Reports from around the world by industry specialists

• construction • demolition • quarrying • mining

Volume 1 No 8

Antarctic 9 weeks per year for contractors at the South Pole

Scotland Novel solution to large diameter pipe cleaning

Indonesia Financing equipment for nickel mining

USA Kick starting infrastructure development

Panorama New Zealand earthquakes and other topics

Page 2 Contractors World Vol 1 No 8

CONTENTSCONTENTSCONTENTSCONTENTSCONTENTS

Keep up with and comment on breaking news, news of a local nature and otherdevelopments on our blog pages.

COVER STORY

12 ANTARCTICErecting new complex for British Antarctic Survey is challenging onboth men and machines.

9 NEW ZEALANDChristchurch implements recovery of massive earthquake

18 SCOTLANDNovel solution to large diameter pipe clean up at Glenlee PowerStation

20 USAIs this the kick-start the US construction industry has been waitingfor? President Obama announces infrastructure initiative. How domanufacturers react to the statement? Contractors World getexclusive comments.

25 INDONESIANickel mining demand investment in equipment

6 PANORAMASnap shot of plant and equipment use on sites around the world

17 World's first full scale floating wind turbineStatoil’s innovative offshore floating Hywind wind turbinedemonstrates how Trelleborg’s syntactic foam buoyancy technologyis contributing to the future of offshore power.

27 Nuts & BoltsNew excavators from Komatsu, cranes from Hitachi Sumitomo andcompact machines from Caterpillar.

32 Protecting the environment and reducing costsInnovative emission control for construction equipment

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Page 3Contractors World Vol 1 No 8

Editorial CommentEditorial CommentEditorial CommentEditorial CommentEditorial Comment

In PIn PIn PIn PIn Praise of Praise of Praise of Praise of Praise of ProjectrojectrojectrojectrojectManagersManagersManagersManagersManagersAs contracts go, the lead article in this issue ofContractors World is comparatively small butfew project managers would relish themultitude of challenges that go with it. Asdemanding as mining, tunnel, high-rise,bridges and other construction projects canbe, there can be none like trying to complete aproject at the South Pole. As the dramatic pictures show, it is not thefriendliest of places, where nature is very extreme and unpredictable.

However, what it does emphasise is the careful need for managinglogistics and this is getting stricter and stricter as cities impose tightconditions on building sites - not only noise, dust and environmentalconcerns but also when and how material can be delivered.

These are not a problem where the construction site has a generousfootprint but with many inner city projects there is little, if any, room to storematerial so inevitably materials are stored on floor slabs as they are put inplace.

Maximising crane time is critical and with the crane operator beingrestricted on where and when he can fly loads without interfering with otheractivities taking place under the hook, calls for skill and good coordinationwith the banksmen and other personnel on site.

I have great admiration for Project Managers, who are so often lockedaway in their offices with little time to actually see the site. Today, theyhave to be much more reliant on their support team and live in dread of anyunexpected change to plan (as can so often happen in a design and buildprojects). Whereas in the past this would have meant simply re-evaluatingblueprints and material requirements. that is no longer the case. Today,any change to approved plans involves a lot of paperwork as additional riskassessments have to be undertaken. There may be health and safetyreviews and negotiations with subcontractors, suppliers, etc.

This is on top of the everyday policing of the site. Ultimately, it is theproject manager who is responsible for unsafe equipment, unskilled orinappropriately trained operators, health and safety, security, hiring andfiring, liaison with the architect, the engineers the client and, if it is aprestigious project such as those being built for the London 2012 OlympicGames, disruptive site visits by dignitaries, VIPs and other activities topromote the project.

Thankfully, most project manager welcome the opportunity to talk abouttheir projects. They all take immense pride in what they are doing. And Iappreciate that their time in valuable so giving up one or two hours to talkto an editor is not always convenient. So to all project Managers a big“Thank you and please invite me to your site. I also want to share whatyou are doing with readers around the world”.

Clients? That’s another story. They show little interest in talking to thetrade press . . . much to the annoyance of contractors and suppliers.Hopefully they will one day recognize the benefits such editorials makepossible, but, after 30 years, I very much doubt it.

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Nick Johnson

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Page 4 Contractors World Vol 1 No 8

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C P & EContractors Plant & Equipment

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USAUSAUSAUSAUSAKKKKKomatsu goes ‘omatsu goes ‘omatsu goes ‘omatsu goes ‘omatsu goes ‘quackers’ inquackers’ inquackers’ inquackers’ inquackers’ inChicagoChicagoChicagoChicagoChicagoA 30-ton Komatsu America Corp. HM300-2 articulateddump truck, “set free” more than 30,000 rubber ducks intothe Chicago River on August 12, for the fifth annual WindyCity Rubber Ducky Derby which benefits Special OlympicsIllinois.

Each year for the Derby, rubber ducks are “adopted” bysponsors (for a monetary donation) to “race” down theChicago River. Prizes are awarded for the first ducks tocross the finish line. This year’s Duck Derby raised morethan $250,000 for Special Olympics.

Komatsu has been part of this Special Olympics Illinoisevent since its inception five years ago. Each year,Komatsu employees have had a “hands-on” role in themanagement of the derby itself, and also organize avariety of fund-raisers throughout the year in support of theevent. Komatsu America then matches those funds.

Special Olympics Illinois is a health and human servicesorganization which offers year-round training andcompetition in 19 sports for nearly 21,000 athletes withintellectual disability and more than 40,000 Young Athletesage 2 to 7.

Komatsu America

CHINACHINACHINACHINACHINA60,000 m³ of60,000 m³ of60,000 m³ of60,000 m³ of60,000 m³ ofconcrete in 60concrete in 60concrete in 60concrete in 60concrete in 60hours pourhours pourhours pourhours pourhours pourEarlier this year, along the banksof the HuangPu River, 405concrete truck mixers shuttledbetween a huge pit 121 mdiameter x 30 m deep, and 5concrete batching plants.

The truck mixers were feedingconcrete into 18 Sany concretepumps parked around the pit.

In 3 days, these 18 units ofconcrete pumps poured a total of60,000 m³ of super-strengthconcrete to form the bottom slab of the building in 60 hoursnon-stopping.

In addition to placing concrete for the foundation slab,Sany’s concrete pumps are going to deliver concrete to theheight of 632 m.

Sany Corporation

http://www.feriazaragoza.com/smopyc.aspx

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GERMANYGERMANYGERMANYGERMANYGERMANYTTTTTelescopic cranes deliver flexibility inelescopic cranes deliver flexibility inelescopic cranes deliver flexibility inelescopic cranes deliver flexibility inelescopic cranes deliver flexibility inbridge construction.bridge construction.bridge construction.bridge construction.bridge construction.German contractor, Alpine Bau is constructing the second longestrailway bridge in Germany and is using a fleet of Sennebogen 643-R crawler cranes for pillar construction on the 2.7 km long Unstruttalbridge.

“We always wanted a telescopic crawler crane on theconstruction site”, says Jens Herrmann, supervisor at Alpine BauDeutschland. “Compared with the all-terrain cranes previouslyused, the telescopic crawler cranes offer more flexibility on theconstruction site as they are able to move the crane under load.This results in massive savings in both time and money".

The two-track rail crossing is part of the new Erfurt-Leipzig/HalleICE route. At a height of 50 m, the bridge crosses the Unstruttal andthe river Unstrut with four arches which presents a real engineeringchallenge. A total of 41 pillars and 4 steel concrete arches form thesturdy base.

Depending on the required work height and progress inconstruction, the Sennebogen 613M, 643R and 683R telescopiccranes are used for a wide variety of lifting work.

Steel parts for scaffolding, reinforcing steel or trussed rafters canbe positioned, sometimes in tandem lift, safely and precisely in the desired location. Primarily in the constructionof pillars, 8 ton shell parts are transported directly to the next pillar at heights of over 40 m with no intermediate lift.“The span width between the pillars is 58 m and we are often faced with difficult ground conditions. Here inparticular, the telescopic crawler cranes have the advantage", states Mr. Herrmann, explaining the situation on-site.

There are three 643 R with boomlengths of 30 m, equipped with a 13 mdouble collapsible jib for added liftingheight. The 683 R is also operated with a flyjib and additional work platform. The workplatform is extremely versatile and offers ahigh level of operational safety for rescuingpersonnel from high positions.

Low fuel consumption, sensitive andprecise operation and user-friendly controlsprovided by the machines are all positivefeatures for contractors facing difficultprojects.

Other equipment on site includes severalLiebherr tower cranes. Construction beganin August 2007 and is expected to becompleted in May 2011.

The project is worth $60 million in totaland is being completed as part of theGerman Unity transport project. Its is partof a 123 km-long German highspeedrailway.

After completion of the entire line thetravel time between Munich and Berlin willbe reduced to three hours and 45 minutes.

Sennebogen

Liebherr

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NEW ZEALANDNEW ZEALANDNEW ZEALANDNEW ZEALANDNEW ZEALAND“No problem“No problem“No problem“No problem“No problem” says authorities” says authorities” says authorities” says authorities” says authoritiesafter shake up.after shake up.after shake up.after shake up.after shake up.What a change it makes to report on a massiveearthquake that occurred on the 6th September close tothe city of Christchurch in New Zealand.

Although the earthquake measure 7.1 on the Richterscale and the damage was substantial, planning andimplementation of strict building regulations means thatthere is no international appeal for help, but a typical laidback approach of New Zealanders faced with a challenge

“No problem” is often the reply when someone isasked to do something out of the ordinary but in thisinstance it does not really sum up the nature of therebuilding task: it does perfectly reflect the stoical attitudeof people living in a country that experiences over 14,000earthquakes every year - thankfully most are minor orvery deep down.

But, as these pictures show, nature can be verydestructive. Authorities around the world should also takenote that major cities, and Christchurch has a populationof 384,000, can reduce impact of severe earthquakes byplanning and enforcing building regulations.

Although over 100,000 houses where damaged andthe city commercial centre was badly hit, there were notfatalities and only 2 serious injuries.

Clean up and rebuilding has already commenced eventhough there are constant aftershocks - over 300 sincethe major one.

New Zealand Railway (KiwiRail) immediately began aprogramme of inspecting bridges and tunnels as well asreplacing track that clearly shows the magnitude of theearthquake - the ground has moved by over 2 metres.

Similarly, the highway authorities have began the jobof fixing the badlydamaged main roads. A problem is that the cracks are not just to the surfacebut can be very deep and, as the picture shows, are also very long.

For the utility companies, the challenge is more. What do you do whenunderground pipelines have been lifted up by close to a metre in somesituations - relay the pipe to the original depth or raise the profile of the road?

Even for NewZealanders that is aproblem [CW]

Photo:Martin Luff, Christchurch,New Zealand

Photo:Greg O'Beirne

Photo: Martin Luff, Christchurch, New Zealand

A Kobelco excavator from Taggart Earthmovingdemolishes building beyond repair, while New Zealandrailway engineers prepare to replace buckled track and

replace damaged cabling.

Long, very deepcracks have damagedkey highways and inresidential areas,stormdrains havebeen pushed over 500mm above the roadsurface.

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MalaysiaMalaysiaMalaysiaMalaysiaMalaysiaFFFFFoundation and underground floorsoundation and underground floorsoundation and underground floorsoundation and underground floorsoundation and underground floorsfor the 348 Sentral project in Kfor the 348 Sentral project in Kfor the 348 Sentral project in Kfor the 348 Sentral project in Kfor the 348 Sentral project in KualaualaualaualaualaLLLLLumpurumpurumpurumpurumpurThe 348 Sentral project, a shopping mall and three high-risetowers with up to 31 floors, which will house a hotel and residentialunits, is under construction in Malaysia’s capital.

MRCB Engineering contracted BAUER Malaysia Sdn.Bhd. toplan and construct the foundations and underground floors on aturnkey basis.

The works started in 2009 and comprise the installation of some 7,000 m² of diaphragm wall and 161 boredpiles in 1200 mm and 1500 mm diameter. Interestingly, the pit construction is using both top-down and bottom-up techniques.

The top-down area includes the 161 piles, 58 with plunge-in-columns to support the top down slab. In thebottom-up area, the 800 mm thick diaphragm wall is retained by 300 temporary anchors and prestressed steelstiffening struts. A special feature of this is that the struts tension against the permanent ceiling slabs of thebasement floor, constructed by the top-down method, thus minimizing the strut lengths.

Bauer Technologies

EnglandEnglandEnglandEnglandEnglandAugur boring speeds up sheet pilingAugur boring speeds up sheet pilingAugur boring speeds up sheet pilingAugur boring speeds up sheet pilingAugur boring speeds up sheet pilingGroundworks contractor Westshield, is working on a project to build a newstorage tank, pumping station and sewer diversion for client United Utilities.Sheet piles had to support a 3 m deep, 250 m long trench for a new sewerpipe. A resonance-free crane suspended vibrator was chosen in preference toa traditional air-hammer in order to avoid causing damage to an old farmbuilding alongside the trench

However, during piling, the contractors came across firm to stiff clays andboulders which the crane suspended hammer could not drive sheets through.The solution was to use an excavator-mounted auger from Piletec, the pilingequipment division of specialist hire company Groundforce, to pre-auger theground to a depth of 6 m before driving the Larssen piles into the loosenedearth.

The auger was then replaced with the crane suspended hammer whichwas now capable of driving the sheets in without difficulty.

Groundforce

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Padre Adelino viaduct has been designed as a single-arch,single-span bridge with a 122 m long viaduct that is 20 m wideand has three lanes in both directions.

This design was chosen because it allows the use of lighterbuilding slabs that are only half a metre in thickness, therebymaximising the height available between the bridge and theroad surface and allowing the passage of large trucks.

Doka Brazil provided their client Construbase with asolution that allows the arch to be moulded to obtain perfectgeometry and providing safety for the awkward work on thesloping structure.

They supplied two sets of MF240 climbing formworktogether with Top 50 beam formwork. The cantilever beamscan be displaced as a unit at any time with a single cranemovement. The key benefit of this system is the adjustablework platform, which remains level for each concrete-pouringstage, despite the slope of the arch.

The platform width of 2.40 m provides plenty of space forfast, safe working. With these two sets of climbing formwork.D2 falsework towers were used to point the arch joint.

Another difficult task was to develop a solution for pouring the single-cell caisson of the superstructure. It hadto be done in such a way as not to require any interruptions to local traffic, as the site is a major link betweendifferent districts. Construbase opted for the successive cantilever segment method, thereby enabling a lighter,more slender superstructure to be built. A further challenge was posed by the cable-tensing niches, the position ofwhich changed for each concrete-pouring section.

For the successive cantilever segment Doka Brazil planned two sets of tailor-made Top 50 formwork. Onceeach segment was complete, the cables had to be tensioned. For this, Doka built peripheral platforms, takingadvantage of the flexibility of the Top 50 system. This solution considerably increases personal safety of theworkers involved in the tensioning process.“

One of the most challenging aspects was the highly congested surroundings in which the site is located, withthe new bridge crossing one of the city's busiestarterial roads and new access road constructionproviding the potential for massive trafficdisruption. The contractors decided to use a singletower crane, the Liebherr 110 EC-B6 configuredwith a boom that could be used to access all thelifting points on the site while minimising the spacebeing utilised. Initially, the 110 EC-B6 was using itsfull jib length of 55 m, but as the project evolvedthis was reduced to 40 m. The crane has amaximum lift capacity of 6 t, which reduces to 1.5 tat the maximum 55 m length of the jib. The cranehas an underhook height of 51.1 m.

With this combination of lifting and formingtechnology, the contractor has been able tominimise any restrictions to traffic flow. Work onthe bridge is now in its final phase, and thestructure is expected to be completed by Octoberthis year at a cost of $64.5 million..

Doka

Liebherr

BRAZILBRAZILBRAZILBRAZILBRAZILImpressive arched bridgeImpressive arched bridgeImpressive arched bridgeImpressive arched bridgeImpressive arched bridgeefficiently formedefficiently formedefficiently formedefficiently formedefficiently formed

Page 12 Contractors World Vol 1 No 8

As tough and demanding as construction projects can be, there will be few managers that have tomanage the extremes thrown up by trying to implement a building project in the Antarctic. Galliford TryInternational is nearing completion in erecting a new, relocatable modular structure for the BritishAntarctic Survey (BAS).

AntarcticAntarcticAntarcticAntarcticAntarcticConstructing Halley VI Research Station inConstructing Halley VI Research Station inConstructing Halley VI Research Station inConstructing Halley VI Research Station inConstructing Halley VI Research Station inextreme conditionsextreme conditionsextreme conditionsextreme conditionsextreme conditionsApart from the extreme weather conditions, the construction window in the Antarctic is just 3 months during whichtime men, materials, supplies and equipment has to be delivered to the site or prepared. At least there is 24hours of daylight, so that is one consideration less. However, the Antarctica weather is difficult to forecast andeven in midsummer, the mean temperature is -15 to -35°C excluding wind chill which can take it down a further 10degrees. Even at mean level, for that part of the world, it is very mild when you consider that severe storms cancause sudden extreme drops in temperature and total whiteout. In winter, mean temperature is -40 to -70°C.

However, for research to continue, some construction work is necessary and the British Antarctic Survey (BAS)is currently having a new facility, called theHalley VI station, built. In the past,structures were permanent meaning thatthey were over time either covered byfreezing snow, or pushed with the ice flowtowards the edge of the sea.

The last structure for BAS was erectedon hydraulic jack legs so each season itcould be raised above the new snow line.However, this did not overcome the gradualshift towards the seas.

Designed for longevitDesigned for longevitDesigned for longevitDesigned for longevitDesigned for longevityyyyyThe new station under construction is builton sledges measuring 4.52 m x 1.10 m and1 m and weighing 1377 kg attached to

Tadano Mantis crawler mounted telescopiccranes lift large dimensioned pre-assembledmodules into position on the Halley VI project.

Page 13Contractors World Vol 1 No 8

hydraulic cylinders and positionedto each corner. This is to enablethe modules to be jacked up andeasily moved to a new location.

Apart from being moveable,the challenge for the designerswas to find a structure that couldwithstand the extremetemperatures, high winds and yetprovide a safe, comfortableworking and living environment.

The challenge was issued aspart of a competition and thewinning design by AECOM andHugh Broughton Architects isbeing built by Galliford TryInternational as the maincontractor.

To evaluate the design, testand determine best constructionmethods and find solutions forpotential problems, one of themodules was first erected in the UK, before being shippedto South Africa from where it was sent to the Brunt IceShelf.

Modern technologyModern technologyModern technologyModern technologyModern technologyThe challenge was to pioneer and prove technology to raise and move large modules over snow successfullyproven. This involved loading a skeletal frame work with more weight than the finished module and thenevaluating the ability to haul the units. Caterpillar Challenger tractors adapted for the climatic conditions provedthat they had the power to haul the modules.

The hydraulic leg jacking system was designed in the UK and also included the hydraulic and electricalcontrol system. The legs not only had to withstand -50º C temperatures but, as the modules were permanentlystanding on the hydraulic cylinders, special vales and continuous monitoring systems had to be developed. Thehydraulic legs also had to be designed in modules so that they could be put together on site.

At this time, all seven modules for the research base are now erected and clad and the contractors say thatone more season will see the project completed. The base is expected to be fully operational by February 2012.

This has only been made possible by close liaison with designers, material manufacturers, transportcompanies, the BAS, the consultant, and contractors working as a team. The construction team comprises 120people working in extreme, and very unfriendly site conditions to a very tight programme - and no opportunity toover run the three month construction period. As many a project manager would say “No pressure then?”

The relocatable modular facility comprises of six blue accommodation, science and life support modules andone larger module to provide the scientists and support teams with a state of the art social centre and place to livethe even harsher winter period. The 164 m² modules typically weigh 80 tonnes and are elevated using hydraulic

Photo: British Antarctic Survey

Bright sunshine, 24 hours a day allows the constructioncrews to rapidly progress the erection of the modules.

But conditions are not always so favourable.

Page 14 Contractors World Vol 1 No 8

legs supported on giant skis. It is not anticipatedthat the modules will have to be moved everyyear. To cope with the movement of the iceshelf, the BAS estimate that it will be 5 yearsbefore they have to relocate, but the solution isstill a far better option than building a new base.

With 24 hour day light, work could take placeround the clock. Within the 9 week period, steelframes had to be erected and the modules cladin high performance fibre reinforced plasticcladding

The construction team at one time thoughtthey had a problem with the FRP as there wassome surface blemishes, but tests showed thatthis was simply small areas where resin wasaccumulating without the fibre.

There was no failure of the product and theproblem was fixed. During construction, minor

modifications was made to the modular elements to strengthen the edges and enable tighter seals. The moduleshave been designed to withstand prevailing winds of up to 90 miles per hour and an average external temperatureof –30ºC degrees (extreme minimum –56ºC). The facility is expected to have a longer life than any previousBritish station on the Brunt Ice Shelf.

Extreme conditions are tough on equipmentExtreme conditions are tough on equipmentExtreme conditions are tough on equipmentExtreme conditions are tough on equipmentExtreme conditions are tough on equipmentIn any normal project, plant and equipment selection is a relatively simple task but choosing equipment foroperations in the Antarctic brings in a whole lot of additional considerations. Service engineers are not availableso not only routine maintenance but heavy duty servicing and repairs also need to be considered. The equipmentalso has to be configured for the climatic conditions. As explained by Tadano Mantis Corporation who providedcrawler mounted Mantis telescopic cranes.

Cranes such as the 30 t. Mantis 6010 telescopic-boom crawler cranes, which are being used, have undergonevarious upgrades to meet the severe conditions of the Antarctic climate. These include accommodations forspecial fuels (Jet A) and low temperature lubricants; pre-wired heaters for engine, batteries, hydraulic reservoir,and fuel reservoir; insulated fuel and hydraulic reservoirs as well as insulated machinery houses.

The first Mantis crane deployed to Antarctica was a Mantis Model 3010 in 1987. The most recent, a Model10010Mx, was shipped in September 2009.

A Cat Challenger tractor, used tohaul heavy loads and is able to

move the modules, sleepsthrough the harsh winter

darkness. Because of the shortworking season, come the

summer it has to work almostimmediately.

Photo: British Antarctic Survey

Tadano Mantis crawler telescopic cranesand Genie aerial access platforms takeon the delicate task of putting in place thelarge winter protection coverings suppliedby Custom Covers

Photo: Custom Covers

Page 15Contractors World Vol 1 No 8

Genie, likewise, who has five Z-60/34aerial access platforms assisting in theconstruction process. Again, these had tobe heavily modified with additional heatersfor fuel and oils, additional insulation suchas thermal wraps to the battery, hydraulicand diesel tanks.

The models also have a built in 110 vgenerator for operating power tools, etc.There is also a battery chargerso that, atnight, the machines could be driven backto base and plugged in to be fully charged.

The aerial work platforms are fitted withLoegering QTS track systems to provide theadditional traction required and the necessarystability in the unpredictable ground conditions toenable working at height without stabilisers.

The articulating boom arrangement gives amaximum working height of 20.39 m with a loadcapacity of 227 kg. A horizontal reach of 11.05 mand up and over reach of 8.23 m enables theconstruction workers to access all areas of themodules with minimal moving of the machines.

Short season demand protectivShort season demand protectivShort season demand protectivShort season demand protectivShort season demand protectiveeeeecococococovvvvversersersersersFor obvious reasons, at the end of each shortworking period, the partially finished modules hadto be protected so special covers had to bedesigned to not only cover the partially builtmodules, but also be durable enough to withstandhigh wind, low temperatures and the weight ofsnow.

The challenge went to Custom Covers, a Southampton, UK company with over 25 years experience.

"We didn’t turn away from any challenge and aim to make covers for absolutely anything", says CustomCovers chief executive Robert Sanders "and this project proves it. We did a lot of research to come up with afabric that was capable of withstanding extreme weather conditions, and a design that would be incredibly durableand prevent spindrift getting through the cover and into the team's equipment turning it to ice."

When it came to putting the structure together, it quickly became obvious that traditional joining methods wereunacceptable, and designers had to find a way of constructing each cover in one piece.

"Once we had a design that had been agreed by the customer," explained Simon Bell Custom Coverstechnical director, "we had to have each cover computer cut and then put together by a team who worked day andnight, and through manyweekends, to get the job done.

Each cover usedapproximately 1400 m² of fabricand weighed just over a ton apiece. They had to withstandwinds of 160 km/h andtemperatures of -50º C. The

The flashlight from the camera of this cat dozertaken during the middle of the Antarctic Wintercreates a stunning effect but also illustrates theconditions equipment has to withstand.

Photo: British Antarctic Survey

Photo: British Antarctic Survey

A heavily modified John Deere skidsteer loader carriescomponents from storage to the modules during erection.

Photo: British Antarctic Survey

A Cat Challenger hauls a TadanoMantis sub-assembly from the

delivery ship to the base. In theseconditions, even for specialized

equipment, a shovel is alwayshandy.

cover sizes nominally are 32 m long x 33 m widemanufactured in one piece without openings. Thematerial used is 730 g/m² PVC coated polyesterwhich is fire retardant with temperature resistance to -54º C/ +70º C. Load analysis confirmed loads on thestructure and factor of safety of the PVC material insitu and showed that 6 ton of webbing strap wererequired, evenly spaced along the cover to giveadditional support to the material. For furtherprotection, 1200 mm of protective chafe was installedto reduce wear of cover against module steelwork

Access to the covers is through double-layer PVC roll up doors, closed with Velcro seal to inner door thenouter laced shut for structural integrity

When the construction team left Antarctica in March 2010, all seven modules were fully clad weather-tight andready to endure the harsh winter months. The next phase of the project, planned for the 2010-11 season willinvolve fitting out the modules and commissioning the technology. It is expected to be operational by February2012.

Describing the successful season, architect Hugh Broughton commented, “The construction of Halley VI hasrequired a Herculean team effort. Everyone involved should feel truly proud of the achievements made thisseason. When complete the new station will provide 21st century accommodation for the British Antarctic Survey,allowing world class scientists to carry out the science which is so crucial for the survival of our planet.”

Peter Willmott of Galliford Try commented, “The build programme was focused on constructing all of themodules and making them weather-tight for the austral winter. Interior fit-out and commissioning will start inNovember ahead of final completion by February 2012”.

Not quiet home from homeNot quiet home from homeNot quiet home from homeNot quiet home from homeNot quiet home from homeThe new station will provide a home and work place for 16 people during the winter and 52 in the summer. Itneeds to respond to the most extreme environment on the planet. Located 10,000 miles from the UK, the stationis being built on the 150 m thick floating Brunt Ice Shelf, which moves 400 m per annum towards the sea. Snowaccumulation means that snow levels rise by over one metre every year. The sun does not rise above the horizonfor three months during the Austral winter.

A concern for all is that a major calving event is predicted in the next decade. There is a risk that the presentresearch station could be lost. Halley VI, because it has a series of mechanical legs on skis means that staysabove the surface of the ice and can be relocated inland to minimize the risk of loss due to future calving events.

Contractors World acknowledges the assistance an access to images provided by the British Antarctic Survey.The project was costed at approximately $30 million and, by the time the complex is complete it will have taken

less than 12 months but phased over 4Antarctic summer time periods.

The British Antarctic Survey

Tadano Mantis

Genie Access Platforms

John Deere

Caterpillar

Custom Covers

Page 16 Contractors World Vol 1 No 8

Partially built Halley VI modules with protectivewinter coverings. Once the modules had beenfully enclosed with their outer cladding, theprotection was no longer necessary. A chancefor them to prove their ability to withstand theconditions.

The protective covers were designed to give totalprotection from the cold, strong winds and heavy snow

falls which, as this picture shows can be substantial

Photo: British Antarctic Survey

Photo: Custom Covers

Page 17Contractors World Vol 1 No 8

Statoil’s innovative offshore floating Hywind wind turbinedemonstrates how Trelleborg’s syntactic foam buoyancy technology iscontributing to the future of offshore power.

“It is subsea technology that has already been extensively proven,”commented Gary Howland, Renewables Sales Manager forTrelleborg Offshore. “Trelleborg Distributed Buoyancy Modules(DBMs) developed for deepwater support of umbilicals and risers inthe oil and gas industry are ideal for this application; helping reduceproject risk by using proven technology.

The subsea portion of the turbine is criticalThe subsea portion of the turbine is criticalThe subsea portion of the turbine is criticalThe subsea portion of the turbine is criticalThe subsea portion of the turbine is critical“People see the tower and turbine, but forget that the expertise indesigning the subsea portion is also critical, as ultimately it keeps thewhole turbine afloat.

“The dynamic floating structure weighs 5,300 t and is 165 m tall; with a total of 65 m above sea surface. The 13km of power offtake and communications cabling attached to the structure further adds to its weight.

“It’s like the proverbial iceberg; the mass floating below the surface ensures stability. Unless the weight issupported by properly designed buoyancy the whole structure would be much less able to resist the extremes ofthe offshore environment and the cable could suffer prematuredamage.”

Designed and supplied buoDesigned and supplied buoDesigned and supplied buoDesigned and supplied buoDesigned and supplied buoyyyyyancy modulesancy modulesancy modulesancy modulesancy modulesFor Hywind, Trelleborg Offshore designed and supplied 45 off polymer-coated syntactic foam DBMs which supply buoyancy support for a 3 t,100 m section of cable as it exits the turbine spar and descends to thesea bed at -220 m..

The buoyancy modules include an internal clamp for securefastening and precise positioning on the cable. The cable is supportedmid-water in what is known as a ‘Lazy Wave’ configuration, featuringgentle long radius curves that minimise stress on the cable whileaccommodating natural movement created by wind and waves.

Howland continued: “For optimum buoyancy under different seaconditions, the precise position of the buoyancy modules on the cableis pre-calculated. The positions must be maintained, despite stressesduring launch and in operation. The clamp is crucial; the design,material selection and manufacturing technique are critical in ensuringthe finished clamp maintains the buoyancy module position, duringcable contraction and expansion, over the 20 year lifetime of theproject."

ProProProProProvvvvven technologyen technologyen technologyen technologyen technology“Trelleborg Offshore has substantial expertise in operating in deepwater marine and subsea environments, and a track record acknowledged by leading offshore engineeringcompanies all around the world. The company has significant experience in the supply of DBMs, within excess of35,000 modules in service, which will be invaluable in the rapid establishment of the far offshore renewablesindustry.

“We have seen many of the technical challenges before, in the offshore oil & gas arena, so our engineers canquickly and easily adapt proven solutions for use in offshore wind power generation. This will greatly reduceproject risk and make development of the industry far quicker and less costly.”

Trelleborg

WWWWWorld's first full scale floatingorld's first full scale floatingorld's first full scale floatingorld's first full scale floatingorld's first full scale floatingwind turbinewind turbinewind turbinewind turbinewind turbine

Photo: Hild Bjelland Vik / Statoil

Page 18 Contractors World Vol 1 No 8

SCOSCOSCOSCOSCOTLANDTLANDTLANDTLANDTLANDCLEAN UPCLEAN UPCLEAN UPCLEAN UPCLEAN UPAAAAAT GLENLEET GLENLEET GLENLEET GLENLEET GLENLEEPOWERPOWERPOWERPOWERPOWERSTSTSTSTSTAAAAATIONTIONTIONTIONTIONThe 12 MW Glenlee hydroelectric power station in Scotland is part of the 106.5 MW Galloway Hydro-Electricpower scheme, which was the first large scale integrated hydroelectricity supply complex in the UK when it wasbuilt and commissioned in the mid 1930s. A 60 km long network of lochs, dams, tunnels, aqueducts, pipelines andrivers interconnect six power stations in a cascade system, which reuses the water several times for powergeneration.

Each station reuses the water that has been discharged by the one above to generate electricity. A dam blocksthe natural outflow of Loch Doon and acts as the main storage reservoir at the top of the scheme, which has adrop of 210 m over its length.

Glenlee is the fifth of the six power stations in the interlinking renewable energy scheme that covers a largearea of Galloway and South Ayrshire. Water for Glenlee Power Station gathers in Loch Clatteringshaws and flowsthrough a 6 km long tunnel to a portal control valve above the power station.

From here water plunges 125 m down the hillside through a 570 m long steel penstock of varying diameter tothe station’s twin 6 MW turbines and out of tailrace valves and into a spillway, for discharge into the River Dee.The discharged water then combines with natural river flows to the downstream Loch Ken, which acts as thereservoir for the last power station in the scheme at Tongland. Outflow from Tongland Power Station rejoins thelower reaches of the River Dee and flows into the Solway Firth at Kirkcudbright Bay.

The Glenlee penstock was in need of cleaning and repaintingand power station operator Scottish Power Generation Ltdawarded a contract for its refurbishment to the specialist contractorConcrete Repairs Ltd based in Falkirk. The flange bolted steelpipeline had not been cleaned and painted internally for over 70years, since it was installed in the 1930s. CRL believed the internalcleaning and paint removal could be done with high-pressurewater jetting and contacted N.E.T. Waterjet Ltd, a contractor basedin Meigle, Perthshire, specialising in ultra high pressure watertechnology and diamond drilling and sawing.

“I believed it was initially feasible to use hand held high-pressure water jetting lances in the penstock’s varying diametersand gradients to remove the old paint coating and peat lying in thebottom, but there was a risk for the operators,” says N.E.T.managing director Tom Wallace. “So I looked at the possibility ofadapting a robot, normally used for the hydrodemolition ofconcrete, and contacted Castellan, the UK agent for Conjethydrodemolition equipment in Sweden.

Castellan’s managing director Colin Jailler arranged for me tovisit the Conjet factory and as soon as I saw the compact 324Robot I knew it would work, using the optional Hammelmann blast

Conjet high-pressure water jetting proved the ideal solution for pipecleaning and could easily be adapted from the usual demolition jettingconfiguration.

Page 19Contractors World Vol 1 No 8

or rotor head instead of the normalconcrete hydrodemolition lance. CRLaccepted my price and I ordered aConjet 324 Robot from Castellan andit arrived on site in May.”

N.E.T. used its new Conjet 324,with optional rotor head, to remove

the build up of debris, old paint coating up to 4 mm thick and unexpected original mill scale, back to a clean andsmooth metal surface. The company had about 4,200 m² to clean from the inner surface of the penstock indiameters from top to bottom of 3 m, 2.7 m, 2.4 m and twin 1.8 m and on varying gradients from 1:100 up to thesteepest 18º.

CRL removed the flange bolted expansion joints and butterfly valves in the penstock to provide N.E.T. accessat several points for the Conjet 324, which was supplied with water at a pressure of 2,500 bar and flow of 25 litres/min from one of N.E.T.’s existing 250 kW Hammelmann 120 high-pressure pumps.

“We are working a single shift seven days a week and averaging to clean about 200 m²/shift, but our best hasbeen 320 m²/shift,” says Tom Wallace. “The surface of the pipe actually gets cleaned twice as the 180 mmdiameter blast head is rotated full circle round the inner circumference of the pipe, then advanced 90 mm by theRobot and then rotated back in the opposite direction. The sequence is repeated continuously. The Conjet Robothas been superb and worked very well and is a lot safer and about three times faster than using hand lancing.There is no fatigue for the operator and the Robot provides consistent speed and removal. It is also possible toquickly and easily change or adjust the blast head settings and forward step speed to suit the adhesion of the old

paint coating.”

There is no dust from the paint removal and the wastewater and debris from the Conjet Robot cleaning processflows down the penstock and is collected by CRL in a sumpin the turbine house. It is then pumped into tankers for offsite environmental treatment and disposal.

“I am very impressed with the cleaning process and theRobot, which is doing a great job. I am also surprised at howquick it is at taking off the old coating back to the baremetal,” says CRL site manager Fran Allan. CRL is followingon spraying on a two coat glass flake epoxy coating from apurpose made gantry that will travel down the inside of thepipe.

CRL is also repainting the outside of the pipe with ahighways bridge specification four-coat epoxy paint system.CRL started on site in February and is on schedule to allowScottish Power Generation to bring Glenlee Power Stationback on stream in autumn 2010.

N.E.T.’s first use of a Conjet Robot has gone extremelywell and the company believes there are considerableopportunities on other similar projects. “This is the first timeI’ve used a Conjet Robot and can foresee a lot of furtheropportunities with the 324, mainly working in concrete andsteel pipes and tunnels up to about 4 m diameter,” says TomWallace.

Conjet

N.E.T. used its new Conjet 324, withoptional rotor head, to remove the buildup of debris, old paint coating up to 4mm thick and unexpected original millscale, back to a clean and smoothmetal surface.

Page 20 Contractors World Vol 1 No 8

The US President Obama has unveiled a $50billion two-faceted infrastructure plan to try andcreate jobs over the long-term by stimulatingconstruction and related activities to improvetransportation by rehabilitating the nationsinfrastructure which, in some areas is in acritical state.

The longer term vision is that a vastlyimproved transportation industry will bringadditional benefits to further stimulate economicrecovery.

However, the question has to be asked “Isthis too little too late for much of the work thathas to be done?” The Highways Bill has beentalked about for many years. Initially, theemphasis was on maintenance andrehabilitation works. With the passing of timeand the further deterioration in roads andbridges, the only option now is to completelyrefurbish, if not rebuild, thousands of miles of

highway and hundreds of bridges.

President Obama recognized this in his choice of words in the official Whitehouse statement which outlinesome of the tangible objectives of the plan over the next six years.

Quoting from the statement: “These include:

• ROADS: Rebuild 150,000 miles of roads – renewing our commitment to the backbone of our transportationsystem;

• RAILWAYS: Construct and maintain 4,000 miles of rail – enough to go coast-to-coast;

• RUNWAYS: Rehabilitate or reconstruct 150 miles of runway – while putting in place a NextGen system thatwill reduce travel time and delays.”

The key word in this statement is ‘rebuild’ . . . the word ‘rehabilitate’ is only used for runways which, by theirvery nature need to be maintained to a very high standard for obvious safety reasons.

The President’s statement said that “the nation’s highways serve as the backbone of our transportationsystem. Many roads and bridges are in need of repair and expansion and many of the Americans, who want to dothis work, face high unemployment right now. Our investments would be focused on modernizing the highwaysystem’s critical assets while providing much-needed jobs.

• Rail

Many parts of transit systems have been allowed to fall into a state of ill-repair. The President’s plan wouldhelp address this by making a major new investment in the nation’s bus and rail transit system. TheAdministration is also committed to expanding public transit systems and would dedicate significant new

USAUSAUSAUSAUSAIs this the kick start theIs this the kick start theIs this the kick start theIs this the kick start theIs this the kick start theconstruction industryconstruction industryconstruction industryconstruction industryconstruction industryhas been waiting for?has been waiting for?has been waiting for?has been waiting for?has been waiting for?

Roger Lindley talks to theleading constructionequipment manufacturerson what the latest USinitiative means for theindustry

A section of an exit ramp (Exit 3Northbound) off Interstate 787 in Albany,

New York, United States slipped off itssupports, coming to rest on the concretepier. The towers are now supporting the

roadway so crews can investigate thedamage and cause.

President Obama hasannounced a massiveinfrastructure incentive torestore the nationssystems.

Page 21Contractors World Vol 1 No 8

funding to the ‘New Starts’ program – which supports locallyplanned, implemented, and operated major transit projects. Inaddition, the Administration is committed to building on itsinvestments so far in highspeed rail – constructing a system thatwill increase convenience and productivity, while also reducingour nation’s dependence on oil and cutting down on pollution. The President’s plan would also invest in along-overdue overhaul of Amtrak’s fleet.

• Runways. The Administration proposes to invest in our nation’s airports by improving their runways and other equipment

and facilities. We also propose a robust investment in our effort to modernize the nation’s air traffic controlsystem This investment will help both the FAA and airlines to install new technologies and, among otherimprovements, move from a national ground-based radar surveillance system to a more accurate satellite-based surveillance system – the backbone of a broader effort to reduce delays for passengers, increase fuelefficiency for carriers, and cut airport noise for those who live and work near airports.

PPPPPermanent infrermanent infrermanent infrermanent infrermanent infrastructure bankastructure bankastructure bankastructure bankastructure bankThe President proposes to fund a permanent infrastructure bank. This bank would leverage private and state andlocal capital to invest in projects that are most critical to our economic progress.

This marks an important departure from the federal government’s traditional way of spending on infrastructurethrough earmarks and formula-based grants that are allocated more by geography and politics than demonstratedvalue. Instead, the Bank will base its investment decisions on clear analytical measures of performance,competing projects against each other to determine which will produce the greatest return for American taxpayers.

Is this enough?Is this enough?Is this enough?Is this enough?Is this enough?Contractors World approached industry leaders to get their comment on the statement. First, we approached theAssociation of Equipment Manufacturers (AEM)

Signs of deterioration on the 11th StreetBridges in Washington, D.C., in November2009. The rust-resistant paint has worn off,

significant rusting of the iron truss whichforms the substructure of the bridge has

occurred.

DennisSlater,President ofthe AEM

Dennis Slater, the President of the AEM (Association of Equipment Manufacturers) who supported theinitiative but with certain caveats and reservations. He told Contractors World:

“President Obama’s recent focus on infrastructure investment is welcome, but thisis only a first step. Any stimulus is a short-term boost. Without the certainty ofcontinued funding, state and local governments can’t adequately plan projects.

We still need a longer term solution - a fully-funded, multi-year transportation bill -and we need it now. In a recent AEM voter poll (conducted by an independent third-party firm), an overwhelming majority – 88 percent – of American voters believe that“modern, safe and efficient” infrastructure is “necessary” to a healthy, growingeconomy.

Yet Congress allowed the law authorizing federal surface transportation programsto expire on September 30, 2009, and no serious attempt has been made to pass anew law. Investing in rebuilding and modernization of our nation's roads, bridges,railways, runways and transit systems is a strategy that Democrats and Republicansalike should be clamouring to support. But while they are caught up in partisanrancour, America is falling behind other nations that are building infrastructure forfuture competition in the global marketplace. In the short term, this will continue to costAmerican jobs.

In the long-term, it will cost us our competitive advantage – and even more jobs..

In a general statement issued on behalf of the AEM, Dennis Slater added

“America’s equipment manufacturing industry applauds the President for recognizing the vitalimportance of infrastructure investment to the long-term strength and competitiveness of our country.What America needs – and what voters want – is the Administration and Congress to work in partnershipright now to finally pass a transportation reauthorization bill that will address long-standing safety andquality issues, and put Americans back to work.

Investing in the rebuilding and modernization of our nation's roads, railways, runways and transitsystems is a strategy that Democrats and Republicans alike should be clamouring to support. Instead,

Ron DeFeo, Chairman and Chief ExecutiveOfficer of the Terex Corporation had similarmixed views. He told Contractors World,

“On the surface, that would seem to be a lot of money and, therefore, a boost forequipment manufacturers and distributors, but I think we should temper our enthusiasm.First, crucial details are lacking.

More importantly, ‘one-off’ proposals are no substitute for well understood mechanismsthat enable long-term planning and provide funding for infrastructure investment overmany years. Such is the case with the surface transportation programs legislation knownas SAFETEA-LU.

That act expired September 30, 2009 and the administration has yet to provideleadership to reauthorize and appropriately fund our highway and transit programs. At thesame time, we must guard against funds being siphoned off for nice sounding programsthat do not benefit the majority of the travelling public and are not economically sound.

The United States once led the world in infrastructure. Sadly, that is no longer the caseand our economic competitiveness is suffering. It will take us many years of carefullyplanned investment to make up this deficit. This is the approach that will be best for our industry and for thecountry. So, let’s not rush to an inadequate program driven by short-term politics. Let’s do this in earnest andwith the care it deserves.”

Congress has let a six-year bill expire while America falls behindother nations that are building infrastructure for future competition inthe global marketplace. In the short term, this has and will continueto cost American jobs. In the long-term, it will cost us our competitiveadvantage – and even more jobs.

While the President’s plan for an Infrastructure Bank andincreased capacity in our infrastructure system is an important step,Congress has the opportunity to act now on transportation

reauthorization that will result in immediate job creation. We need a strategic vision for modernizing ourcountry’s infrastructure, and leaders with the courage to make it happen. We need Congress to pass atransportation bill, and they need to come together on a robust, multifaceted and sustainable way to pay for it,including consideration of a user fee increase. Maybe this is not the most popular policy stance in an electionyear, but there is no such thing as a safe road built by American workers for free.”

Ron DeFeo, Chairmanand Chief ExecutiveOfficer of the Terex

Corporation

Photo: Bernard GagnonInterstate 17 - Arizona showing deteriorationwhich is repeated across the USA

Page 22 Contractors World Vol 1 No 8

Following conversation with several people throughout the Liebherr Group,a spokesman for the company, in summing up, told Contractros World that

Liebherr applauds President Obama’s comments recognizing the importance of investing in infrastructure tocreate jobs and get the economy moving. The deteriorating US infrastructure poses a general challenge for theAmerican economy.

He went on to say, “The stimulus bill passed last year devoted much less to infrastructure than mostunderstood which explains the limited impact. On September 30, 2009 the multi-year Surface Transportation Billexpired. Since then a new Highway Reauthorization Bill has been stalled in Congress with short-term extensionspassed every few months. Without the certain funding of a multi-year bill, long term and larger projects remainstalled. This has impacted Liebherr customers and dealers as equipment has sat idle, employees terminated orlaid-off; all while the critical needs of the US infrastructure continue to escalate.

Liebherr welcomes the President’s comments and hope Congress and the administration will come together topass a multi-year Highway Bill. This is a critical first step toward the infrastructure investment required to get theUS economy moving and to provide meaningful job growth.”

John Patterson, JCB Deputy Chairman and JCB Inc CEO said: “"We (manufacturers)have collectively been urging Congress and the Administration to work together onlegislation that would improve the nation’s roads, rail systems and overall infrastructure.

"The stimulus act that was passed last year was originally proposed as a transportationbill aimed at jump-starting the economy. With less than 7% of that funding actually going to"transportation" projects it had no impact on our industry whatsoever. President Obama's

Caterpillar CEO Doug Oberhelman applaudsPresidential leadership on Infrastructure investment andcalls for bipartisan support for a multi-year HighwayReauthorization Bill

Citing the need for businesses large and small to remain competitive in the globaleconomy, Caterpillar Inc. is urging Congress and the Administration to work togetheron legislation that would improve the nation’s highways, ports, airports, railways andinfrastructure.

“Every week as I talk with our customers around the country, I hear from them thata long-term, multi-year highway bill for the United States is the fastest way to get moreconstruction workers back on job sites,” said Doug Oberhelman. “In addition, as anation we are at risk of falling behind other countries who have made aggressiveinvestments in infrastructure improvements in recent years, putting companies like

Caterpillar at a competitive disadvantage.”

“We know there are still many details and specifics to be worked out; however, it is our hope that theAdministration and Congress will come together and work toward a solution to improve our aging infrastructure,”Oberhelman added.

Similar comments from another side of the equipment manufacturers - pumps, by PerOhstrom, Vice President of Worldwide Marketing and Business Development for

Godwin Pumps who said.

“The administrations infrastructure plan is welcome news. Moreactivity will mean more business for Godwin Pumps customers, andonce completed the upgrades help facilitate economic growth foryears to come. Repair and maintenance of roads and bridges isespecially welcome, since there have been years of under-investment. For companies and manufacturers involved in thedewatering industry, transit projects are good news as they often

generate demand for pumping solutions.

What seems to be missing in this latest proposal is specific investments in the Waterand Waste water infrastructure, which is also in need of upgrades, especially in oldercities and towns. Updated water handling is also more efficient and hence sustainableas it helps reduce losses and conserve water. I believe access to water is a growingissue, which will need to be dealt with very soon.” [CW]

Caterpillar CEO,Doug Oberhelman

Eric Etchart, President and General Manager ofManitowoc told Contractors World, “The prospect of in-vesting $50 billion to help improve transportation infra-structure in the United States can only be good news for the construction industry andequipment suppliers.

Most lifting equipment manufacturers would agree there wasn’t significant improve-mentin new equipment sales as a result of the nearly $40 billion made available by theAmerican Recovery and Reinvestment Act. As of this past summer, more than 11,000highway and bridge projects have moved to the construction phase. But only a smallpercentage of these projects, which total more than $23 billion, required the purchase ofnew cranes.

It is understandable that contractors are being cautious in the down market. However, wehope this proposed six-year, $50 billion development program will drive additionalprojects and spur the cycle of new equipment investment.

Per Ohstrom, VicePresident of

Worldwide Marketingand Business

Development forGodwin Pumps

Eric P. Etchart has beenPresident and GeneralManager of ManitowocCrane Group ofManitowoc Co.

Page 23Contractors World Vol 1 No 8

announcement of a new infrastructure plan sounds similar to what the stimulus act was supposed to be, butwithout any details about how the plan will be funded or carried out, and the failure of the stimulus act to improveconditions, I can only be hopeful that this time the Administration and Congress will get it right.

"I worry that if something is not done with some urgency, the US will begin to fall behind Countries that haveput plans in place to improve their overall infrastructure. The story is the same with every customer or colleague Ispeak with - we need a long term solution."

Page 24Contractors World Vol 1 No 8

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IndonesiaIndonesiaIndonesiaIndonesiaIndonesiaNickel mining in tough,Nickel mining in tough,Nickel mining in tough,Nickel mining in tough,Nickel mining in tough,tropical conditionstropical conditionstropical conditionstropical conditionstropical conditionsMining is always demanding on men and machines. Addto that the high heat, humidity and extremely stickyunderfoot conditions and it is a bigger challenge. Andthose are the conditions experienced by the company,Yudistira Bumi Bhakti (YBB), who started nickel mining forPT Antam TBK in 1999 at Tanjung Buli on Halmahera, oneof the larger islands that make up Indonesia.

The mine owners state that Antam’s nickel deposits aretypically shallow. The limonite rests atop the saprolite, ischeaper to mine and the first to be extracted followed by the saprolite. The oresusually can be easily mined and extracted using open pit mining techniques andsimple truck and shovel operations.

No drilling or blasting is required. Little benefication is required other than dryingand screening and sometimes limited crushing of oversize material. In particular, thelower part of the saprolite ore is often lumpy and requires crushing to reduce it tothe required size specifications.

Financial support critical for equipment purchaseFinancial support critical for equipment purchaseFinancial support critical for equipment purchaseFinancial support critical for equipment purchaseFinancial support critical for equipment purchaseAlthough YBB is a successful companywith 750 employees and a yearly outputof five million tonnes, it has not beeneasy for the company. In the beginningthey faced many obstacles in financingequipment from local dealers. As company director Mr. JuandyTanumiharja says “Many of them weren’t sure if we were a credible andtrustworthy company.” Fortunately for YBB, one dealer was preparedto take the risk and it has certainly paid dividends for them and thebrands they represent. As Mr Juandy explains “Volvo’s Indonesiandealer, Intraco Penta, stepped in to help giving us financial help andequipment which enabled us to start our business. For this, we arevery thankful to Volvo and Intraco Penta.”

Nickel mining requires ongoing cost analysis as profitability isimpacted on by any lowering in the commodity price, fuel and transportcosts. So equipment selection has to deliver the highest levels ofproductivity at the lowest possible cost.

For the dealer and Volvo it was a requirement that perfectly mettheir product match as the operating conditions at the mine demandedarticulated dump trucks, excavators and wheel loaders. “We startedwith e articulated haulers, before adding excavators and wheel

Mr. Juandy Tanumiharja,Director, YBB

Page 25 Contractors World Vol 1 No 8

Page 26 Contractors World Vol 1 No 8

With finance provided by the dealership,YBB started with articulated dump truckand then added excavators and loaders.

loaders to the fleet,” says Mr. Juandy.

At the Tanjung Buli site, YBB uses 10 EC460BLC 46tonne excavators and four EC460B prime excavators to digout and load the raw nickel; one L120C and one L120Fwheel loader to help load the raw nickel; and five VolvoA40D, four A35D, two A35C and seven A40E articulatedhaulers to haul and transport the metal.

TTTTTough Enough Enough Enough Enough EnvironmentvironmentvironmentvironmentvironmentThe machines work 20 hours per day in two shifts of 10hours in far from ideal conditions. Constant rainy weathercreates muddy ground and the island’s mountainous terrainmeans the machines have to work on very steep gradients.

But according to Mr. Juandy, “The machines are stablein wet conditions and the A35D haulers are able to carry aload of 37 tonnes over gradients of more than 40%.

I believe that no other manufacturer can match thereliability, performance and value,” he adds. “We are findingthe machines to be incredibly fuel efficient. The excavatorsuse 20% less fuel and the haulers use 10% less fuel.

YBB has a Blue Contract service agreement with IntracoPenta for maintenance and to provide technical assistance

when required – but so far there have been few problems. “The response time to service and maintenance by thedealer has been great,” says Mr. Juandy.

Importance of Customer TImportance of Customer TImportance of Customer TImportance of Customer TImportance of Customer ToolsoolsoolsoolsoolsContractors World asked Volvo if financial solutions, such as those making it possible for YBB to acquire latesthigh-production machine, are generally available. Volvo Construction Equipment said that they offer acomprehensive package of business services to support its product range. Providing customers with a financingoption along with a machine sale is one that is proving particularly popular, with one in three of all machines nowsold with some form of finance.

Since 2001, The Volvo Group has had its own dedicated finance company – Volvo Financial Services (VFS).Active in Europe, the Americas and Asia Pacific, VFS is helping customers worldwide procure Volvo CEmachines, and currently has a global portfolio of almost SEK 100 billion (US$14 billion).

Working through dealer partners, Volvo CE and VFS have a common interest in making sure that customersare as happy with their Volvo loan agreement as they are with their Volvo Machines. It’s more than just theconvenience of getting finance and machine in a one-stop-shop: VFS understands the needs and challenges ofbeing in the construction equipment industry far more than a normal commercial lender. For the long term, leadingto repeat purchases.

Volvo Construction Equipment

Even with advanced equipment, there is still a great deal ofmanual work in the nickel mines.(below left) Excavated material is stock piled for later recovery.

Page 27Contractors World Vol 1 No 8

New 20 t excavator from KNew 20 t excavator from KNew 20 t excavator from KNew 20 t excavator from KNew 20 t excavator from KomatsuomatsuomatsuomatsuomatsuThe existing Komatsu PC180-7 tracked excavator is being replaced by the new PC190-8 crawler excavator.Weighing in at up to 20 tonnes, it is similar to the former model but the real benefit is derived from the new engineconfiguration which gives a power increase of 7% over the previous generation. Power is delivered by a KomatsuSAA4D107E-1 engine that provides high torque, and better performance at low speed as well as delivering lowfuel consumption. This ecot3 engine features a new combustion chamber design with optimised ignition andcombustion timing. Of course, the engine is fully compliant with regulatory requirements as dictated by differentmarkets.

The excavator features a redesigned monoboom that is 200 mm longer, and a maximum bucket capacity of1.14 m³ to improve the productivity of the PC190-8. For more versatility, lifting capacity is also improved by morethan 1 tonne. Komatsu claim that, with a maximum digging force of 12,500 kg (ISO), it is the best-in-classenabling the machine to be more productive in demanding ground conditions. As with the full range of Komatsuexcavators, there are many configurations possible, all of which can be easily carried out.

OperOperOperOperOperator in controlator in controlator in controlator in controlator in controlThe operator has a choice of 5 main working modes allowing the operator to optimize the performance of the

PC190-8 to perfectly suit the task at hand, regardless of thecombination of equipment that is used.

The variable “Economy” mode gives a strong performancefor levelling or for loose material excavation with the bestbalance between productivity and fuel consumption.Alternatively, when only extreme high power will do - forinstance in bulk earthmoving, the PC190-8’s “Power” modedelivers truly exceptional productivity.

It is interesting to see that Komatsu continue to offer a widerange of working modes when advanced computer aidedtechnology made available by the latest engines does allow thisto be automatically managed. Work modes are often not fullyutilised, especially in hired machines.

However, a good operator will maximise machineperformance by changing work modes according to differentworking conditions and this comes down to training. It has beenshown by independent testing that there are significant fuelsavings and lower maintenance costs possible when a machineis operated correctly and all features fully utilised - andtechnology makes changing setting as simple as pressing in abutton.

Spacious, pressurizedcab with heated seat,instrument panels andjoy stick withproportional controlbutton for attachments(inset)

The major exhibitionsmay be behind us butequipmentmanufacturers continueto push out new modelswhich promise to delivereven more operatorcomfort, fuel efficiencyand productivity.

Nuts & BoltsNuts & BoltsNuts & BoltsNuts & BoltsNuts & Bolts

The cab, which has a positive internal air pressure of 60Pa to keep out dust and moisture, is equipped with a heated,air-suspension seat, featuring a high back with excellentsupport. A standard fit automatic climate control system, withcontrols integrated to the wide-screen TFT monitor panel,allows the convenient setting of preferred workingconditions.

To increase the excavator’s versatility and ease of use,Komatsu has installed, as standard, an additional hydrauliccircuit with sliding proportional thumb switch controls, and a

factory installed quick coupler circuit,.

InInInInInvvvvvestment in safetestment in safetestment in safetestment in safetestment in safetyyyyyBuilt around the proven Dash 8 series, this model features a unique roll-over protection cab, specifically developed for hydraulic excavators.Komatsu invested over 1 million Euros to test this potentially life-savingfeature and to make sure that the cab’s integrated tubular steel skeletonoffers the essential protection to the operator in the event of a machine rollover. To further increase the safety of persons around the workingexcavator, the PC190-8 is also fully equipped as standard with a travelalarm, anti-slip steps and a rear-view camera.

The latest version of KOMTRAX satellite-based machine managementand monitoring system, is factory fitted on all PC190-8 machines. Machine data, including working time, workloadand fuel consumption, is easily accessible over the Internet. Owners or fleet managers are informed of themachine’s operational status, without having to attend the site in person. The system can also be configured tosend an email to a designated person in the event of the onboard diagnostics reporting a caution alert or if it isactivated outside an engine lock period.

Easy maintenanceEasy maintenanceEasy maintenanceEasy maintenanceEasy maintenanceServicing is an essential function to ensure that machines deliver reliability and productivity. Service times arereduced by considerate design. On the PC 190-8, the radiator, aftercooler and oil cooler are arranged in parallel,so are easy to clean, remove and install.

The engine oil filter and fuel drain valve are mounted remotely to improve accessibility and a water separatoris standard equipment to remove any water that has become mixed with the fuel,preventing fuel system damage. To facilitate daily checks and servicing, large areaaccess panels open wide.

TTTTTechnical dataechnical dataechnical dataechnical dataechnical dataThe excavator is available with four grouser shoe widths, 500 mm, 600 mm,700 mm and 800 mm. In LC configuration, ground pressure can be as lowas 0.50 kg/cm³ (monoboom/500 mm shoes). With widest shoes, maximumwidth is 3 m and track length 4.065 m.

Maximum digging force is 11,500 kg (12,500 kg at PowerMax). Crowdforce is 9,050 kg maximum (9,700 kg at PowerMax). Withmonoboom, maximum digging depth is 5.476 m, diggingreach 9.445 m and dump height of 6.655 m.

The Komatsu SAA4D107E-1 engines delivers 97kw@2,200 rpm (ISO 14396) providing a maximum travelspeed of 5.5 km/h and gradeability of 70% (35º).

With the addition of the PC 190-8, the Komatsu range of largertracked excavators today exceeds 20 models ranging from the PC 130-8through to the PC 2000-8.

Komatsu

The digital display gauges instead of numbers for easy referenceand settings are quickly accomplished.

(Below) Komatsu’s unique roll-over protection cage keeps theoperator safe.

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Page 28Contractors World Vol 1 No 8

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TTTTTwo cranes from Hitachi Sumitomowo cranes from Hitachi Sumitomowo cranes from Hitachi Sumitomowo cranes from Hitachi Sumitomowo cranes from Hitachi SumitomoHitachi Sumitomo Heavy Industries Construction Crane Co., Ltd.has launched two new cranes models for markets around theworld (excluding the European market).

The SCX1200HD-2, 120 t heavy duty machine is a scaled-upversion of 90 t on SCX900HD-2, which was released in 2008.This new model is designed to meet increasing safety concernsand demands for larger-scale models in heavy-duty machinemarkets.

Key features include a larger 272 kW Mitsubishi 6M70-TLengine and a 25 t line pull front / rear winch drums with 28 mmdiameter cable. These winch drums are to a new design concept,and realize better feeling over brake operation in general lift cranework as well as duty cycle job.

An aluminium oil cooler with an independent cooling fan givesoil cooling and heat balance and is located separately from engineradiator.

Multiple wet-disc brakes perform well giving a constant brakepedal feeling regardless of what the load is - light or heavy.

Machine data is displayed on a high quality LCD panel as usedin all SCX-2 series. A new LMI indicates actual load, rated load,load ratio, working radius, boom angle and engine rpmsimultaneously to clearly show the operator the machine status. Avoice warning and display alarm are activated whenever liftingload moment reaches 90% of rated load.

Maximum lift capacity120 t × 4.5 m. Basic boomlength 15 m with maximum

possible of 72 m

New mobile crNew mobile crNew mobile crNew mobile crNew mobile craneaneaneaneaneThe new UCX350 has a high lifting performance in general use and isideal for applications from cargo handling to warehouse work.

It has a nominal lift capacity of 35 t and a winch drum with reductiongear unit installed within drum inside combined with a free-fall function.The prime mover is from an ISUZU 6GB1T engine developing 110kW@2000 rpm.

The chassis frame is designed around a high torsion-resistant boxGerman Kessler brand axles that are designed for reliability and travelperformance.

With a newly designed cab and simple / functional layout of controls.Two joysticks and a tiltable power steering wheel column give operatorcomfort. All round visibility through to the front, , rear and right-handside ensure safer operation.. For a further operator comfort, the cabfeatures an automotive style air-conditioning system as standard.

A keyboard type Load Moment Limiter gives a good feed back to theoperator of the status of critical machine loads and positions. Maximumlift capacity is 35.0 t 3.0 m. Basic boom length 9.0 m and maximumboom length 24.0 m

Hitachi Sumitomo

NOTE: These machines do not meet European Regulations

Page 29 Contractors World Vol 1 No 8

Page 30Contractors World Vol 1 No 8

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To satisfy this ever increasing demand for more versatility and productivityfrom compact machines, Caterpillar has introduced new skidsteer loaders andcompact track loaders.

More compact machines from CaterpillarMore compact machines from CaterpillarMore compact machines from CaterpillarMore compact machines from CaterpillarMore compact machines from Caterpillar“More safety, reliability, convenience and power” is the promise from Caterpillar in introducing the latest models totheir range of skidsteer loads (SSL) and compact tracked loaders. The latter, Caterpillar refer to, for some reasonor other, as Multi-terrain loaders (MTL) which to Contractors World implies that other compact tracked machinesare not multi-terrain which, of course they are when compared to skidsteers which cannot operator on sensitivesurfaces.

MTLs are defined as extremely low ground pressure where traditional compact loaders cannot work, but theyare not suitable for rough ground conditions because the tracks would wear too quickly.

Is this a classic case of obscuring reality by trying to differentiate products? Caterpillar explains the differenceon the following page.

With the new 242B3 skidsteer and 257B3 compact loader, Caterpillar introduces a redesign that involvesadding substantial power to the engine and the hydraulic.The objective being to increase productivity and performanceof these compact machines to those of larger machines whenworking in confined spaces. This has basically beenachieved by using a Cat C3.4 DIT diesel engine, rated at 53kW which effectively increases the net power by a massive25% compared to their B-Series 2 equivalent, and a 28%boost in peak torque. The C3.4 DIT also runs at the lower,more-fuel-efficient speed of 2500 rpm which is 500 rpm lowerthan the B-Series 2 engine.

Complementing the more powerful engine is a morecapable hydraulic system, having a 24.2 lpm increase in

The past decade has seen a revolution taking place in the compact equipmentmarket. With the introduction of track-mounted compact loaders (in otherwords, skidsteers on track), the market has seen significant growth and manycustomers have switched from wheeled to tracked because the latter can beused on more surfaces.

An ever increasing array of attachments has made these machine theworkhorse for many contractors.

standard flow, from 59 to 83.3lpm. This translates to aworking hydraulic power thatis almost 40% higher. Thisincrease significantly improvesthe capability and efficiency ofthe 242B3 and 257B3 whenhandling standard-flow worktools, such as brush cutters,power box rakes andtrenchers.

Larger lift and tilt cylindersincrease boom and bucketbreakout force, from 13 to19%, depending on model andcircuit. The higher breakoutforces allow for moreaggressive material handlingin loading, lifting and digging.

Rated operating capacity isalso greater. The 242B3 israted at 975 kg at 50% oftipping load, or at 1,000 kg when using an optionalcounterweight. The 257B3, when rated at 50% tipping load,has an operating capacity of 1,213 kg, which increases to1,236 kg with the optional counterweight. Standard ratedoperating capacity for the 257B3 is 848 kg at 35% of tippingload.

Both feature an engine-mounted air-conditionercompressor, eliminating the hydraulic motor and plumbingrequired to drive the compressor on B-Series 2 models. Thenew configuration is a simpler design that uses fewer parts,reduces the number of hydraulic connections and lowerssound levels in the cab.

An option is a two-speed travel system that gives the242B3 top speeds of 11.4 and 17.0 km/h with 10 x 16.5 tires,and 12.4 and 18.4 km/h with larger 12 x 16.5 tires. Topspeeds for the two-speed-equipped 257B3 are 11.1 and 16.1km/h.

Caterpillar

Caterpillar defines MTL & CTLCaterpillar defines MTL & CTLCaterpillar defines MTL & CTLCaterpillar defines MTL & CTLCaterpillar defines MTL & CTL

Multi Terrain LoaderUndercarriage (MTL)

The Cat 247B Series 3 and 257B Series 3 MultiTerrain Loaders feature a fully suspended,rugged, durable rubber track that is lightweightand pliable, yet reinforced with high tensilestrength cords. The undercarriage providesextremely low ground pressure, allowing thesemachines to operate over sensitive surfaces andin soft underfoot conditions.

The independently suspended undercarriagedistributes the load and greatly reduces shockand vibration throughout the machine for acomfortable ride and excellent bucket loadretention. The undercarriage also features:

• Heavy duty torsion axles that independentlysuspend each side of the machine frame fora smoother ride over rough terrain, even athigh speeds.

• Components that are replaceable asindividual wear items, reducing owning andoperating costs.

• Low ground pressure: 27.3 kPa (4.0 psi) forthe 247B Series 3 and 31 kPa (4.5 psi) forthe 257B Series 3.

Compact Track LoaderUndercarriage (CTL)

The Cat 259B Series 3 Compact Track Loaderfeatures a fully suspended, steel embeddedrubber track undercarriage for versatility,durability and comfort. Heavy-duty torsion axlessuspend the undercarriage and can moveindependently relative to the machine and eachother. These axles absorb most of the shock tothe machine and operator, especially over veryrough terrain. This means smooth travel, even athigh speeds, as well as better load retention andgreater productivity. The undercarriage alsofeatures:

• Steel embedded rubber track that providesexcellent durability in a wide variety ofapplications.

• Steel rollers with metal face seals for long-term durability and reliability in even thetoughest conditions.

• Simple recoil grease tensioning system forquick track tension adjustment.

• Two track options – standard track width of320 mm (12.6 in) or optional 400 mm (15.7in) track.

• Low ground pressure: 41.2 kPa (6.0 psi) withthe standard track and 34.4 kPa (5.0 psi) withoptional 400 mm (15.7 in) track.

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Page 31 Contractors World Vol 1 No 8

Innovative emission control for constructionequipment

PPPPProtecting the environmentrotecting the environmentrotecting the environmentrotecting the environmentrotecting the environmentand reducing costsand reducing costsand reducing costsand reducing costsand reducing costsIt is almost the perfect storm scenario for contractors. Not onlyare they facing economic crisis but also having to calculate forhigher fuel costs, more stringent emission regulations plus the added purchasecosts OEMs have had to implement as a result of implementing latest engine technology. Addto this a more competitive market place which reduces bottom line profit to marginalpercentages, banks making finance all but impossible to get and you have all the ingredients forunprecedented market conditions.

For those contractors lucky enough to be able to finance new plant and equipment, their expectations onreliability, productivity, operating efficiency and a high resale value are significantly higher. This shifts much of theonus onto the manufacturer. The are almost forced into evaluating virtually every piece of technology that comesup to see if it is viable in terms of performance and cost.

An area that has been causing some concern is the stricter regulations of particulate emission - especially inenvironmentally sensitive areas. Not every experience has proven successful. The use of closed particulatefilters, especially in Switzerland, often had the opposite effect and unfortunately made many constructioncompanies very sceptical of even stricter future emission limits.

These are challenges R&D engineers thrive on and one company that is leading the way is the Germanycompany, Emitec Gesellschaft für Emissionstechnologie mbH who have shown a solution that is both affordableand does “what it says on the box’.

The new SCRi system, a selective catalytic reduction (SCR) system with integrated particulate filter, is a newemission control technology that combines maximum efficiency and reliability with very low fuel consumption. Theprocess of SCR has been used in commercial vehicles on a daily basis for several years as it largely eliminatestoxic nitrogen oxides that are generated during the combustion of diesel fuels (by up to 95%).

The integrated PM-Metalit particulate filter (PM = particulate matter) reduces particulate levels to a minimumand ensures that harmful nanoparticles, in particular, are separated by 80% or more and burned off immediately.Continuous soot burn-off and the partial-flow process are based on a completely different operating principle thanconventional closed particulate filters, which are generally made from fragile ceramics. The PM-Metalit is an all-metal construction (metal foil plus metal fleece) and hence particularly suitable for construction equipment, whichhas to operate as effectively as possible and remain fully functional under extremely harsh conditions.

TTTTTriple benefitsriple benefitsriple benefitsriple benefitsriple benefitsEmitec’s SCRi system not only stays well within the current and future emission limits specified in EU Stages IIIBand IV but is also able to cut fuel consumption by up to 15% compared to other technologies. This is achieved byresetting the engine characteristics within the engine management and reducing the resulting higher nitrogenoxide emissions with the SCRi system. Numerous examples from practical applications have shown that anadditional investment in the latest emission technology pays off in full within two years and that contractorssubsequently save money because construction equipment uses far less fuel. Furthermore, contractors are ableto work in those areas where there is strict control over particulate emissions.

The modular SCRi system consists of compact catalysts, a particulate filter, an AdBlue tank and a controlsystem and can be optimally adapted to almost any diesel engine driven equipment, even very small machines.Fitting such filters to compact machines has been a concern for many manufacturers. However, the flexibility ofthe design and the turbulence-generating structures of the Metalit catalysts provide maximum effectiveness in avery small installation space.

As a result, the SCR catalyst can be fitted close to the engine, ideally under the bonnet, so that additionalcomponents do not obstruct the driver’s view. Components that do not project from the machine cannot bedamaged or broken off. The close-coupled arrangement supports the fast light-off of the SCRi system even whenthe engine is idling or running at low loads for longer periods.

Machines using the latest emission control technology protect the environment and reduce operating costs atthe same time. This should make their acquisition an easy decision for building contractors.

Emitec

TTTTTechnologyechnologyechnologyechnologyechnology

Page 32Contractors World Vol 1 No 8

Page 33 Contractors World Vol 1 No 8

Association of EquipmentManufacturers

Bauer

British Antarctic Survey

Case

Caterpillar

Conjet

Custom Covers

Doka

Emitec

Genie Platforms

Godwin Pumps

Groundforce

Hitachi Sumitomo

JCB Inc

John Deere

Kobelco Excavators

Komatsu America

Komatsu Euope

Liebherr

Lighthouse Club

Manitowoc

New Holland

Sany

Sennebogen

SMOPYC

Tadano Mantis

Terex

Trelleborg

Volvo

COMPCOMPCOMPCOMPCOMPANIES FEAANIES FEAANIES FEAANIES FEAANIES FEATUREDTUREDTUREDTUREDTUREDContractors WContractors WContractors WContractors WContractors Worldorldorldorldorld

VVVVVol 1 Issue 8ol 1 Issue 8ol 1 Issue 8ol 1 Issue 8ol 1 Issue 8

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FFFFForworworworworward the link to a colleague who maard the link to a colleague who maard the link to a colleague who maard the link to a colleague who maard the link to a colleague who may also be interestedy also be interestedy also be interestedy also be interestedy also be interestedin reading our magazines.in reading our magazines.in reading our magazines.in reading our magazines.in reading our magazines.

Editorial Comment 4Acknowledgement to Project Managers4USA - Komatsu goes ‘quackers’ in Chicago

Komatsu America 6CHINA - 60,000 m³ of concrete in 60 hours

6Sany Corporation 6GERMANY - Telescopic crane deliver flexibil-

ity in bridge construction. 8Sennebogen 8

Liebherr8NEW ZEALAND - “No problem” says

authorities after shake up. 9Malaysia - Foundation and underground

floors for the 348 Sentral project inKuala Lumpur10

Bauer Technologies 10England - Augur boring speeds up piling

10 Groundforce 10

BRAZIL- Impressive arched bridge 11Doka

Liebherr11

Antarctic - Construction Halley VI ResearchStation in extreme conditions 12

Designed for longevity 12Modern technology 13Extreme conditions are tough on equipment

14Short season demand protective covers

15Not quiet home from home 16The British Antarctic Survey 16Tadano Mantis 16Genie Access Platforms 16John Deere16Caterpillar 16Custom Covers 16World's first full scale floating wind turbine

17The subsea portion of the turbine is critical

17

Designed and supplied buoyancy modules 17Proven technology 17Trelleborg 17SCOTLAND -CLEAN UP AT GLENLEE POWER

STATION 18Conjet 19USA - Is this the kick start the construction

industry has been waiting for? 20Indonesia - Nickel mining in tough, tropical

conditions 25Financial support critical for equipment pur-

chase 25Tough Environment 26Importance of Customer Tools 26Volvo Construction Equipment 26New 20 t excavator from Komatsu 27Operator in control 27Investment in safety 28Easy maintenance 28Technical data 28Komatsu 28Two cranes from Hitachi Sumitomo 29New mobile crane 29Hitachi Sumitomo 29More compact machines from Caterpillar 30Caterpillar defines MTL & CTL 31Protecting the environment and reducing costs

32

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