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By A. Peterse
Wikipedia’s definition is rather broad, yet it is in line with the com- Project cargo
mon use of this term, together with even broader cargo categories on container
such as “general cargo” and “break bulk”, that is, any dry cargo flatbeds.
which is not unitised and not (major) bulk.
In its bi-annual market reviews, Drewry [1] distinguishes a number
of dry cargo segments, as depicted in the table below. Drewry em-
phasises two points:
• Project cargo is ‘the invisible break bulk volume: it has become
the foundation of the most dynamic part of the break bulk mar-
ket, but no trade or port statistics exist.’
• Project cargo is carried on multi-purpose/heavy lift vessels, but
– depending on prevailing conditions of their specific market
segment – container vessels, roll-on/roll-off (ro-ro) ships, gear-
less coasters and bulkers, will take their share.
These factors complicate any attempt to analyse and forecast mar-
ket conditions.
Global Break-Bulk Market Outlook 10
Est. Global
Primary
Source: Drewry
Dry bulk cargo market segments (by Drewry). Project cargo on a open top, gearless vessel, the Oceanic (picture by Flying Focus).
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Arie Peterse is member of the Supervisory Board and
former Managing Director of BigLift Shipping BV.
As far as heavy lifts are concerned – arbitrarily: any indivisible load over 100 mt – it can easily be identified which industry sector drives the
demand for heavy lift transportation:
The Gloria Virentium was built in 1977 and was equipped with two 400-mt derricks and a
DDG Hansa’s Uhenfels built in1967, with a lift capacity of 2 x 275-mt with Stülcken derricks. ro-ro ramp.
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The Dock Express 11, built in 1979, with originally two gantries of 600 mt, ro-ro and flo-flo.
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Five MPV
categories
(source DNV GL).
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FEM analysis of
a cargo vessel.
• Finite Element Method (FEM) analysis: The strength analysis of handling restricted to lift-on/lift-off (lo-lo) or will ro-ro by stern ramp
the large open box structure of the vessel being subjected to or even float-on/float-off (flo-flo) be included? Trade areas may im-
loads in port due to the operations of the heavy lift cranes and pose limits, think of the Great Lakes for example, and of course the
at sea due to dynamic forces acting on heavy cargo items available budget may do so as well.
stowed on deck, is only possible by FEM analysis of a detailed Items to consider are:
structural model of at least the mid body of the ship. More de- • Vessel lay-out: One or two box-shaped holds. Note that the typi-
tailed analysis is required on the transfer of the crane loads into cal lay-out of a long hold with a small hold forward, is often dic-
the local ship structure [6]. Deformations of the ship structure, tated by damage stability requirements; one long hold is feasi-
which may be considerable, are to be calculated, in order to de- ble, but will restrict maximum draft, and as such the deadweight.
sign the hatch covers and, if required, stoppers to limit deforma-
tions.
• Damage stability: The probabilistic approach of damage stability
gives the naval architect more freedom in the subdivision of the
vessel than the former “one or two compartment standard”, but
it will be clear that the requirements of maximum hold length
and narrow side tanks present some challenges.
Deformations for inward/outward deflections. A modern heavy lift carrier, the BigLift Happy Star (picture by Flying Focus).
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Stability
pontoons are
fixed to the side
of the ship during
heavy lifting
(picture (left) by
K. Goudriaan).
Deadweight may not be of prime importance for the carriage of although during the handling of heavy loads by a ship’s gear,
project cargo and heavy lifts, but if a multi-purpose function is very critical stability situations may occur. Accidents happen
envisaged as primarily role, whereby for instance bulk or steel during lifting operations as it is not always understood that the
cargoes are to be carried, it will limit the intake. stability of the ship will suddenly change in the instance a load
• Cranes: Mostly there are two located at one of the ship’s sides, becomes free-hanging in the ship’s crane; at that moment, the
able to work in tandem. Larger vessels may have a third crane, gravity force of the cargo applies at the top of the crane, the
often of reduced capacity. The choice of lifting capacity, out- metacentric height (GM) of the ship is drastically reduced, pos-
reach, boom length, height of pivot point above deck and so on sibly even negative. A number of heavy lift operators use as an
will all have their impact on the ship’s structure, stability and (unofficial) standard that the vessel’s GM should be a minimum
ballast requirements. of one metre during the whole cycle of cargo operations. There-
• Ballast system: Ballast tanks are to be arranged in such a way fore, heavy lift vessels may have a relatively large beam. How-
that stability in all situations is ensured and that during lifting ever, too large a beam will result in high GM values in sailing
operations, heel can be compensated. Ideally, all double bottom conditions, giving unfavourable roll motions in sea conditions,
tanks remain one hundred per cent filled during heavy lift opera- thereby applying high dynamic forces on the cargo and its
tions and heel can be compensated by pumping ballast between lashings.
the side tanks, without the need to pump ballast in or out. The A compromise is found in the application of a “stability pon-
speed of heavy lift handling will be determined by the installed toon”, fixed to the side of the ship during the lifting of heavy
ballast pump capacity and the ballast lines. Water ballast treat- cargo. The stability pontoon increases the waterline area, re-
ment is compulsory for newbuilds. In ports in the United States spectively the moment of inertia of the waterline area, and so
this also applies to existing vessels. The application of solid bal- the metacentric height: it is not intended, as is often misunder-
last, such as magnetite, in some side compartments can be con- stood, to create additional anti-heel ballast capacity.
sidered to enhance heel compensation, while sacrificing some Disadvantages of the stability pontoon are the time and effort it
deadweight. takes to install and dismantle the system when handling heavy
• Hatch covers: Upperdeck: foldable or lift-off panels or a combi- lifts and the space it takes on deck during the sea voyage. Fur-
nation thereof. Allowable loads on the upper deck hatch covers thermore, it is clear that lifting operations require utmost atten-
are often low, 1.5 t/m2 for weight and cost savings, but will then tion to the safety of the system; if the pontoon is lifted out of the
restrict the stowage of heavy cargo. Tween deck pontoons are water due to heel of the vessel during the handling of a heavy
the standard; so are adjustable tween deck heights. The tween load or is submerged, the ship will lose its stability and may
deck pontoons may be used to create separation bulkheads. capsize, see for instance the tragic accident with the Stella
• Allowable loads: High allowable loads will facilitate stowage of Mare at Albany in 2003.
heavy cargo items. On the tanktop 15-20 t/m2 can be created, for An alternative way to increase the ship’s stability for cargo op-
tween deck and upper deck pontoons this will normally be re- erations can be the temporary fitting of tween deck hatch cov-
stricted to 5 t/m2. ers along the ship’s side, although the contribution to the stabili-
• Stability and damage stability: For seagoing conditions, SOLAS ty will be less than when using a stability pontoon.
regulations regarding intact and damage stability apply. No in- DNV-GL has a set of rules regarding stability, with special atten-
ternationally recognised requirements apply to stability in port, tion to safety against capsizing. This applies to ships having the
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Project Cargo Special
voluntary class notation “crane vessel”, which may include, in rules for a class notation “hatchcoverless”, while national au-
their definition, heavy lift ships [7]. These rules also introduce thorities need to grant an exemption of the International Con-
the “accidental load drop criterion”: requirements to the ship’s vention on Load Lines [9, 10].
stability when there is an accidental loss of the hook load due to • Location of the superstructure: For specialised heavy lift car-
failure of the lifting gear and the ship rolls away from the side of riers, the choice to locate the superstructure forward is logical:
the lift. In the past, the Dutch port labour inspectorate (Havenar- ro-ro facilities over the stern are made feasible, large deck
beidsinspectie) applied similar regulations to Dutch flag heavy loads will not hamper visibility from the bridge and the forward
lift ships. superstructure will reduce the risk of green water washing over
• Open sailing: Flexibility of stowage of heavy and large loads can the bow damaging cargo stowed on deck or entering the hold in
be obtained if the heavy lift vessel is allowed to sail, at reduced case of open top sailing.
draft, without (or partially without) the upper deck hatch covers The ship’s officers generally see no disadvantages in steering
in place. Cargo can be stowed on the tank top or tween deck, is and manoeuvring from a wheel house located forward; all on
better protected and subject to lower dynamic forces than on board enjoy the quiet in their cabins away from the engine room
the upper deck. and propeller.
As early as the 1980s, the heavy lift Dock Express vessels and • DP: The top end heavy lift carriers are often not just used for the
the Happy Buccaneer were already allowed to sail “open top”. transport of heavy lifts, but also work at the destination as
The exemption of the load line convention was based on an crane vessels, directly installing the heavy lifts, for example in-
adaption of existing guidelines for open top container vessels stallation of wharf decks, assembling cranes et cetera. Offshore
[8]. Basic requirement is that the vessels are fitted with a bilge installation work is an option as well, but generally dynamic po-
system for dewatering the holds in case a quantity – to be de- sitioning (DP2) will be a requirement for the installation of sub-
termined in tank tests – of green or rain water has entered the sea structures, wind turbine transition pieces and so on. Fur-
hold. Stability with the holds partly flooded is to be considered thermore, requirements may not stop there: heave compensa-
and fire protection measures are required. tion of the cranes, additional accommodation, a helideck or a fly
Recently the need was felt by national authorities and classifi- jib may be needed for specific offshore projects. Investment in
cation societies to formalise the regulations for open top multi- such equipment will certainly make the vessel versatile for
purpose vessels, especially regarding the assumed conditions offshore installation contracts, but too expensive to operate in
of flooded holds: classification societies introduced voluntary the regular heavy lift transportation market.
Lifting by running the hoisting winch(es) causes ship’s heel. There is a risk of overload of Controlled safe lifting by transfer of ballast between side tanks.
crane(s) due to increased outreach; taut mooring lines; transverse forces on crane top(s);
and swinging of load when getting free from the ground.
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Operational Aspects
Loss prevention is an important issue in the transportation of pro-
ject cargo: the cargo is often of great value as well as critical to the
project. Loss of, or damage to the cargo will have direct financial
consequences, but may also cause long delays in the completion of
the project. Project owners, engineers/contractors and the insur-
ance companies involved will therefore closely watch the trans-
portation of their cargo. Under the usual conditions of charter par-
ties and Bills of Lading, liability for damage or loss of cargo is limit-
ed and for cargo stowed on deck entirely excluded, while the ship
owner or operator is not responsible for any delays. Marine War-
ranty Surveyors (MWS) are often appointed to guide the selection
of the ocean carrier, do plan approval of the planning and engineer-
ing of the transport and attend the actual loading, stowage, and
seafastening. The vessel will not leave the load port without a
signed “sail away certificate” of the MWS.
Shipment of project cargoes and especially heavy lifts require care- Safe lift due to large lifting triangle.
ful planning and coordination with all involved. Shipping manuals
are prepared in the office of the ship owner or operator by staff with
a nautical background and experience and naval architects. Super- • Rules of thumb: For example, for lashing of boxes and crates:
intendents will travel to load ports to coordinate operations. sum of minimum breaking loads of the lashings shall be twice
For large projects, extensive manuals are prepared and discussed the static weight of the cargo.
with clients and MWS. Method statements and stowage/lifting/lash- • Calculation of the forces on cargo stowed on board using for in-
ing plans are standard and voyage planning, mooring plans, risk stance: accelerations as given in “advanced calculation me-
analysis, project specific Health, Safety & Environment (HSE) proce- thod” of the CSS code [11]; accelerations as per class require-
dures are not exceptional. Subjects which certainly need to be ad- ments for the design loads on ship structure [12]; assumed ship
dressed are: motions, for example Noble Denton “default motion criteria”
• A stowage plan: including deck strength calculations for the [13]. Wind forces can be added separately.
heavy loads as well as of load spreaders if required. • The design wave method: a wave spectrum is assessed, based
• For all heavy lifts: lifting plans: rigging plan, calculation of sling on the extreme wave condition (ten year return) to be expected
forces, selection of slings/grommets, shackles, lifting beams/ on the route. Ship motion response is calculated by diffraction
spreaders. programmes on the basis of the actual ship dimensions, charac-
Lifting operations will always require full attention to the risks in- teristics and loading conditions. From the ship motions, local
volved. The incident rate of accidents due to mechanical failure or accelerations are calculated; the design value is generally ac-
due to human error is low. However, there can be serious conse- cepted as having a ten per cent exceedance.
quences. Another issue, often overlooked, is the stability of the load
being lifted while the lifting points are situated below the location of
the load’s centre of gravity.
Cargo lashing is always a topic of much discussion and, fortunately,
also a subject of extensive studies. It may be time-consuming and
costly, however, with proper engineering and design, an ample
stock of lashing material as part of the ship’s onboard inventory and
a skilled crew, it does not have to be. According to the SOLAS regu-
lations, all vessels must have a Cargo Securing Manual (CSM) on
board describing the types of cargo, which the ship is suitable to
carry, and the proper way of loading, stowing and lashing of these
cargoes. It will be impossible to include all project cargoes of any
type, size and weight in such a CSM. Specific calculations are then
to be made for each shipment to design proper stowage and lash-
ing, to be approved by the MWS. Example: Noble Denton: transverse force based on roll twenty degrees, ten seconds and
Various methods can be seen in the engineering and design of lash- heave 0.2 g. Rotational inertia of the load is often not taken into account, but may be
ing plans, with increasing sophistication: considerable for high structures.
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as an indication of actual market conditions “Toepfer’s Multipur- very positive. From 1 January 2020, the International Maritime
pose Index”, that is, the development of the time charter rate of a Organization’s regulations on the sulphur cap of bunker fuels will
12.500-t dwt “F type” multipurpose vessel, which vessel type is come into force. It is expected that many owners of multi-purpose
widely used in the market. vessels will not have the financial resources to install scrubbers.
DNV-GL [21] publishes an “MPV Update”, giving technological infor- Although there is still uncertainty on how bunker prices will
mation on the design and operations of multi-purpose ships and develop, it may realistically be expected that the voyage expenses
regulatory issues, besides market trends. will rise considerably when they have to run the vessels on low
Recently, the various market reviews show some optimism on the sulphur fuel; for older tonnage it can mean a last voyage to the
basis of an increase on reported worldwide investment plans of the scrap yard. If so, it will certainly help to bring the multi-purpose
energy and mining industry, with the provision that there may be market in an upward cycle again. However, at this moment there is
some years in the process of planning and design, firm investment as yet no sign of increased scrapping of multi-purpose-heavy lift
decisions and execution. Furthermore, the multi-purpose market tonnage.
has its interdependence with other dry cargo markets, the bulk mar- Newbuilding orders are extremely scarce due to the current market
ket as well as the container markets. Today’s geopolitical situation conditions; when new orders will be placed, it will be interesting to
and the threat of trade wars make the outlook for these markets not see if a choice for LNG will be made.
References
1. Drewry: Outlook for breakbulk and project cargo market, www. 11. IMO Code for the safe practice of cargo stowage and secur-
drewry.co.uk ing, Annex 13, Methods to assess the efficiency of securing ar-
2. DNV GL, www.dnvgl.com/expert-story/maritime-impact/ rangements for non-standardized cargo
One-step-at-a-time.html 12. DNV GL Rules for the Classification of Ships, /36/, Part 3, Chap-
3. DNV-GL MPV Update 2017 ter 4, Section 3
4. http://www.ttsgroup.com/Products/Heavylift/ 13. Noble Denton Marine Services, Marine Warranty Wizard
5. https://www.huismanequipment.com/en/products/cranes/ 14. Marin Safe Trans, The safe design and operation of marine
heavy_lift_mast_cranes transports
6. DNVGL-CG-0151 “Strength Analysis of General Cargo and Mul- 15. https://gcaptain.com/superyacht-my-song-lost-during-
ti-purpose Dry Cargo Ships”, February 2016 transport/
7. DNV-GL Rules for classification Part 5, Chapter 10, Section 2 16. www.meteogroup.com, Spos9 factsheet
“Crane vessel”, October 2015 17. www.amercon.com, Octopus on board
8. IMO MSC/circ. 608 “Interim guidelines for open-top contain- 18. https://www.drewry.co.uk/maritime-research-products/
er ships” multipurpose-shipping-annual-review-and-forecast-201920
9. DNV-GL Rules for classification Part 6 Chapter 5 Section 2 “Ships 19. https://www.dynamar.com/
Designed Without Hatch Cover Hatchcoverless” July 2017 20. https://www.toepfer-transport.com/tt-reports/mpp-report/
10. N. van de Minkelis A. de Bruijn “Voorwaarden voor varen met 21. https://www.dnvgl.com/maritime/insights/publications.
open top” SWZ|Maritime, July/August 2018 html?takeCount=1
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