December 8th 2016
The Changing Environment in Construction Industries and Heavy Lifts in the Middle East
1
CONSOLIDATED CONTRACTORS COMPANY Speaker Introduction Name : Maher Kabbani Manager (HLD) Consolidated Contractors Co. Abu Dhabi – U.A.E. Masters Degree in Mechanical Engineering George Washington University United States of America Heavy Lift work experience: 25 yrs.
Consolidated Contractors Company (www.ccc.gr)
2
Contents 1. Company Introduction 2. CCC Heavy Lift Division 3. Regional Scenarios and Impact 4. Technology influencing Heavy Lift environment 5. Prospects in Middle East 6. Conclusion
Consolidated Contractors Company (www.ccc.gr)
3
Company Introduction •
Consolidated Contractors Company (CCC) was originally formed in 1952 in Lebanon
•
CCC currently employs approximately 187,000 people in its worldwide operations
•
CCC is an ISO 14001 and OHSAS 18001 certified company with the highest level of commitment to HSE
•
CCC is an ISO 9001:2008 certified company with the highest level of commitment to Quality
•
CCC is an ISO/IEC 27001:2013 certified company and applies the Information Security Management System (ISMS) to all company activities
•
CCC is predominately a construction company, providing project management, engineering, procurement and construction services to the industry
•
Currently ranked 1st in the Middle East and 21st in ENR Top International Contractors (2016)
Consolidated Contractors Company (www.ccc.gr)
4
Consolidated Contractors Company (www.ccc.gr)
5
Consolidated Contractors Company (www.ccc.gr)
6
Olefins II, Ethylene Plant
Consolidated Contractors Company (www.ccc.gr)
7
Consolidated Contractors Company (www.ccc.gr)
8
HSE Certificates & Awards
Consolidated Contractors Company (www.ccc.gr)
9
Quality Management & Certificates Overriding commitment to providing quality products • ISO 9001: 2008 • ASME Stamp “A” • ASME Stamp “U” • ASME Stamp “U2” • NB Stamp “R” CCC’s aim is to remain a market leader by pursuing a program of continuous quality improvement
Consolidated Contractors Company (www.ccc.gr)
10
(US$ Millions)
Consolidated Contractors Company (www.ccc.gr)
11
(Thousands)
Consolidated Contractors Company (www.ccc.gr)
12
2016
ELECTRIC GENERATORS & LIGHTING TOWERS
713
EARTHMOVING EQUIPMENT
942
PIPELAYING EQUIPMENT
215
CIVIL ENGINEERING & CONSTRUCTION EQUIPMENT AIR COMPRESSORS
372
1,278
HEAVY DUTY VEHICLES
WORK/SURVEY BOATS & STANDARD FACILITIES
169
1,861
CRANES
759
Consolidated Contractors Company (www.ccc.gr)
VEHICLES & LIGHT TRUCKS
WELDING MACHINES
6,442
2,795
TOTAL NO. OF EQUIPMENT: TOTAL VALUE OF EQUIPMENT:
15,546 US$ 1,119 MILLION
13
14
Heavy Lift Division CCC has been involved in the heavy lift business since the 1980’s empowered by a professional team consisting of Engineers, draftsmen, specialists and supervisors dedicated for this critical operation and following Company Safety and Quality standards. The Heavy Lift Division provides the following services: • Heavy Lift Feed Study • Heavy Lift turnkey project • Heavy Lift Execution • Heavy Lift Consultation • Heavy Lift Management • Heavy Lift Engineering CCC owns over 759 cranes with a capacity ranging from 1600 to 8 tons.
Consolidated Contractors Company (www.ccc.gr)
15
CCC Records in Heavy Lifts QGXII, QCS, RGX & AKG2 Qatar. Most repetitive lifts Erected 7 Absorbers each weighing 1,475 T [45.7m length x 7.1m dia.]
Ruwais 3rd NGL 960T Demethanizer
The heaviest load test was part of the Platform Ringer’s 4 year mandatory inspection. The total weight lifted by the crane was 2,080 tons.
THE HIGHEST FLARE STACK Erected 200mtr high Derrick Flare Stack 28FL8401 using Demag CC8800 at QGX Qatar.
Yanpet Ethylene Expansion KSA The tallest vertical equipment 2C-1504B 1,233T [92.7m length x 6.4m dia.] was erected utilizing the Twin Ring Platform Ringer
Rabigh Development KSA The largest diameter equipment Erected 882T Regenerator R230-R-0002 having diameter 17.05mtr utilizing MSG-80 as main crane and CC4800-S3 as tail crane.
Consolidated Contractors Company (www.ccc.gr)
16
The Changing Environment in Construction Industries and Heavy Lifts in the Middle East
Regional Political Scenario Geo Political turmoil War in Syria, Yemen & Iraq Lifting of Iranian sanctions Donald Trump Victory in US Elections
Consolidated Contractors Company (www.ccc.gr)
18
Regional Economic scenario •
Low Oil price
•
Government dependence on Oil revenue & lack of economic diversification
•
Lower demand / depletion of oil resources
•
China’s economic conditions – Concentration on Service sectors compared to Export & Production sectors.
Consolidated Contractors Company (www.ccc.gr)
19
Impact of current scenarios • Cancelled/delayed projects. • Cash flow shortage, spending slowdown, payment issues • Introduction of Taxes. • Withdrawal of subsidies. • Higher competition among HL Contractors. • Shifting of HL resources to the regions such as American Continent.
Consolidated Contractors Company (www.ccc.gr)
20
Impact of current scenarios • Restructuring of Oil and Gas, Construction and HL companies to improve performance. • Kuwait is the only country investing heavily in oil and gas simply because Projects should have been done 10 years ago. • Market flooded with HL cranes where 600T crane became a commodity compared to 10-15 years ago. • How many crane more than 1000T is available in the Middle East? How many in the world ?
Consolidated Contractors Company (www.ccc.gr)
21
Construction Projects – Contract Value 1980’s
1990’s
2000 to 2005
2005 onwards
Up to US$ 100m
UP to US$ 500m
Excess of US$ 1 billion
Excess of US$ 1.5 billion Splitting of packages
Consolidated Contractors Company (www.ccc.gr)
22
Construction Projects – Contracts 1980’s
Cost
+
Reimbursable
1990’s
Re-measured Contracts
2000’s Re-measured to Lump Sum Turnkey
2010’s
Lump Sum
Lump Sum with more risk towards Contractors
HL Contracts remains unchanged to the exception of transfer of Risk. All Risk on Client
Consolidated Contractors Company (www.ccc.gr)
Partial Risk
23
All Risk on HL Contractor
Technology influencing Heavy Lift environment
Consolidated Contractors Company (www.ccc.gr)
24
Technology Transformation Type of Heavy Lifts • 1980’s - Straight forward single lift, up to 200T • 1990’s - Complex, Tandem & Multiple Lift, up to 800T • 2000’s - Excess of 2000T • 2005
- Introduction of Modularization
• 2010’s – Modules up to 5000T (Onshore) • Future - ?
Heavy Lift Cranes • 1980’s – AM Hoist 9310, Skyhorse, Manitowoc M1200 Ringer, Gottwald cranes up to 800T
Engineering • 1980’s - Hand sketches
• 1990’s – Multi purpose Lifting Machines
• 1990’s - Scale drawings, Pencil drawings & Stencils, Introduction of AutoCAD
• 2000’s – PTC 35, Terex Demag CC8800-1 Twin (3200T), Liebherr LR 13000
• 2010’s – AutoCAD 3D Crane job planning software's such as Cranimax, 3D Lift Plan / 4D Animations / 3D projections.
Ringer / Mammoet Sliding Gantry (MSG) series, CC4800 Twin Ring, PT50
• 2010’s – PTC200-DS (3200T), ALE SK 90 (4300T), Sarens SGC-120 (3200T),
• 2000’s - Enhanced AutoCAD with internal Programs.
• Future - Voice activated software's !!!
Superlift enhancement systems,
Boom Booster, AL SK350 (5000T)
• Future - Mammoet & Stoof [Focus] Design stage – 24,000T, Shortage of 700T to 1000T crawler cranes.
Consolidated Contractors Company (www.ccc.gr)
25
Hand Sketch
Consolidated Contractors Company (www.ccc.gr)
26
DEMAG CC8800-1 SSL CRAWLER CRANE (1600T)
0°
270°
CRANE LIFT DATA
D EMAG CC280 0-1 SSL C RAWLER CRANE(600T)
300T. C/Wt.
1
DEMAG CC88 00-1 HSSL CRAWLER CRANE (1 600T)
2
E QUIP ME NT No.
NOTE 1
. 00 0m .
AutoCAD DWG
12
90°
1 2 .0
180°
V-112-0113
00m .
.
T IMBER MATS 5.0mX1.0m X0.2m
4.997m. TRAVEL DISTANCE
T AS .M
R1 =
4 5
% O F CHART CAPACITY
86.49%
6
TAIL CRANE LIFT DATA 7
DEMAG CC 2 800 -1 SSL CRAWLER CRANE (6 00T)
8
MAX IMUM LOAD (R2)
495,221
% O F CHART CAPACITY
89.02%
PICKING RADIUS
R2 = TOTAL
1 ,100,7 68Kgs.
TOTAL LIFT WEIGHT 1,078,000 + 8,892 + 13,876 = 1,100,768 Kgs. 440t C/Wt.
3
440T. C/Wt.
C.G.
1 ,078,000
WEIG HT OF REACTOR
SLEW, TRAVEL & ERECTION RADIUS
04
R2 R1
V-112-0113
m 00 .0 50
60.000 m . MA IN BO OM
300T. C/Wt.
0m 00 4. R1
22. 000m.
14.000m.
LIFTING COVER AND TAILING FRAME ORIENTATION
S TEEL MATS 6.0m X 3.0m X 0.350m
NOTE:
04
PART PLOT PLAN S TEEL MATS (6.0m x 3.0m x 0.35m)
04
9 10 11
04
12
SECTION INSTALLATION
DEMAG CC2800-1 SSL CRAW LER CRANE (600T)
D R AWIN G No.
D ESCR IPTION
DETAIL-1
DESCRIPTION
BY
T AS .M
-1 12
-0 1
13
DATE
V
m 00 .0 30
48 .0 00
m . BO OM LE NGTH
R EFER ENCE DR AWINGS
HEAD
TAIL
"A"
C.G. 300t C/Wt.
V-112-0113
T IMBER MATS
5.0m x1.0m x 0.2m TAILING ELEVATION
Consolidated Contractors Company (www.ccc.gr)
ELEVATION
TACKLE ARRANGEMENT
VIEW-A
KNPC-RS-001 1 OF 1
27
AutoCAD 3D DWG
Consolidated Contractors Company (www.ccc.gr)
28
Legislations, Regulations and Procedures • Oil and Gas Sector is very well structured, more stringent procedures, Method Statement, Risk Analysis, Certification and Safety requirements. • Heavy Civil projects still lack legislations and procedures. • Regulations & International standards reference varies from one country to another. (Kuwait, import/export) • Reactive Construction Industry. • Lack of safety culture in the region. • Local Content.
Consolidated Contractors Company (www.ccc.gr)
29
Prospects in Middle East • Construction Projects – Concept of Modularization (Some cases followed as a trend). • Opportunities seen in the field of Renewable Energy Projects - Solar / Wind and Nuclear. • Major global events that are planned in the region – (EXPO 2020, Qatar 2022 FIFA World Cup) – Focus on Infrastructure (Airports, Metro, Roads, Bridges, Stadiums, Hospitality & Tourism). • Re-alignment on business strategy (Lean construction, Value Engineering, Innovative ideas, Training methodology using Simulators, Online Webinars, Fanous platform Knowledge Management).
Consolidated Contractors Company (www.ccc.gr)
30
Conclusion • Getting in the habit of doing more for less. • Change our work methodology. • Modularization seems to be the way forward. • Expect more Heavy Lift competition in this region from East Asian companies.
Consolidated Contractors Company (www.ccc.gr)
31
THANK YOU Consolidated Contractors Company (www.ccc.gr)
32