the Clients."

The above picture is the 50th boiler drumLifted by Fagioli India Pvt Limited atRatnagiri, Maharashtra. We started bylifting the 1st drum in August 2004 andnow 53 weeks later we have lifted the50th drum - ie an average of 1 drum aweek.

The 240 tonne drum was lifted in aninclined manner to a height of 65m withthe help of Fagioli Strand Jacks andPower Pack. After reaching the height of65m the boiler drum was skiddedhorizontal to 3.7m before final placement.This was done due to existing column upto a height of 55m. The completeoperation was done within a span of 6hours.

50th Boiler Drum

Lift for India....

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US Projects.............

Diablo Canyon ProjectOver the last few years, Fagioli havetransported most of the replacementsteam generators to nuclear power plantsin the United States of America. For the Diablo Canyon Project Fagioliwas contracted for a total of 8 steamgenerators, each weighing 327 tons, tobe transported from the manufacturingfacility in Santander, Spain to the finaldestination in California. Joint effortswithin the group from the Italian and USoffice made this another successfulproject.

Four units and two generators weredelivered in Autumn 2007,another fourunits and one generator were delivered inSummer 2008. Fagioli Inc. also movedthe generators from the Storage Area tothe containment building in early 2008.After the loading in Spain, on a heavy liftvessel, the generators were shipped toPort Hueneme in California. Two oceangoing deck barges were used for thetransport to the plant.

The only accessible location to land thegenerators in the plant is the Intake Cove,a very sensitive place for the safety ofplant operation, because of the reactor

cooling system. In addition the access tothe cove is on the Northern CaliforniaCoast exposed to ocean swell and wind.

The generators were positioned ontobarge deck on tailor made saddles,specially designed to fit Fagioli 600 tonsscrew-jacks system. This allowed thegenerators to navigate in a lower positionand minimise the grillage and seafastening.

Upon their arrival and with favourableweather conditions, the barges weremanoeuvred one by one in the intakecove by two smaller tugboats to thelanding area and secured. After releaseof the sea fastening, the screw jackssmoothly lifted each generator in onehour to load the double wide 14 axle linesSPMT.

The SPMT with its uniquemanoeuvrability was perfectly suited toroll-off the generators in the small landingarea and turn them onto the road fordelivery to the plant. Before deliveringthem inside the storage building, thegenerators were lifted again, rotated totheir installation orientation and thetransport saddles replaced with smallersaddles.

Port of HoustonTransport and lifting of several itemsat Houston port by means of SPMT’sand gantry cranes: a 250 tonnetransformer and a 320 tonnegenerator

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Pacifico Power PlantIn late Spring 2008 Fagioli Inc. was calledto perform heavy lifting services at thePacifico Power Plant in Petacalco,Guerrero State, Mexico.

The initial challenges were to design asystem to lift the heaviest components –a 390 tons generator and three turbinesrespectively 227 tons, 228 tons and 190tons in the machine hall from the groundto height of 13.5m with less than a monthto ship it to the site. Additional lifting andrigging engineering for the CondenserPolisher System composed of 7 bulkytanks weighing up to 30 tons, the BFP Aand B Turbines, each 43 tons and theDearator and Storage Tank 105 tonswere completed at the same time.

Fagioli engineers worked with theirpartners in Mexico and the client to adaptthe existing lifting system to the machinehall, only minor changes needed to becarried out there wasn’t need for anyfoundations.

A complete set of calculations wereprovided in record time and equipmentdispatched from Houston. The site teamfaced further challenges, dealing with themonsoon season and the extremely busysite.

The items of the Condenser PolisherSystem were skidded horizontally in thecentre aisle of a very tight building, rotated

upright and moved aside before settingthem on their foundations. The ‘bull rigging’work was carried out using skid tracks,rollers, chain blocks and other rigginghardware.

To reach the foundation of the BFPTurbines, Fagioli used a 4 axle lines ofSPMTs at the ground floor of the machinehall with very little clearance. Skid tracksset on supports and beams, together withrollers, hydraulic jacks and chain blockswere used to set the Turbines in place.

The 390 tons generator, the 2 LP turbineseach 228 tons and the 190 tons HPTurbine were lifted to about 15m byStrand Jacks on top of header beamssupported by EZ600 telegantries.

The system was supported by ‘minitowers’ and several beams that spanned40m between the lifting area and thefoundations. Upon completion of the lift,the heavy items were moved between40m and 75m by the hydraulic gantrycranes on tracks supported by jackstands, before the setting on thefoundation. The Dearator and StorageTank were then lifted 30m by StrandJacks, moved 11m transversally beforelowering to its final position.

The work was completed in less than 3months.

Nitrogen Plant, Arkansas In Blythville, Arkansas, Fagioli Inc. used its SPMT’s to transport fivereactors from the Nitrogen Plant to the railing side and lifted them ontorailcars with its EZ600 hydraulic gantry cranes.

Big transports require a big organisationthat can handle all kinds of transportmatters.

People who are not necessarily involvedin heavy transport might assume that it isonly a matter of transporting an item fromA to B and nothing more!

But there are many activities that need tobe considered before handling a heavytransport, especially when dealing with aproject on a turn-key basis fromconceptual design through to positioningonto foundation including lifting andlogistics operations.

The first step is the analysis of the itemand an accurate road survey in order toascertain the feasibility of the transport aswell as identifying any foreseeableproblems.

The survey is performed by experiencedpersonnel who literally check the wholeroute, step by step taking into accountmeasurements and making a detailed listof all the eventual obstacles and items tobe removed such as street lamps, road

signs etc…, roads to be strengthened,any temporary road supports to bepositioned during the passage of theconvoy. This survey is extremelyimportant as the whole of the engineeringis based on this important information.

The engineering department designs themethod of transport according to the job-specific parameters. It prepares thetechnical specifications for theprocurement and the construction of theequipment such as specific saddles,supports, beams...etc. that will be usedduring the transport operations as well as3D cad drawings, and safety-orienteddocuments such as method statementsand risk assessments.

The logistics team is responsible fororganising various activities involved inthe transport, such as pre-positioning ofpersonnel and equipment. And some of

these large turnkey projects require awide range of equipment, such as strandjacks, tower lift systems, crawler cranes,gantry cranes, screw jacks….etc. Fagiolican cater for any heavy lifting and heavytransportation requirement.So, as you can see, a heavy transport

project is made up of many elements andit is not just the case of simply turning onthe engine.

An example of this type of heavytransport project is the transportation of aconcrete bedplate from Brescia to Ternod’Isola in Italy (almost 50km). Thedimension of this item was 7m long, 4.5mwide and 2.1m high with a total weight of240 tonnes. Fagioli used two 11 axletrailers with a gooseneck supportstructure including a 25m long beam. Theimpressive convoy was 63m long, 5.50mwide and 4.30m high for a total weight ofabout 400 tonnes (including the trailers).Experience and competence werenecessary to overcome all the difficultiesfaced during the transport. Detailedstudies were carried out to calculate theimpact of the item on the civil structuressuch as bridges and the road capacityconsidering the length and the weight ofthe convoy.

The structure and the shape of the itemsare always different. This means differentequipment, different configurations andtailor-made analysis of the transport.Fagioli offers a huge range of equipmentbut it’s having the know-how andcompetence to use the equipment thatreally matters and this is where Fagiolireally excel.

A 16 axle modular trailer was used for the

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Heavy TransportsBig transports require a big organisation...

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Three heavy pontoons (see picture left)weighing more than 500 tonnes werelaunched in Marghera port. Fagioliperformed the heavy transport using upto 60 axles lines of SPMT’s for theheaviest one.

transport of a huge exchanger (seepicture left) weighing 190 tonnes, 18.3mlong, 4.9m wide and 5.05m high fromAlbignasego to Marghera port with finaldestination to China.

Fagioli was awarded by Foster Wheelerthe load out operations of a Reformer(see pictures below) weighing 730tonnes, 20m long, 20m wide and 30mhigh using two 16 axle lines of SPMTs.

Fagioli carried out the transportation ofseveral heavy items from Korea to Egyptat the end of 2008 for the delivery of aSplitter and a Deethanizer Stripper (seepicture right). The blocks were loadedonto a heavy lift self-geared ship inKorea, Masan and unloaded ontoSPMT’s in Port Said, Egypt. Fagioliloaded three out of six of the sectionsonto trailers at Port Said Harbour andperformed the inland transport andoffloading operations. The Splitter wasdelivered in 4 sections with a maximumweight of 290 tonnes and a maximumlength of 26m. The Deethanizer was

separated into two sections with amaximum length of 24m and weight of294 tonnes. Fagioli will be performing thelifting and installation in the next fewmonths which will be shown in the nestnews letter.

Fagioli’s track record in the ship industryincreased when we launched two hugeship sections weighing 1,994 and 1,229tonnes and the launch of an entire ship(see picture right) weighing 3,300 tonnes.Fagioli used 132 axle lines of SPMT’s toperform the launching operation. Theship, called “A.H. CAMOGLI” was safelymoved onto a barge and transported to afloating dock ready for the launch.

A combination of road transport and finalinstallation by gantry cranes was the keysuccess for the positioning of generatorsand engines in Croce sull’Arno, Tuscany(see picture above)

Another interesting project was the loadout of a 1,100 tonne jacket (see picturebelow) with 48 axle lines of SPMT’s.

Fagioli were awarded a project to move abridge (see picture right) 58m long, and6m wide, weighing 140 tonnes. Thebridge was moved close to the viaductusing two 6 axle line of SPMT’s. The finalinstallation of the bridge was performedby the clients own crane.

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Over the last two decades Fagioli hasbeen constantly present in Libyaperforming several on-going projectswhich has led to the opening of an officeand allocation of equipment. One of thefirst projects performed in Libya withmore than 350,000 FT forwarded withpieces up to 260 tonnes was the“Western Libya Gas Project”. Fagioli andSomeport Walon (a participated Frenchcompany) are now completing the finaldelivery and installation of evaporatorsand boilers for this long term project bymeans of group-owned trailers, SPMT’sand screw jacks. (see both picturesdirectly below)

A total of ten evaporators (composed of 5sections each) and ten boilers wereunloaded onto Fagioli multi-axle trailersand delivered onto supports positioned ina storage zone close to the installationareas. Once positioned, the sectionswere lifted by Fagioli screw jacks in orderto allow the SPMT’s to be positioned

under the items. Once the modules wereloaded onto the SPMT’s they weremoved onto their foundations andlowered to final position.

Another job performed for the shipyardindustry was the transport of a ship (seepicture below) weighing 160 tonnes from

Marghera to Fusina. The vesseldimensions were 45.52m long, 8.85mwide with a height of 7.80m.

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Fagioli provide a fully comprehensive andprofessional freight management servicerun by a dedicated team that ensures allaspects and co-ordination of thetransport is taken care of, includingliaising with local agents.

In our last issue of the News letter wementioned the award of a project for theinstallation of three power plants inAlgeria. Fagioli is now completing theexecution of these three important plantsin Larbaa, M’sila, Batna. The scope ofwork involved the collection andtransportation of general cargo andheavy lift turbines and generatorsincluding the final installation. This is agreat example of a true door-to-doortransport from the manufacturing facilityin Italy to their foundations in Algeria.Fagioli heavy lift vessels loaded the itemsand delivered them to Algeria ports.

In Genoa Fagioli trailers transportedalongside the quay several generatorsfrom 190 to 325 tonnes. They wereloaded and secured onto our group-owned ship with heavy lift vessel gears.The generators were unloaded in Skikdaport (see picture below).

In Marina di Carrara Fagioli moved andtransported several turbines weighing308 tonnes also destined to Skikda port.Whilst in Naples they moved andtransported several transformersweighing up to 186 tonnes destined toAlgiers port. All the components anditems were sea transported with Fagioliself-geared vessels which are ideally

suited for the low draft water in theMediterranean Sea. Once the items hadreached their unloading ports the itemswere transferred to their final destinationsites. This was not an easy task as theroads to the sites were extremely sandyand uneven and the bridges were unableto cope with the weight of the convoy.So large concrete pipes were constructednext to the original bridges to allow theriver to bypass and allow the convoy totravel over them. Once they reachedtheir destination the items weretranshipped and positioned onto theirfoundations by means of 600 tonnecapacity gantry cranes. (pictures aboveand below )

Project Logistics

The execution of this project gave us theopportunity to open two offices in Oranand Algiers. These offices supported bythe head office are able to carry outproject forwarding activities as well asHeavy transport, lifting and logisticsactivities.

The Middle East remains a buoyantmarket for our project logistic activities;we are currently completing a 200,000freight tonnes project in UAE and otheropportunities are yet to come.

Jumping from West to East we areworking very hard in India on heavytransport and lifting and for projectactivities. Thanks also to local partnerswe are strengthening our presence onthe territory working for huge EPCcontractors active in the oil & gas sectors.

In Europe our specialised commercialdepartment is very active in all the mainItalian ports. Fagioli completed theshipment of two vessel columns fromNaples to their final destination in Baiji(Iraq) via Mersina. (see picture below)

Delivery of skid mounted equipment andloose material destined to compression

plants in Sidra and Wachkah (Libya) wereloaded onto heavy lift motor vessels inAncona port for the gas transmissionpipeline project. Weights of the packaged

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skids were approximately 40tonnes each and a total of7,000 cubic meters of materialwas forwarded. (see pictureabove)

In Chioggia port Fagioli carriedout another loading operationof two columns weighing up to28 tonnes with a maximumlength of 29m (see pictureright).

And finally the incredible jobsperformed by our “Humanitarian aid”team who continue under immensepressure to provide a professionalservice to troubled countries aroundthe world who are scourged by warsand natural disasters…

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The last part of 2008 was a busy periodfor our group-owned ships, performingchallenging sea transports in theMediterranean Sea.

As well as the lo-lo and ro-ro servicesFagioli’s vessels offer a remarkable low-draft facility, this combined with asupportive road transport team, andstate-of the art equipment and a highprofile engineering department are thekey factors to successful heavy lift seatransports.

Fagioli carried out a double ro/rotransport using both Storm and StormanAsia vessels which included roadtransport to Nogaro Port, sea transport toMarghera Port and unloading operations.

The items transported were two largecomponents of a quench tower; a unitbottom section weighing 835 tonne,46.10m long, 10.91m wide and 11.05mhigh. (see picture below)

The unit top section weighed 433 tonne,31.26m long, 10.46m wide and 10.78mhigh (see picture right)

River and Maritime Activities

The biggest one wastransported andembarked using 52 axlelines of SPMT’s (2 x 14and 2 x 12) while thesmaller one by meansof 2 x 14 axle lines. Theitems, once arrived atthe port, werepositioned alongside

the quay. Ro-ro allows our trailers andSPMTs to roll onboard (see picturesabove) with the heavy items lashed andsecured and roll off the ships ready fortheir onward journey by road. All theoperations concerning engineering, sea /fastening and welding were performedunder Fagioli control.

A combination of SPMT’s and shipsderricks completed the launching of aferryboat at Izola, Slovenia. Fagioli wereawarded the project from a localcompany, which involved the transport a550 tonne ferry boat, 52m long by 16mwide using 2 x 12 axle lines of SPMT’s. Itwas transported close to the quay where8 shackles were used to hook theferryboat to Fagioli derricks. It was thenlaunched using the 700 tonne capacityderricks. (see picture above)

The river transport is another importantactivity for Fagioli especially with the sizeof the items getting bigger and bigger andthe new infrastructures do not alwayscater for these large items to betransported by convoy. The roads can benarrow and extremely busy, so a moreconvenient way of transportation in theNorth of Italy is by barge along the river toMarghera port (Venice). The group own

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a range of specialised riverbarges which include riverpushers, heavy transportbarges, chemical products,double skin oil productbarges and bulk cargobarges. This large fleetoperating mainly on theItalian navigable riversperforms heavy transports

of oversized items that could not bedelivered by road or by train due tocertain restrictions like Bridges etc.. Atthe port in Cremona along the mainItalian river Fagioli has a private operatorberth with gantry cranes ready to loadand unload items from barges. Picturebelow shows a typical loading operation.

On page 23, the gantry cranes page wemention the lifting of a 165 tonne reactorbut not about the activities before andafter: the transportation of the module toCremona River Port using a 14 axlemodular trailer and then transportation toVenice port by barge (see picture below).

Fagioli believes that river transport is agreat opportunity to perform safetransport: water transportation providestremendous carrying capacity whileconsuming far less energy compared toother modes of transport such as truck,rail or air. One of the biggest benefits ofriver transport is the substantial costsavings. A standard barge has a cargocapacity 50 times more than a normaltrailer. It also helps towards limiting roadcongestion, has low environmentalimpact as well as a zero fatality record.

The vast range of river equipment ownedby Fagioli through its 100% controlled S.Marco Shipping company includes notonly barges for heavy lift items, but alsofor petrochemical products using doubleskin vessels and special bulk cargovessels for wheat products.

several tests, by providing rail cars whichwere ideal for testing heavy loads.

22

Over the last five years Italy has beenworking on its “high speed rail “networklinking Italy’s North and South. Theconstruction of this project has not beenwithout problems due to the mountainsand hills that literally “ cut the boot” in half.

High-speed rail is a type of passenger railtransport that operates significantly fasterthan the normal speed of rail traffic. Itrequires continuous welded rail whichreduces track vibrations anddiscrepancies between rail segmentsenough to allow trains to pass at speedsin excess of 200 km/h. This created theneed to construct new specially maderails all over Italy. Fagioli helped theItalian National Rails company to perform

High speed rail

in Italy...........

Viaducts and bridges are the weakestpoints of the whole infrastructure,considering the weight of an entire traindriven at full speed. This is the mainreason why these sections must bechecked with severe load tests. Fagioliused its railcars (2 x 24 axles) loaded withsteel billets. The first railcar waspositioned on the viaduct / bridge loadedwith more than 430 tonne of steel billetsthis provided a total weight of more than550 tonne. The train stood still withoutmoving for half an hour than thetechnicians took the measurements of theloads. After this operation another Fagioliloaded railcar was positioned on the railtracks on the other side of the bridge. Twohours later measurements were taken bytechnicians in order to calculate the loadson the structure. Fagioli performedseveral high-speed rail tests all over Italy.Picture above shows the railcars loadedwith billets during the test.

The last issue of our news letter wementioned the rail transport of severalgenerators in Poland. This job is stillongoing throughout 2009. The itemweights vary from 230 to 460 tonne andrequire a 32 axle lines railcar withdifferent configurations to perform thetransports. (See photo left)

The picture above shows the transport fromMarghera port (Venice) to Mendrisio(Switzerland) of a transformer weighing 165tonne by means of a 16 axle lines railcar.

power plant turbine sections.The sections were transferredonto a barge using cranes. Aftera seven hour journey the bargearrived at the client’s facilitywhere we positioned our 800tonne capacity gantry crane.

(see picture left)The gantry liftedeach of thesections andpositioned themonto a Fagiolitrailer ready to be movedto the manufacturer sothey could be cleanedand restored. Thesections maximumweight was 50 tonne.

Fagioli is often called torelocate heavy items and install newones in restricted areas where crawlercranes, tower-lifts and strand jackssystems are all too big to be used,particularly in warehouses or coveredareas. Fagioli was called to relocate a292 tonne stator inCassano d’Adda, North-East of Milan.(see picturebelow left) The item waslifted and movedapproximately 100mwithin the warehouse.Fagioli lifted the statorusing their gantry craneand positioned it onto 2x6axle lines of SPMTs. Thegantry crane was thendismantled andrepositioned in anotherarea to perform theunloading operation.

23

Fagioli has its own medium-range cranesand proprietary gantry systems to conductheavy-lift assembly and erection activitiesin different industrial sectors for the finalpositioning of turbine-generator sets,boiler sections, transformers, storagetanks….

The gantry crane system is a mobile, self-propelled, variable height, hydraulic liftingframe. The gantries are designed to beoperated on steel plates or tracks. TheFagioli Gantry Crane system provides aneconomical way to lift heavy itemsanywhere in a facility with hoistingcapacity up to 800 tonne each.

Fagioli monitor all the different stages ofthe project from the erection andassembly schedule, alignment andlevelling operations as well as transportfrom origin to final destination.

Gantry cranes are extremely useful inrestricted areas an example of this is a 2week project Fagioli performed onMaggiore Lake (the second biggest lakein Italy) for the refurbishment of four

Gantry Lifting System

Fagioli was called to remove andsubstitute a generator and a turbine fromtheir original foundations. The weight ofthe generator was 165 tonne. (seepicture above) First they were lifted bygantry cranes, positioned onto SPMT’sand moved to a storage area. After fewmonths a new generator was positionedonto foundations!

The photo below shows another exampleof a hoisting operation in restricted areaof a 165 tonne reactor.

Contributions & Comments

Thank you to all those who contributed to this edition of the News Letter. We appreciate your comments please continue to send them to either of the personsnamed below:

Nicola Mowatt Rudy CorbettaFagioli Limited Fagioli S.p.A

The Ridgeway, Iver Via Vigentina 2, Bucks, SL0 9JE, UK 20090 OPERA, Italy

Tel: +44 1753 659000 Tel: +39 02 576901Fax: +44 1753 655998 Fax: +39 02 57690454n.mowatt@fagioli.com r.corbetta@fagioli.com

Visit our website at www.Fagioligroup.com

Fagioli World

Abu Dhabi (U.A.E.), Algiers (Algeria), Atyrau (Kazakhstan), Bejing (China), Bierun

(Poland), Calgary (Canada), Dammam (Kingdom of Saudi Arabia), Durres (Albania),

Essen (Germany), Hong Kong (China), Houston (USA), Istanbul (Turkey), London

(UK), Moscow (Russia), Mumbai (India), Oran, (Algeria), Paris (France), Seoul (Korea),

Singapore (Singapore), Tehran (Iran), Tripoli (Libya), Tubli (Bahrain), Tunis (Tunisia).

Fagioli’s involvement in a number ofprojects in Algeria was the main reasonwhy Fagioli decided to book a stand atthe Algeria’s largest and mostrecognised oil and gas event ALOGEheld in Algiers on 15th - 19thNovember 2008.

This allowed Fagioli to showcase thework recently carried out for severalpower plants, the transport andinstallation of generators, turbines,transformers..............

From 14th - 19th October last yearFagioli Inc. exhibited at the 19th AnnualBreakbulk Conference & Exhibition atthe Earnest N. Morial ConventionCenter in New Orleans, LA – Theexhibition seemed to be a greatsuccess as it really gained the interestof people and companies who were notaware of the work carried out by FagioliUSA over the last 10 years and by thegroup all over the world.

ADRIATIC LNG PROJECTA new 20 minute dvd is now availableshowing this incredible project, the firstoff-shore LNG re-gasification terminal inthe world!!

For a copy please contact Nicola orRudy!

Exhibiting in New Orleans

and Algeria