It takes a strong team to build a berth together

We recently completed a major berth expansion project in India for our client Afcons Infrastructure Limited. Afcons subcontracted the JSI Alliance to perform critical heavy-lift operations for the construction of a new liquid cargo berth in Dahej.

Using the J-Class heavy-lift vessel (HLV) Jumbo Javelin, we transported and installed eight jackets and fifteen berthing dolphins weighing between 500 and 600 t. The structures were installed at an outreach of 10 m as part of the new berth development.

Complex and challenging undertaking

The project was carried out in a highly challenging environment. The site experiences a tidal rise of up to 10 m, resulting in currents reaching 5 kn. In addition, the seabed consists primarily of sand, making many conventional mooring solutions unsuitable.

The work also had to be executed alongside two live and frequently used berths, which remained operational throughout the project. This created significant space restrictions and added further complexity to the mooring arrangement.

To meet the project’s requirements, the JSI Alliance mobilised the Jumbo Javelin and equipped the vessel with a fly jib to perform the required lifting scope. Mobilisation commenced on 3 November and was completed over a period of fifteen days.

Custom heavy-duty mooring solution

To maintain the vessel’s position in the strong currents, the Jumbo Javelin was outfitted with a custom-designed eight-point mooring spread tailored to the local seabed and tidal conditions. Creating sufficient holding force within the restricted working area required the use of 17 t anchors and 64 mm and 52 mm mooring lines, each with a minimum breaking load of approximately 300 t.

The vessel was also fitted with custom-made 250 t winches. Following detailed engineering, it was decided to install eight winches rather than four, providing back-up wires to ensure additional safety and redundancy during operations.

The significant forces involved also required local strengthening of the vessel with additional steel. Installation of the mooring spread was supported by anchor handling vessels capable of managing the heavy-duty components. The moorings had to be installed within a four-hour tidal window when currents were at their lowest.

Once connected to the mooring spread, the Jumbo Javelin was able to remain in position for several days at a time, avoiding disruption to ongoing port operations.

Efficient execution and demobilisation

The first loadout took place at Dighi Port on 3 December. In total, the Jumbo Javelin completed six voyages between Dighi and Dahej. The final component was installed on 14 March, after which the vessel returned to Dighi Port for demobilisation.

Demobilisation was completed in just seven and a half days before the vessel sailed to Singapore to return equipment to suppliers. Discharge operations were completed within two days and the project was fully completed on 6 April.

Robert de Waard, Project Manager at the JSI Alliance, said, “The successful completion of this project is a testament to the teamwork, expertise and commitment of everyone involved. By drawing on the shared resources and capabilities of the JSI Alliance, we were able to develop a solution tailored to the complex site conditions and deliver the project safely and efficiently.

I would like to thank all those involved for their efforts, including my colleagues from all departments, as well as our suppliers, including Franklin Offshore International and Mooreast Asia, for their support with the anchor handling equipment. I would also like to extend my appreciation to Seacontractors, who supported Afcons with the provision of two vessels for anchor handling and contributed to the successful execution of the project.

Of course, we are also extremely grateful to Afcons for placing its trust in the JSI Alliance. Our two teams have worked together closely throughout the project, with Afcons being involved and providing expert guidance in all aspects. We have enjoyed the collaboration and look forward to working together again in the future.”