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Marine projects

landmark marine projects

Upgrade to berths 1 to 4, 13 and 14 of Maydon Wharf for Transnet, KZN, South Africa 2014-2018

A joint venture, consisting of Stefanutti Stocks Coastal and its enterprise development partner, Axsys Projects, used some technical innovations while reconstructing and deepening the six berths that form the Port of Durban’s largest break-bulk, edible-oils and dry bulk-handling precinct.

The scope of work, included a new HZM-AZ combination wall system with anchor piles, a new cope, underwater sheet pile installation, earthworks, re-surfacing, dredging and scour protection.

Techniques, never used in South Africa, were implemented for the installation of anchor piles, as well as the in-situ construction of the submerged fender panels for the cope structure.

This marine construction project was named the winner of the Railway & Harbour category in the 2016 SAICE-SAFCEC Awards.

In March 2017 the project achieved 2-million Lost Time Injury Free man hours worked.

  • Stefanutti Stocks Coastal Marine Berth 208
  • Stefanutti Stocks Coastal Marine Berth 208

Construction of new liquid chemical berth (Berth 208) for Transnet, KZN 2010

Stefanutti Stocks Coastal constructed the new Liquid Chemical Berth 208 for Transnet Capital Projects (TCP). This marine infrastructure construction project included the positioning of 72 reinforced precast concrete beams, which had to straddle adjacent pile caps. The beams, weighing between 65 and 75 ton were placed off a barge and this activity required careful planning in order to optimise safe working conditions. The beams could not be placed if the wind speed exceeded 40km/hr,if wave heights exceeded 0.5m and/or if tidal heights weren’t within a specific window.

Kwale Mineral Sands projects for Base Titanium Limited, Kenya 2013

The Kwale Mineral Sands project was awarded based on an alternate design that allowed for a reduced contract price through a reduction of both the concrete volume and the pile steel quantities.

Stefanutti Stocks Coastal proposed an alternative solution that entailed the use of prefabricated structural steel headstocks (nine in total) in lieu of reinforced concrete platforms. The headstocks were also utilised as pile guides, whereby the installation of the raker piles and structural steel headstocks were concluded simultaneously. This methodology translated into savings on cost and time.

The marine infrastructure work consisted of a conveyor (access) trestle, a concrete decked load-out platform with crane rails for a shiploader, two mooring dolphins and two berthing dolphins. Structural steel elements were manufactured in South Africa and then shipped to Mombasa. The marine piling comprised of 60 steel tube piles including compression; tension piles up to 45 metres in length; upright piles; as well as 1:4 raker piles.

While Stefanutti Stocks was busy with the Kwale Mineral Sands Marine infrastructure project, client Base Titanium Ltd also appointed the marine contractor to assemble its shiploader. The project included pre-assembly; dummy erection in Durban; loading for transportation; offloading in Mombasa and the final erection of the Kwale Mineral Sands Shiploader in Mombasa Kenya. The erection was undertaken from three barges on three work-fronts. The lifts consisted of various loads with the largest lift being a 90-ton tandem lift off from a floating barge. Once all the barges and cranes were off-hired, the final fitment of the smaller mechanical items and the electrical and instrumentation installation started. The on-site installation process took four months to complete before cold commissioning could begin in early November 2013.

  • Stefanutti Stocks Coastal Marine Kissy Jetty
  • Stefanutti Stocks Coastal Marine Kissy Jetty Birdseye New Fuel Import Facility
  • Stefanutti Stocks Coastal Marine Kissy Jetty Hosetower
  • Stefanutti Stocks Coastal Marine Kissy Jetty Piling
  • Stefanutti Stocks Coastal Marine Kissy Jetty Plant
  • Stefanutti Stocks Coastal Marine Kissy Jetty Prefabricated Superstructure
  • Stefanutti Stocks Coastal Marine Kissy Jetty
  • Stefanutti Stocks Coastal Marine Kissy Jetty Birdseye New Fuel Import Facility
  • Stefanutti Stocks Coastal Marine Kissy Jetty Hosetower
  • Stefanutti Stocks Coastal Marine Kissy Jetty Piling
  • Stefanutti Stocks Coastal Marine Kissy Jetty Plant
  • Stefanutti Stocks Coastal Marine Kissy Jetty Prefabricated Superstructure

New Kissy Oil Jetty for Oryx Energies, Peninsula Freetown, Sierra Leone 2013-2015

This project entailed the design and construction of a new fuel import facility to support the safe importation of fuels into Sierra Leone. The new jetty replaced the existing facility, which was beyond its operational lifespan and did not conform to international standards. Stefanutti Stocks and its joint venture partner were awarded the project on an EPC FIDIC Silver Book Contract basis, in 2013.

The turnkey scope of works began with design, followed by construction work consisting of:

  • a steel piled substructure with mooring and berthing dolphins,
  • a prefabricated superstructure for both liquid product lines,
  • a fire fighting system, and
  • the final testing and commissioning of the system.

The design was optimised by using prefabricated steel structures manufactured in the Netherlands. This resulted in no delay due to the lack of local supplies and ensured a rapid construction programme. The project, that commenced in early 2014 was delayed for eight months due to the ebola epidemic. Once the epidemic receded the staff were remobilised and the project was successfully completed in 2015.

  • Bel Air Img
  • Bel Air Img

Quarry and Port Civil Works for the Bel Air Mine, Guinea 2017-2018

This mining infrastructure development project, undertaken by Stefanutti Stocks Coastal in French-speaking Guinea, entails the construction of a 1 400m long rock breakwater, with a 100-metre-long precast concrete barge berth. The project scope includes the greenfield establishment and operation of an armour rock quarry – to drill and blast over 500 000m3 of rock fill. Furthermore, a precast yard was established on site to manufacture the berth wall components and provide in situ concrete for the cope beam.

In April 2018 the project reached the milestone of 750 000 Lost Time Injury Free man hours worked.

Port Nolloth marine infrastructure rehabilitated for Transnet, Northern Cape, 2016-2017

The scope of marine infrastructure refurbishment undertaken by Stefanutti Stocks Coastal at Port Nolloth, included:

  • removal of existing tyre fenders;
  • installation of new tyre fenders;
  • refurbishment of existing bollards;
  • concrete rehabilitation to the side faces and underside of the jetty structure; and
  • rock revetment construction.

The water-based remedial work, undertaken to the underside of the jetty structure was accessed using a temporary access platform constructed below neap low tide level.

The 70-metre rock revetment was completed within five months, by offloading and placing rocks using special excavator mounted thumbs welded onto an excavator boom on site.

Marine works for Strandfontein desalination plant for PROXA, Western Cape, South Africa 2018

Stefanutti Stocks Coastal, in joint venture with TAG Diving undertook the marine scope of work for the Strandfontein desalination plant. The bulk of the original scope of work was completed within a period of nine weeks and included the procurement, manufacture, installation and commissioning of the plant and materials for the Strandfontein seawater intake line, brine line and pump station.

Through early contractor involvement Stefanutti Stocks Coastal and PROXA’s design engineer, PRDW, value engineered the pipe-line configuration to achieve an excellent balance between the design requirements (for the total weight and stability of the pipeline on the seabed), and the practicality of manufacturing and installing this pipeline. The outcome was a dual pipe – two 600-metre long, 500mm OD HDPE piping – installed side by side in the pipe-stringing yard.

The pipe was launched in two 300-metre long strings, with the first string including the 144-metre brine line. The launching and towing was undertaken by a tug boat (with a 500-metre towline attached to the pipeline) and six synchronised excavators walking the pipeline into the sea.