DONGE FLUSHING YARD Introduction: Donge Flushing Yard (DFY) designs and constructs dredging and port equipment. DFY has developed 6 major standard product-types. Macon Charter, a sister company, charters out dipperdredger/ backhoe-dredgers and other equipment, such as offshore pontoons and splitbarges, worldwide. 1 This combination of using and constructing equipment improves the quality of our products since 25 years. History: DFY was founded in Raamsdonksveer, NL, around 1830 and got its B.V. status in 1966, when the present owner took over the exploitation. The yard started as a supplier and repairer of small wooden row-boats and merchant sailing vessels. Especially in the first years after the World War II, the repair, rebuilding and enlarging of inland vessels was a rich field. Since the 1970 s, the yard has concentrated entirely on new construction and has succeeded in achieving its own place as an independent dredging and port equipment supplier. 90% of the production is exported all over the world and via existing standard programme in New Zealand, Thailand, Turkey, Portugal, India and the USA. 2 3 In 1977 a sister company Macon Charter was founded, which deals with leasing and chartering dredgers and offshore pontoons; the dredging experiences thus gained are integrated in the design of present new tools. In 2000 a new, second shipyard was founded. Design and development: All designs are done in-house and as most ships are standard, extra emphasis can be laid on development. 4 Production programme: In order to guarantee a reasonable price, a good delivery time and a max. developed vessel with many standard parts, we set up a standard range of: 1. Backacter Dipperdredgers 2. Self Elevating Platforms 3. Cranebarges and splitbarges 4. Drill barges 5. Truckboats 5
1. BACKACTER DIPPERDREDGERS DFY developed the only standard building programme for dipperdredgers. The different types are adapted to the range of excavators, working depths and to the specific site / environmental conditions. In 1977 an affiliated Macon Charter was founded, which deals with leasing and chartering dredgers including crew; the dredging experiences thus gained, are integrated in the design of present and new equipment. As from 1977 till today, 80 classic dipperdredgers with adapted Mining machines have been designed and build by us and 200 charter jobs were executed for main dredging contractors. In all cases our dredging equipment is chartered out with our own crew. Thus we have dredging experience in-house. In 2005, due to the technical problems and incapability with especially the big classic mining excavators we designed the one and only marine excavator, the Backacter, of which about 20 units have been delivered. Our designs have been standardised. Nevertheless various options and special client requirements are easily integrated in these designs as practically any variation has been made before in our many deliveries, e.g.: Collapsible spuds for the passing of bridges, increased stability, accessibility to lower sheaves Monohull or demountable. Self-propelled or non-propelled, etc. All products are delivered according class requirements of e.g. Bureau Veritas, Germanischer Lloyd, Lloyds, ABS, etc.
In 2005/2006, the design and production of the Backacter series started. The development of these Marine-excavators derives from more than 30 years in dredging with heavy, classic, mining excavators world-wide. With the development of the Backacter, being world s first Marine dredging excavator, the performance of these specialized excavators has much increased and optimized in terms if production, penetration force, reliability, maintenance, etc. Five Backacter types are available: BA 1100, BA 900, BA 800, BA 700 and BA 600 BA 1100 The Backacter (BA) 1100 is the biggest and strongest marine excavator in the world. Its own weight is about 525 tons, not taking in account the weight of its powerpacks which are positioned inside the hull. On the photos, the BA 1100 dredging is shown with a 18 meter monobloc, 6.5 meter stick and a 25 m 3 SAE bucket. The maximum dredging depth with this attachment is about 18 meters. Other attachment combinations are : Boom 18.00 m, Stick 10.5 m, Bucket 20 m 3 SAE, max. depth about 22.00 m Boom 23.80 m, Stick 6.5 m, Bucket 20 m 3 SAE, max. depth about 22.00 m Boom 23.80 m, Stick 10.5 m, Bucket 15 m 3 SAE, max. depth about 26.00 m Boom 23.80 m, Stick 17.3 m, Bucket 10 m 3 SAE, max. depth about 32.00 m BA 900 The BA 900 is one of the biggest and strongest marine excavator in the world. Its weight is about 380 tons, not taking in account the weight of its powerpacks which are positioned inside the hull. On the photos, the BA 1100 dredging is shown with a 18 meter monobloc, 6.5 meter stick and a 25 m 3 SAE bucket. The maximum dredging depth with this attachment is about 18 meters. Other attachment combinations are : Boom 16.0 m, Stick 7.0 m, Bucket 18 m 3 SAE, max. depth about 18.50 m Boom 16.0 m, Stick 10.0 m, Bucket 13 m 3 SAE, max. depth about 21.50 m Boom 20.0 m, Stick 10.0 m, Bucket 10 m 3 SAE, max. depth about 25.00 m Other attachment combinations are also possible.
Since 30 years the dipperdredger design has been standardized into several types. For example, the D-type and S-type of dipperdredgers are the biggest available type and both are suitable to work at sea. DFY designs and builds them in such way that its structural elements and lifting systems can suit such demanding environment, also on the long run. DFY has adequate understanding of the conditions which can occur in a real-live dredging operation. Our designs are based on these experiences, instead of merely on the basis of calculations / the drawing office. Some conditions that can occur are: CURRENT SURVIVAL What can this kind of dipper cope with, when it gets tough?! DFY s affiliated charter company Macon Charter executed approx. 250 dredging jobs with this kind of heavy equipment, enables us to show you some examples: Project: Penarth, near Cardiff, UK, in an area where currents of 12 km/hr exist. Here tidal levels vary till 13 m. In this area we dredged a trench in hard limestone. It has to be considered that the tug cannot hold the dredge in such extreme, transverse, directed currents! Nevertheless the spuds were to be put down on the seafloor, imagine the stresses the spuds had to cope with. Project: Cape Lambert, Ore-loader cleaning, 2 km. offshore Suddenly in Australia swell can and came up as high as 5 m. The S1-type dipperdredger Obscured By Clouds proved able to cope with these waves, while lifted to its max. and standing on the ends of its 30 m. legs. Green seas came on deck and the barge was jumping as high as 6 m up and down. WAVES PENETRATION Project Aveiro, Portugal About 20 tons weighing Tetrapods had to be dredged in the surfzone. Long, high waves caused problems, but no damage to the dredge. Project: Barcelona, Spain 2008 The BA 1100 performing a demolishing job breaking and removal of concrete caissons. The breaking up of caissons is however no normal dredging practice.
2. SELF ELEVATING PLATFORMS For the offshore industry, we offer a standard range of self-elevating platforms (S.E.P.). The engineering, drawings and construction of our S.E.P.'s are done by ourselves, in accordance with the latest technical insights and classed in conformity with the latest rules for Offshore Platforms Bureau Veritas, Germanischer Lloyd, ABS, etc. In 2001, the engineering started of the first big S.E.P. for our client "Mammoet", dim. 90 x 33 m., which is jacked- up and down by means of our standard winch-wire rope principle. Traditionally S.E.P.' s were elevated by hydraulic cylinders. As a hydraulic cylinder system has many disadvantages, we designed a system which operates with hydraulic winches in combination with a wire-ropereeving-system. The design is similar to the spud design of our -standard- large dipperdredgers. Winches are placed below deck e.g. to keep a clear, spacious deck. Besides the engineering of the legs, the construction of these legs, its legcans and accommodation was done. The diam. of the legs is 3.5 m.; some of the biggest square legs ever build. An even bigger (dimensions: 112 x 32 x 7.5 m.) and self-propelled S.E.P. was engineered by De Donge for an English client. Model impact tests were executed at the Dutch Marin institute, which proved that our design can lift out and into the water while coping with 2 m significant waves, which raises considerably the number of days such S.E.P. can be operational.
3. CRANEBARGES & SPLITBARGES The design and construction of cranebarges and splitbarges is also one of our specialities. E.g. In 200 we delivered the Kee 315 for the Harbour Authorities of Keelung, Taiwan. This self-propelled, spudstabilised cranebarge, equipped with a 150 tons Amclyde crane, is used for dredging and salvage operations. The 150 tons crane is mounted on a 15 m. high pedestal. Donge Flushing Yard has one of the most modern Yards in The Netherlands. All work is done under cover and with max. efficiency: 3 gangway cranes of in total 192 tons! assemble the ship sections and other parts on the covered slipway. A vessel of max. 4000 tons can be pulled out of the water. A large number of splitbarges has been delivered over the years in all kinds of shapes and sizes. E.g. we designed / build splitbarges ranging from 100 m3 to 5000 m3 (worlds biggest).
4. DRILLBARGES In 2003 DFY received an order of the Panama Canal Authorities (PCA) for the delivery of a drilling platform which is foreseen to execute the drilling and blasting for the widening of the Panama Canal. A special drillbarge was designed with the objective to create the most modern and best drillbarge in the world, named Baru, which is in many aspects improved than the drillbarge Thor also owned by the P.C.A. which dates back from the 1960 s. We mention the following key features: The barge can be lifted out of its floatation by means of its 4 spuds which are operated by hydraulic winches, thus the barge can continue drilling while seaships pass inside the canal. The barge has 4 drilling towers which can be shifted alongside the barge as well as outside the barge! The latter is done by hydraulic cylinders. Thus an optimal drilling pattern can be delivered with minimal repositioning of the barge / time consumption. In cooperation with the Panama Canal Authorities and our drill tower supplier Klemm a new drilling technique has been developed which minimizes the time and effort inwhich a hole can be delivered. Often can one observe how much time is lost during a dredging operation due to inefficient drilling and blasting. This is often primarily caused by the fact that the present drilling and blasting unit is a collection of pontoon, land-based drilling equipment and much improvising.
5. TRUCKBOAT In order to serve the transport e.g. in isolated areas for transportation of components, oils, spares, etc. between floating equipment and shore. Two sizes amphibious Truckboats were developed: - Truckboat TB30 transports cargos up to 25 tons, dimensions 14 x 4.0 m - Truckboat TB50 transports cargos up to 50 tons, dimensions 19 x 5.4 m Various hold types can be delivered Donge Flushing Yard B.V. Portugalweg 3, 4455 TZ Nieuwdorp, Harbour nr. 5910, Vlissingen-Oost, Netherlands Tel. +31(0)113.613100, Fax. +31(0)113.614190 Email: info@shipyarddedonge.nl Website: www.shipyarddedonge.nl