Capabilities

www.ale-heavylift.Com

worldwide heavy transportation and lifting

ALE is a global leader and continues to grow

year after year by pursuing challenging new
opportunities and delivering ingenious solutions.

03

Contents
05

Introduction

SERVICES

06

Health, Safety, Quality & Environment

26

Services: Transportation

MARKETS

30

Services: Load-in and load-out

08

Markets: Civil

34

Services: Skidding

10

Markets: Power generation

38

Services: Jacking

12

Markets: Nuclear

40

Services: Weighing

14

Markets: Renewables

42

Services: Lifting systems

16

Markets: Shipyards

48

Services: Heavy crane lifting

18

Markets: Ports

52

Services: Ballasting

20

Markets: Minerals and metals

54

Services: Logistics

22

Markets: Offshore

56

Services: Turnkey projects

24

Markets: Oil, gas and petrochemical

60

Services: Engineering

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Introduction

05

ALE combines exceptional project management with engineering intelligence to offer worldwide
heavy transportation and lifting services to all industry sectors. Founded in 1983, the company
has expanded steadily through a balanced strategy of organic growth and the acquisition of key
companies whose experience has enhanced our specialist capabilities.

Now were one of the worlds major international heavy

Crucially, however, we invest as much in our people as we

transport and installation contractors with a global

do in our equipment, so we have a world-class management

network of operating centres and a large eet of heavy

structure in place to support our technical potential. That

cranes, specialist transport and installation equipment.

means that as well as having the best project managers and

As a complete solution provider for lifting, transporting,

engineers available today, well also have the best tomorrow.

installing, ballasting, jacking and weighing large, heavy

And with the ability to get maximum value from our next-

loads, organisations all over the world turn to us to push the

generation equipment, we can meet our customers needs

boundaries of whats possible with their high prole projects.

effectively and build long-term strategic partnerships for an

ever-improving service.

Were committed to investing in technology, systems and

equipment to ensure we remain at the forefront of the

Our values of ingenuity, responsibility and exibility reect

industry. Our dedicated Research and Development facility

our combined commitments to safety and excellence.

is responsible for the record-breaking SK190 and SK350

We take full responsibility for the quality of our processes

cranes, which have the capacity to lift up to 5,000te.

to keep risk to an absolute minimum, while adapting to

changing conditions and new challenges with competence
and agility.

Health, Safety, Quality & Environment

One of our core strengths is our commitment

to responsible working practices and the
importance we place in health, safety, quality
and the environment. As well as complying
fully with the most stringent local and
international regulations, the company has a
team of professionally qualied personnel who
are dedicated to developing, implementing
and evaluating our online Integrated HSQE
Management System. All employees, in every
country and at every level, are responsible for
adhering to its guidelines.
Achieving a safe and healthy working environment is our
priority, and one weve succeeded in maintaining despite
the ambition and scale of the projects we undertake. Health,
safety, quality and environmental considerations are
reected in all our activities, from the purchase, maintenance
and improvement of plant and equipment through to the
provision of HSQE advisors onsite. As a result of these
measures we have an excellent safety record.

07

Our global HSQE objectives include prioritising

customer satisfaction, continually improving
competence, eliminating health and safety
incidents and reducing waste and pollutants.
We work in partnership with our clients
and stakeholders to achieve high-quality,
safe, efcient and environmentally-friendly
working practices, rigorously evaluating our
subcontractors and suppliers and encouraging
them to implement their own HSQE policies and
effective management systems.
Furthermore, we have established Centres of
Excellence in each of our service areas to enable
experienced members of staff to pass on their
invaluable knowledge. This practical aspect of
training complements comprehensive classroombased study and external training.
Our Integrated Management System has been
assessed and certied by an accredited external
organisation to Environmental standard ISO
14001:2004 since 2008 and to Quality standard
ISO 9001:2008 since 1994.

663373

EMS532261

663298

FS26821

663298

SGI 6005514

Markets

Civil
ALE has a long and proud history working
closely with major civil engineering
companies all over the world. With
experience in high-prole infrastructure
projects such as the removal and
installation of innovative road, rail, river
and canal bridges, lock gates, stadium
roofs and airport architecture, we full
our role accurately, safely and with
minimal disruption.
We have an in-depth understanding of the
highly specialised equipment required for the
safe and accurate execution of such projects.
An appreciation of the control of loads and their
distribution, as well as a eet of Self-Propelled
Modular Transporters (SPMTs) and proven
expertise in lifting, skidding and jacking techniques
means were well equipped to move enormous
structures with minute precision. Our strategically
located equipment and full project management
service means we can meticulously plan and
execute complex projects despite the time-critical
nature of much of this work. If necessary, well
design purpose-built tools to ensure a project is
completed to the total satisfaction of our client.



Case study:

Services required:

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The viaduct consists of two main sections with a total

length of nearly 400 metres, which are supported on

Background:
ALE was appointed to assist with the
construction of a viaduct on La Plata
highway over the Tajo River.

concrete pillars rising from the banks of the river and from
steel arches in the centre. ALEs responsibilities included
pushing the bridge sections into place, skidding the steel
arches over the bridge and lowering them into position,
tilting and closing the semi arches, skidding the semidecks
from both abutments and replacing the temporary
supports with the nal supports.

Markets

Power generation
The energy sector has been one of our core
businesses since our inception, and to date
weve worked on energy projects in more
than 100 countries. Consequently, were
world leaders in global power plant lifting
and transportation.

Weve collaborated with all the major power equipment

manufacturers to develop mutually benecial technology
and machinery as the power industry has evolved over the
last 25 years. We have vast experience in transporting highvalue components such as gas turbines, generators and
transformers, providing delivery solutions for the power
trains of Combined Cycle Gas Turbine (CCGT) equipment
as well as moving and installing condensers, HRSGs and
steam turbine equipment during the build process.



With a fully integrated from source to site logistical

service which combines technical excellence with
rigorous safety standards, we work in partnership
with our clients to solve their problems. Taking care
of everything from investment and infrastructure

Case study:
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to permits and programme, we also ensure health,

Background:

safety and environmental factors are considered at

ALE was asked to provide an

every stage.

innovative solution to the complex

delivery of a four-unit CCGT power
station. The project involved river
transport, SPMTs and a 28-axle girder
frame trailer.

Services required:
Four gas turbines, four generators
and four transformers each weighing
up to 370te were received using
SPMTs and stored prior to being
transported down the River Trent by
barge. ALEs Lift n Lock system was
used to trans-ship the cargo onto a
girder frame transporter for a 30-mile
road route. It was then trans-shipped
to SPMTs for transportation on public
roads using a second Lift n Lock
system. The nal leg of the journey to
site was undertaken using SPMTs for
installation onto foundations using
ALEs modular gantry system.

Markets

Nuclear
Nowhere does our reputation for safety,
precision and responsibility carry more
weight than in the nuclear power sector.
Our understanding of the health, safety and quality
standards of the industry has enabled us to develop
strong working relationships with key nuclear energy
providers over the last 20 years, supporting projects
ranging from the replacement of steam generators and
reactor heads to the design of systems for dismantling
turbines and electrical generators. From this platform
of experience, were well-equipped to support the
imminent increase in nuclear power generation.
ALE is accomplished at carrying out pre-engineering
works ahead of critical plant outages to ensure that the
minimum programme and operational impact is made.
To achieve this, we provide engineering resource early
in the planning process to produce the necessary HSE
and nuclear safety documentation.
Although we prioritise risk and safety, we also
champion innovative engineering. Manoeuvres can
combine lifting, tilting, skidding and hydraulic turning
and this demands careful planning and faultless
execution, with activity precisely scheduled to coincide
with planned stoppages of the plant for minimal
disruption and downtime.
Indeed such is our experience that we can design
bespoke lifting systems to t within existing station
designs a skill which has won us recognition for our
exibility and multiple project awards.

Case study:
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Background:
ALE was appointed to replace the nuclear reactor
head at the Quinshan Nuclear Power Plant in
China during the critical period of the shut down.

Services required:
The new reactor head was tilted from a vertical to
horizontal position in the turbine building using a
specially designed tilting frame driven by hydraulic
jacks. Once in the horizontal position, it was able
to exit the building onto a platform trailer for
transport to the containment building. The old
head was removed from the containment building
using a similar method and the new head was then
lifted, skidded into the building and tilted into its
nal vertical position. The whole operation was
completed in 36 hours.

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Renewables

Case study:
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Background:
The Greater Gabbard wind farm, located in the
North Sea off the coast of Suffolk, will consist
of 142 wind turbines with a total capacity of
around 500MW when its completed.

Services required:
ALEs responsibilities included receiving and

With innovative engineering we work to minimise the

storing the offshore wind components and

effect of weather delays and continuously improve

redelivering them to installation vessels as

health and safety standards. The development of

and when required. ALE minimised the risk

innovative techniques also maximises the commercial

of weather delays and issues associated with

savings for our clients in this progressive sector.

working at height by developing innovative

handling solutions which reduce dependency

We are delighted to be putting our engineering

on cranes and increase the speed and reliability

capabilities to the test in this rapidly developing sector.

of operations. ALEs handling solutions also

help maximise the use of available land
because ALE components require only a small
access area around them far less than larger
crawler cranes would require. ALE created
a purpose-built site for the EPC contractor
which enables large quantities of wind farm
components to be stored for any period of time
to t the offshore installation schedule.

15

Markets

Shipyards
ALE provides a number of services to the marine and shipbuilding industry, including the
lengthening of vessels and the enlargement or complete revamping of hulls.



Case study:
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Background:
When ALEs client embarked on the
revitalisation of their luxury cruise
ships, they approached ALE to
assist with the lengthening of M/S
Enchantment of the Seas.

Other projects include handling vessels which cant be

Services required:

constructed on the slipway for launch and transporting

ALEs work scope included the load-

ship sections from fabrication to installation yards. In fact

out of a 2,800te mid-section in Finland,

we offer whole block transportation for major ship and

sea-fastening and barge transportation

submarine building projects which includes load-out,

to Rotterdam. Following this ALE lifted

marine engineering, barging, transportation and lifting

the mid-section from the barge it was

services. Were also regularly called on to expedite key

brought in on using eight hydraulic

repairs by removing engines or parts from engine rooms or

jacking towers. ALE then lowered it

suspending complete engines while work is carried out.

onto a hydraulic compensating skid

system which ALE had installed at

ALE plays a vital role in these processes, designing and

implementing the movements of huge sections and
positioning them for welding with complete accuracy.
Our vast experience enables us to achieve these feats
under extremely strict time constraints, keeping vessels
productive until the very last minute for optimum
commercial efciency.

dock-oor level. The ship itself was

docked on a specially developed
skidding system on which ALE moved
the bow of the ship forward. The midsection was then accurately aligned
between each end of the ship and
inserted by means of the hydraulic
skidding system.

Markets

Ports
ALE provides a range of services to
ports across the world including the
transportation, erection and vertical
extension of harbour cranes. We also have
the experience, the skills and the global
sourcing contacts to relocate heavy port
cranes and cargo handling equipment
worldwide and to jack-up heavy cranes
using state-of-the-art equipment so
theyre ready for new sections to be
added. Our schemes for recovering
cranes after collision or storm damage
are designed to address the unique
requirements of the circumstances.
As well as using our varied eet of trailers and
skidding capabilities to relocate cranes within ports,
we also deliver new cranes from suppliers and
ship cranes from port to port with all the marine
engineering, barging and sea-fastening that entails.
In fact, weve transported a variety of types of
crane on ve continents, with the result that both
global and local manufacturers use us repeatedly
to execute their projects quickly, efciently and
safely. Our continual investment in new design and
engineering methods enables us to maintain our
position as leaders in this eld.



Case study:
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Background:
ALE was contracted to carry out the
land and marine transportation of two
Liebherr Container Cranes from Port
Khalid, Sharjah to Khorfakkan Port.

Services required:
With dimensions of 116 x 26 x 76
metres, the cranes required 96-axle
SPMTs. The centre of gravity from
the crane rails was 35 metres, so
extensive engineering was needed to
design safe and cost-effective seafastening and ballasting systems. The
two cranes were transported by sea
on a single barge (138 x 30 metres)
for 176 nautical miles.

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Minerals and metals


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For existing mines, our SPMTs and lifting, jacking and

skidding capabilities enable us to move fully assembled
equipment a much more cost-effective method than
dismantling machinery to move it piece by piece. We
can also deliver equipment to site from ports, again
transporting items whole and positioning them exactly
where theyre required.
ALEs seamless logistics service and modularization
abilities mean mine operators can have their heavy
components moved safely and efciently whenever
and wherever necessary.

Case study:

Background:

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During a six-month period, ALE transported around

75,000te as part of the G3 expansion of Alcan Goves
alumina renery in Australias Northern Territory.

Services required:
ALE loaded-in pre-assembled modules when they
arrived in Vietnam from Thailand, and positioned
them on top of pre-cast concrete bases using a ramp.
This created a SUPERPAM for shipping to Australia
that would be ready for load-out and installation on
arrival. The modules were moved using SPMTs and
are the heaviest to have been loaded-out in Vietnam
they were built with their foundations incorporated in
order to minimise the site work required.

21

Markets

Offshore
Our heritage in offshore structures extends
back many years, with some of our key
personnel having begun their careers
during the boom period in the 70s and
80s. Because of this, we are considered
the market leader in providing specialist
transportation services to the offshore
industry. Weve developed state-of-theart ballasting and weighing systems, and
loaded-out over 1,000 structures and
probably more tonnage than any other
company in the world.
Technical advances in offshore installation and
oatover capabilities have made the fabrication of
complete topsides weighing in excess of 30,000te
possible. In response, we have designed and
developed systems to safely load-out such structures
using integrated skid systems, SPMTs and high
capacity ballasting. Indeed ALE has succeeded
in staying ahead of the industry by developing
the mega-jack: a unique system capable of lifting
platforms weighing up to 40,000te to an elevation
of 30 metres. We are world leaders in oatover
installations, having the largest integrated ballasting
systems of over 60,000te capacity supported by a
dedicated marine engineering division with years
of experience.

Case study:
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Background:
ALE was approached to assist with
the installation of a 21,800te oatover
topsides deck on the LUN-A Platform
Russias rst offshore gas platform in
the Lunskoye Field. The project set a
new record as the industrys heaviest
oatover deck installation.

Services required:
ALE was contracted to engineer,
design and perform the barge
ballasting for both the load-out and
offshore oatover installation. ALE
used computer modelling to design
a pumping system capable of
delivering sufciently high ow rates,
and fabricated non-standard pipework
as required. The purpose-built barge
transported the topsides 1,500 nautical
miles to the offshore installation
site, where ALE also performed all
the engineering associated with the
mating, including ballast and
mooring calculations.

Markets

Oil, gas and

petrochemical
With a presence in all the major oil and gas
centres in the world, ALE works closely with
blue-chip oil and EPC contractors to provide a
fully engineered, efcient and cost-effective
transportation and installation solution for
the handling of critical items of process plant
and equipment.
Given our intelligent engineering skills and aptitude
for fastidious project management, we are wellequipped to meet the demands of long-term operations
and high-pressure work carried out during revamps
and shutdowns.
Our engineering skills enable us to transport, lift and
position reactors, process columns, furnaces and
other large elements, manoeuvring these items with
precision and safety often in very restricted spaces
and within tight time frames. Using combinations
of advanced heavy lift cranes, trailers and gantry lift
systems we undertake the replacement and installation
of items including columns, boilers and fractioning
towers, working towards an outcome that exceeds all
expectations. Indeed our comprehensive eet of heavy
cranes including the worlds largest land-based crane
allows us to engineer schemes such as lifting off
plot that were previously impossible.

Case study:

Services required:

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From the engineering and planning stage in Houston

to the installation of two 2,200te reactors, ALE

Background:
ALE has been heavily involved in the EGTL Project,
ofoading, transporting and installing all items
onsite over 100te.

personnel have been a constant presence on the

EGTL site in the Niger Delta. As well as designing
an innovative gantry system which can be quickly
skidded from one position to another (see the concrete
skidding foundations in the photograph), ALE also
provided heavy cranes up to 1,500te capacity and a
large SPMT eet for the duration of the project.

Services

Transportation
With years of experience and one of the largest
eets of heavy transportation axles and ancillary
equipment in the world, ALE is a globally
renowned authority in moving heavy loads. Our
substantial eet of latest-generation equipment
is operated by a team of highly trained personnel
who maintain it to the highest standards. All
trailers and ancillary equipment are strategically
located around the world for maximum
availability and to keep mobilisation costs to an
absolute minimum.

ALE has pioneered the use of frame trailers in power plant

equipment transportation. Our versatile eet developed
and built in-house can be congured to transport all
types of generating equipment and to overcome route
restrictions. In addition, our SPMTs dominate the current
generation of heavy transport equipment by combining
state-of-the-art design with tried and tested components.
They make the movement of large items efcient, costeffective and safe, and, coupled with our expert project
management, completely seamless. These capabilities
are further augmented by our considerable eet of
conventional modular trailers, which we frequently use for
long distance road movements.

Case study:

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The heaviest of these 30 items was a column weighing

471te with an offset centre of gravity. Due to weight

Background:
Over the course of six months, ALE received
30 heavy lifts from ten ships at Salalah Port in
the south of Oman.

and route restrictions a four-le, ten-axle SPMT with

bolsters was required to move the 60-metre long,
9-metre diameter vessel.

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Transportation

Case study:

Equipment used:

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The images show the transportation of the rst gas turbine, which
weighed 310te. It was loaded onto a barge in Porto Marghera and

Background:
ALE was contracted to transport two
gas turbines and two generators
from Marghera to Piacenza in Italy.

taken to Mantova where it was discharged at the Belleli Energy Port.

Using the port derricks, the turbine was then loaded onto a 30-axle
frame trailer for delivery to Piacenza. The gantry and elevated skidway
were prepared onsite to lift and install the turbine onto its supports.
The remaining generators and turbine were delivered using the same
methodology.

Case study:

Equipment used:

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ALE transported the Separator using a tractor

and 14-axle Goldhofer trailer as part of a
larger operation. This included the load-out

Background:
ALE used a conventional trailer to
transport a 120te Separator for an
FPSO being tted out in Singapore.

of the Separator from the manufacturers, its

transportation to a UK port, engineering and
supply of lifting equipment and its shipment
to Rotterdam.

Services

Load-in and load-out

Having loaded-out more than 1,000 structures
since the 80s, ALE is an authority on the design
and development of load-out systems for
platforms and jackets. Our speciality service
allows modules to be transported hundreds of
metres to the load-out quay, so that several
modules can be built at the fabrication facility
without impeding access to the quay, and
multiple load-outs can be executed from a
single load-out point. The result is minimum site
disruption and maximum efciency.
The 360 computer controlled steering capability of our
SPMTs provides a wide choice of build positions, and
our trailer congurations are always designed to meet
the specic parameters and constraints of each project.
Low ground bearing pressures minimise the need for site
preparation or strengthening. Alternatively, if there is an
existing skidway, we can help minimise costs by providing
the strand jacking equipment required to pull equipment
for load-out, where our high capacity ballast systems with
manifold and integrated pipework can perform ballasting
operations of up to 60,000te per hour.

Case study:

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During the course of the project ALE was responsible

for preparing method statements and engineering

Background:
ALE successfully completed various site moves and
weighing operations which culminated with the
load-out operation of the QU Deck with a load-out
weight of 11,300te.

calculations, moving various structures onsite,

loading-in the living quarters module and loadingout a QU Deck weighing 11,300te. ALE performed
all barge management operations during load-out
including mooring and ballasting.

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Load-in and load-out

Case study:

Equipment used:

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The jackets were loaded-out one at a time onto the barge

using a gripper jack system, with ALE providing the pumping

Background:
ALE was awarded the contract to supply and
operate an external barge ballast and de-ballast
system for six jackets as part of the ACG Full
Field Development in the Caspian Sea.

and ow distribution elements and computer monitoring of

the ballasting. ALE overcame specic engineering challenges
during the course of the project. Using CAD, ALE successfully
congured the required ballast plan to overcome these
obstructions without any reduction in ow rate.

Case study:

Equipment used:

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ALE used SPMTs for the site movement and load-out

of the topside module, and assumed responsibility

Background:
ALE undertook the site move and load-out of a 1,700te
topside module for the ANGSI-D Project in Malaysia.

for all barge management, ballasting and engineering

services during the operation.

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Case study:
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Background:
ALE completed the launch of the Estrecho de
Paredes viaduct, which bypasses the Estrecho
de Paredes gorge and is part of a new
highway in the province of Cuenca, Spain.

Equipment used:
The viaduct was made up of multiple sections
with a total length of 380 metres and a total
weight of 2,700te. ALE used strand jacks
for both pulling and restraining the bridge
sections. Finally, each section of the viaduct
was jacked down onto its permanent supports.

35

Skidding
ALE was the rst company to design, develop
and operate the hydraulic compensated skidshoe system. Skid systems are designed to
make safe and precise horizontal movements,
and as such are an effective means of moving
plant and structures in conned or restricted
environments. The movement equipment has
hydraulic skid-shoes with stainless steel bases
which move over low-friction blocks laid into
steel skid-tracks in an extend/retract sequence.
ALE operates 25, 50, 300, 500, 650 and 1,000te capacity
skid-shoe systems, with the option of combining a number
of skid-shoes to create the most suitable system for moving
complex loads. This has enabled us to load-out structures
weighing more than 20,000te. The integral hydraulic
cylinder of the skid-shoes can be interlinked to provide a
hydraulically compensated suspension system.

$-:>1+-;

Skidding

Case study:
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Background:
ALE performed the unloading, transportation
and installation of two transformers on the two
400MW CCGT power plant in Surgut, Russia.

Equipment used:
Both transformers arrived on special railway
carriages which could hydraulically jack
themselves up in order to install ALEs climbing
jacks and load-spreading mats underneath. Using
a skid system the transformers were skidded
sideways onto a temporary storage area, jacked
up and positioned at the required height to allow
a four-le, six-axle SPMT to drive underneath. The
SPMT transported the transformers in front of
their foundations and positioned them on using
the climbing jacks and a skid system.

Case study:

Equipment used:

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Using four 500te capacity skid-shoes under the

brackets closer to the cutting head and two 300te
capacity skid-shoes under the brackets of the shortest

Background:
ALE carried out the skidding of a tunnel
boring machine on a curve with a central radius
of 220 metres.

articulated part, the machine was skidded a total

length of 130 metres.

$-:>1+-;

Jacking

Case study:
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More recently, we developed the 40,000te capacity mega-jack
system which enables jacking of large structures from a low
elevation up to 30 metres. It was designed to assist with the
onshore fabrication of increasingly large and heavy topside
platforms for the offshore industry, although its versatility
means there is great potential for its use in other market
sectors as well.
The mega-jack has both heavy and light jacking modes,
and its modular set-up makes it suitable for a wide range of
applications. By adding jacking towers, the capacity can be
increased or the ground bearing loads per position reduced.
A key difference between it and traditional jacking systems
is that during normal jacking operations, the jacks remain at

Background:
ALE transported a steam turbine generator
weighing 230te and installed it at the
Mesaieed Power Station in Qatar.

ground level and the steel jacking beams rise by each jacking
step. This way all operations are performed at ground level
and working at height is kept to an absolute minimum. ALE

Equipment used:

also operates a large inventory of hydraulic climbing jacks

Using jacking towers and a four-point lift

up to 1,000te capacity which can be operated in multiple

system, ALE installed the turbine onto a

hydraulic circuits for load equalisation.

high-level foundation 12 metres above

ground level.

Case study:
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Background:
ALE was contracted to jack-up and install a 560te
bridge in Berlin, Germany.

Equipment used:
Over the course of one day, the bridge was jacked
from its construction position to an elevation of 4.9
metres using four climbing jacks. The jacking timbers
had to be stabilised halfway due to the imposed
horizontal forces. The bridge was then transported to
its nal position and jacked down onto its bearings.

$-:>1+-;

Weighing

Case study:
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)88:78:1)<-
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;<:=+<=:-;
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Background:
ALE was required to perform the weighing of

Specic calibrations are carried out prior to each

a topside at Samsung Heavy Industries facility

weighing operation, either at our main equipment

in South Korea prior to skidding the module

base or onsite using portable calibration rigs. We

onto a barge.

are then able to guarantee accuracy to plus or

minus 0.5% of the total weight of any structure, and
can calculate with precision the centre of gravity.

Equipment used:
Using 24 500s Weightor jacking units with
integrated load-cells, ALE weighed the structure
at 5649.28te. This weight result was 99.91%
accurate giving a calculated centre of gravity to
within 10mm.

Case study:

Equipment used:

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-@1+7

The weighing system ALE initially mobilised in

the area a eet of 300s Weightor weighing jacks

Background:
ALE has provided weighing services in central Mexico
for a total weight of 92,945te, and is now established
as the regions leading sub-contractor for load-out
and weighing work.

complete with computerised interface is capable of

lifts up to 4,000te and ideally suited to typical eightleg platform fabrications. As the size of fabrication
projects increased, we mobilised an additional eet of
500s Weightor weighing jacks, enabling weighing or
jacking of up to 20,000te with short mobilisation periods
around the Gulf of Mexico.

Services

Lifting systems
ALE offers a specialist lifting
service to all markets. With a
strong heritage in engineering and
innovation, we are perfectly placed
to undertake the most complex and
intricate lifting projects. Our team
of experienced multidisciplinary
engineers investigate and prepare
lifting schemes and tailor-make
solutions for complex lifting
operations. Our range of lifting
equipment includes bespoke gantry
systems, modular tower systems,
hydraulic lift systems and strand
jack systems.
We believe that technology, design and
ingenuity are essential requirements in
providing customer-focused solutions
that address the very specic challenges
each project brings. The exclusive lifting
equipment weve developed is the result
of many years experience and detailed
research carried out at our Research and
Development facility.

Case study:
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7.

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014-

Background:
ALE undertook the
uprighting of two columns
at the Mejillones Power
Plant in Antofagasta, Chile

Equipment
used:
Using two 45-metre,
self-stabilising A frame
gantries, ALE successfully
lifted and tailed two
columns into the vertical
position. Each gantry
was provided with a
200te lifting unit and an
auxiliary lifting unit for
stabilisation and retention.
The columns, measuring
85 metres long, were
both manoeuvred upright
and positioned on their
foundations within
ve hours.

$-:>1+-;

Lifting systems

Case study:
6;<)44)<176
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Background:
ALE performed the installation of the living
quarters module at San Roque shipyard in
Salvador de Bahia, Brazil.

Equipment used:
The 1,350te living quarters module was lifted a
total of 25 metres above the deck using two ALE
gantries. Using a fully computerised heavy lift
system developed by ALE, the lifting operation
was completed in ve hours. After the module
was lifted above the deck, the LQ module was
skidded 22 metres longitudinally across the deck
using 16 skid-shoes.

45

$-:>1+-;

Lifting systems

Case study:
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Background:
ALE successfully lifted and installed a Gas
Turbine Generator at West Burton B Station
in West Yorkshire.

Equipment used:
ALE lifted the 239te Gas Turbine Generator from
an SPMT to a height of ve metres and propelled
it 20 metres longitudinally before setting it down
on its foundations using a Lift n Lock. With
a capacity of 426te at 12.4m, the Lift n Lock
integrates with ALEs Teon-coated side shift to
allow transverse alignment. Each jack was tted
with an electronic monitoring system developed
specically by ALE to allow real-time feedback
to the operator, guaranteeing safe control of the
entire lifting operation.

47

Services

Heavy crane lifting

ALE operates a comprehensive eet of heavy
cranes including crawler cranes and pedestal
cranes ranging from 200 to 5,000te capacity.
The eet includes some of the largest
equipment and latest technology available
today, and has been designed to provide a topto-bottom range of capacities that combined
act as complete project eets, providing
the range, sizes and capabilities to meet the
demands of modern day projects.

The cranes are based in strategic locations worldwide

to provide an efcient and cost-effective solution,
minimising mobilisation and maximising use.
Our crane engineering and rigging teams provide
innovative and client-focused solutions to their rigging
and lifting requirements, and produce technically
sound, well-thought-out schemes.

The SK190 and SK350 cranes

We are proud to have introduced the worlds highestcapacity land-based cranes the SK190 and SK350.
With the ability to lift up to 5,000te, they can be
dismantled and shipped around the world in ISO
containers. They are also capable of being relocated
fully-rigged onsite saving considerable time during the
construction of major projects.
For ballast, the SK190 and SK350 use locally available
material such as sand or gravel, which is loaded
into 100te capacity containers. Uniquely, the ballast
remains static while the crane slews around a pivot
system, making them much more appropriate for
congested sites than ring cranes.
These cranes can offer signicant benets over
traditional cranes and can substantially reduce
construction schedules and costs.

Case study:
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Background:
ALE was asked to complete major
lifts at a petrochemical plant in
Jubail in the Kingdom of Saudi
Arabia using the SK190 crane.

Equipment used:
ALE performed more than 100 lifts
on this project during a ve-month
period. The SK190 crane was used
to lift a depropaniser column and
a C3 splitter column into place,
working at 84 metres and 75.4
metres outreach respectively. The
ability to lift these loads at such
distances allowed onsite engineers
to complete foundation and pipe
racks in advance of installation.

$-:>1+-;

Heavy crane lifting

Case study:
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Background:
ALE was contracted to perform
the land transportation, site
movements and erection of 26
columns and reactors for the new
Sines Renery Conversion Project.

Equipment used:
The scope of supply included up
to 96 axle lines of SPMTs, CC88001 1,650te, LR1750 750te and
CC2800-1 600te crawler cranes
as well as hydraulic cranes and
a tailing gantry device specially
designed for the erection of the
two main reactors. The heaviest
lift was the Hydrocraker Reactor
weighing 1,500te.

Case study:
 !
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Background:
ALE was contracted to
engineer and perform
the erection of 34 major
columns and towers
weighing up to 1,240te.

Equipment used:
ALE supplied a 3,000te
gantry system and two
crawler cranes of CC2800-1
600te and LR1800 800te.
A 1,400te capacity strand jack
system was used to lift the
process towers as the project
site was very compact with no
access for a large lifting crane.

$-:>1+-;

Ballasting

Case study:
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Background:
Control of the ALE barge ballasting system can be offered

ALE was tasked with completing the skidding,

at two levels: locally, via the mounted panel situated on

ballasting, barge management and load-out

each hydraulic power pack which allows the operator to

of a 4,500te CPOC jacket in Malaysia.

control each pump or ow distribution buttery valve

individually; or remotely, using in-house designed software
and accompanying PLC control interface panels mounted
on each power pack.
We hold a variety of common barge congurations on
database so as to minimise set-up time on new operations.

Equipment used:
The operation was performed in three stages
using four 500-tonne capacity strand jacks.
The jacket was skidded 150 metres during
stage one, a further 70 metres to the quay
edge during stage two and then loaded-out
onto barge SLB1 for the nal stage. The
ballasting operation was performed using
ten submersible pumps with a total capacity
of 9,000 metres3 per hour. The pumps were
controlled from a single point using bespoke
software operating each pump individually
while monitoring the water level in each
tank. Finally the barge was ballasted to its
sea tow condition.

Case study:

Equipment used:

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7:-)

ALE used computer modelling to analyse and design a

pumping system capable of delivering the high ow rates
necessary. The systems were based around ALEs stock
of standard 250mm, 400mm and 600mm bore lightweight
galvanised pipe lengths and elements. Additional branches
were designed and fabricated using 700mm bore pipework
to allow for the high ow. The PC-based ballast monitoring

Background:

system provides real-time feedback from depth transducers

tted into each tank of the barge, and can be pre-programmed

ALE supplied and operated an external

with the necessary steps of load-out versus tide and load

ballasting system for the load-out of

transfer to target each critical stage of the load-out.

the 21,800te LUN-A topside, as well as

performing the load-out engineering and
barge management.

Services

Logistics
ALE offers a wide range of global logistical
solutions, particularly for the multi-modal
transportation of oversized and heavy cargos.
Our breadth of experience and enormous eet
of transporters and equipment gives us the
ability to meet all customer requirements, no
matter how challenging the project.

ALEs logistics capabilities range from the

support of single import/export jobs to
complete end-to-end projects involving
the transportation of complex freight
items across some of the worlds harshest
environments. We plan bespoke, multimodal packages incorporating all the
necessary services from our huge range
to execute every delivery as expeditiously
and cost-effectively as possible. All ALE
departments and ofces across the world
work together to achieve this.
Our logistics projects include full blueprint
to delivery consultancy and all the
necessary support services. We will handle,
secure and supervise cargo, chartering
marine vessels or aircraft and performing
heavy lift engineering as necessary. Well
also manage domestic and international
road and rail freight both in and out of
gauge, and take care of import and export
customs management as part of our
worldwide door-to-door service.

Case study:

Equipment used:

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The work involved in this logistical operation

included a transport study from the factory to
Montreal airport; a rigging study and loading and

Background:
ALE arranged the door-to-door transportation of
a hydro turbine runner from Montreal, Canada to
a hydro power station in Sweden.

lashing plan at the airport; and rigging, discharge

and transport studies for operations in Sweden
including access to the underground turbine hall.
ALE coordinated the transportation of the runner
from the factory to Montreal airport and supervised
the loading together with the chartering of the
aircraft. ALE also oversaw the discharge in Sweden
and the transportation to site.

$-:>1+-;

Case study:
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Background:
ALE undertook a full turnkey project to
transport, barge and install evaporators
weighing 2,000te from Hamriayah to
Fujairah in the UAE.

Equipment used:
ALEs team of naval architects and
engineering specialists carried out a range of
services including ballasting, sea-fastening,
barging, transportation from jetty and
positioning onto foundation. In addition to
76 SPMT axles, ALE used their own Londonregistered, fully ballastable 76-metre barge,
the ALE 250. The ALE 250 is equipped with
winches, ballast pumps, integral load-out
ramps and all machines and equipment
required for sea-fastening heavy lift cargo.

57

Turnkey projects
In recent years, major new projects have
grown both in size and in the demands
of the highest standards in performance.
Such projects require activities spanning
multiple disciplines such as sea transport,
land transport, lifting and installation as
well as signicant human resources in
HSQE, engineering, project management
and supervision.
In order to meet these requirements we formed a
dedicated projects team that has the human
resources necessary to address the demands and
challenges posed by major projects. The levels
of management and business processes that are
required in these projects are addressed in the
training of our staff.
Our highly developed project management skills
enable us to undertake high-value, long-term
transportation and installation contracts that require
multiple teams to work together to deliver optimum
value and efciency.

Services

Turnkey projects

Case study:
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Background:
ALE managed several operations
for the FCC renery of Punta Cardn
including the transportation of a new
reactor; the site movement of a new
domo; and the removal of the existing
stripper, absorber, reactor, regenerator,
fractionator and domo.

Equipment used:
The removal manoeuvres were
executed using a 70-metre, selfstabilising skidding gantry which
covered an area of 45 metres2 and
included two strand lifting units of
500te capacity each. Transporting
the 510te new reactor from the preassembling area to under the lifting
gantry required 28 SPMT lines with
a turning frame. Along the route, the
transport had to negotiate bends of 90
and pass under a pipe rack. For this,
ALE had to jack down the reactor along
the total length of the pipe rack using
four climbing jacks of 300te each and
four skid lines with SS-150 skidding
equipment. The new domo, weighing
420te, was moved using SPMTs.

Services

Engineering
With more than 100 highly qualied engineers,
a Research and Development facility capable
of designing record-breaking equipment, and
a pedigree in delivering innovative solutions
for some of the worlds largest organisations,
our engineering skills are proven. Ingenuity
is one of our core values, and a trait which is
evident in every scheme we design and every
problem we solve.

As a result, weve kept abreast of developments in all

the industries we serve, indeed often devising, testing
and implementing technologies ahead of when theyre
required. The mega-jack system we developed and our
SK190 and SK350 cranes are recent examples of equipment
that pay testament to this commitment to progress.
We also harness our knowledge and skills to provide
proactive risk management, engineering and planning
surveys, getting to the bottom of the complex technical and
logistical issues facing each project at an early stage and
collating our investigative efforts in a detailed technical
report. Our experience means were well-equipped to
support the full FEED process, from conceptual design
stage to the production of cost estimates.

Case study:

Engineering required:

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ALEs team of naval architects and structural

engineers provided engineering supervision,

Background:
ALE carried out engineering works for the seafastening, ballasting, load-out and oat-off of the
Super M2 Rig Hull using a semi-submersible vessel.

mooring calculations, barge deck strength analysis,

semi-submersible longitudinal frame analysis,
ballast calculations for roll-on and oat-off, bollard
pull calculations, sea-fastening calculations, semisubmersible stability analysis and marine management.

Our philosophy is to produce engineers of the highest

standard. We start at the recruitment stage, by employing
the nest young graduates who demonstrate air and
innovation and who will enable ALE to undertake the most
challenging projects for our customers. Our recruitment and
training programmes include exposure to all aspects of our
business, with introductions into offshore operations and
marine, heavy-transportation and lifting together with design
of new products at our R&D section in the Netherlands.
Roger Harries, CEO

Capabilities

www.ale-heavylift.com

worldwide heavy transportation and lifting