Thinking out of the BoxSalvaging a 900-Ton Ship Loader

Case Study

Having been smashed off its rail mountings by a passing ship, a 900-ton ship loader belonging to Durban Port operator Bulk Connections, a Bidvest Company, lay badly damaged at a 27 degree angle, supported only by what was left of the shore-side supply conveyor. Had it not been for the conveyor, the ship loader may have toppled over completely!

Anxious for an urgent salvage solution, Bulk Connections, supported by their insurance company, contacted three companies they thought could handle a job of this size, Vanguard being the only South African company with the required capabilities.

Under the guidance of MD Roland Cumings, Vanguard’s senior project engineer Ron Wiggle and his department handled the tender. Within the required 14 days, Vanguard had devised a workable solution and presented it to the client. After an exhaustive due diligence process, the client concluded that despite the other companies’ vast international experience, Vanguard’s proposal – from all aspects of getting the job done, not least of which was the safety factor – was by far the most feasible, and an order with us was duly placed.

Pre-engineering and fabrication started almost immediately as Vanguard’s heavy lift department kicked into action. Having completed modifications to our EZ 600 Ton Hydraulic Lift System specifically for this job, Vanguard was ready to begin the on-site work within the allotted 10 days.

Using a combination of hydraulic lift systems, specially modified to reduce the potential side load, PST trailers and mobile cranes, the 900-ton ship loader was eventually lifted back into an upright position and relocated about 150 m on the quayside and then re-positioned back onto its bogies as per the specified scope of works.

Kevin Munisur, operations engineer for the client, said of Vanguard on completion of the project: “These are the most amazing guys, and what an incredible job. It is not often that a construction company delivers exactly what they said they would, without any price change and most impressive was that they handed the ship loader back to us on precisely the day they said they would. Thanks a lot Vanguard!”

Vanguard Equipment Used:

600 ton Hydraulic Lift System,specially modified to reduce potentialside load

22 PST Self-Propelled Axle Lines 2 Power Packs 400 ton Mobile Crane 250 ton Mobile Crane

The sight that greeted Vanguard on our arrival at the client’s facility. After the accident, the ship loader was

left leaning against the remains of the bulk conveyor at an angle of nearly 30 degrees. The impact of the

colliding vessel resulted in the boom snapping off from its main pinion joints, and it had swung around 180

degrees and was now hanging very precariously.

The first and most vital step was to stabilise

the load and make it as safe as possible

before any further work could start.

To match the interface of the supporting beams

and the underside of the ship loader we used

600-ton turntables mounted on each self-

propelled trailers (PST) at the back of the load

and the 600-ton gantries in the front.

The next task was to cut free and remove the badly damaged, 27 m-long boom. This was achieved by

using a 400-ton and 250-ton mobile crane in a tandem lift.

Having finally brought the ship loader back into an upright position, the gantries were removed and the

PST combination was repositioned to lift the complete machine and return it onto its transport bogies.