SC&RA Job of the Year: Axle line armada

Fagioli expertly planned and executed the loadout of the B212-Charybdis Offshore Wind Turbine Installation jack-up vessel built by Seatrium Amfels in Brownsville, Texas. The project involved 880 axles of SPMT, 28 power packs, three semi-submersible barges, four spacer barges and up to 10 tugboats.

Using 880 Scheuerle SPMT axle lines, Fagioli transported the 51 million pound vessel from the port onto three semisubmersible barges from where it was launched into the water.

In the process, Fagioli set three world records: largest number of axle lines under one load, heaviest weight ever moved by SPMT axle lines and heaviest load on wheels transferred onto multiple barges.

Execution required coordination with multiple international entities under tight time constraints. With barges in loadout configuration, the Port of Brownsville was shut down and Fagioli was given three days to complete the project.

“The first of its kind built at the shipyard, the vessel presented several issues, including weight and load distribution, which left the minimum amount for the support saddles,” said Fagioli’s Edoardo Ascione. “The loading dock, with its 2,000 psf maximum bearing pressure and 9-foot height above the water, combined with the vessel weight of over 51 million pounds and the center of gravity, were factored into equipment requirements. The result was 880 axle lines of SPMT in three groups. Three very large barges with sufficient buoyancy and an internal ballast system were required. But none were operating in the U.S.”

Sourcing the equipment

The central SPMT group with 340 axles was 150 and 115 feet away from the two side groups with 200 axles each. Ensuring communication among the 880 axles and 28 power packs was a major challenge. Several generations of equipment were used, requiring extensive vetting and compatibility testing. Long hydraulic hoses connected two groups for three-point support, enabling control from a single box.

Ensuring communication among the 880 axles and 28 power packs was a major challenge.

Fagioli sourced axle lines and power packs from its U.S., European and Asian fleets, with a few rentals in the U.S. The three barges were contracted from BOA Barge in Norway. The central barge, which measured 500 by 125 by 30 feet, is among the world’s largest. The two side barges measured 407 by 105 by 26 feet each. Despite their buoyancy, crane mats were needed to manage dock height and maintain level positioning during tidal cycles. Barges were connected by spacer barges and secured by winches, mooring lines and five tugboats.

Preparations took a year, factoring in equipment readiness, weather, tides and port traffic. The loadout date shifted several times, complicating asset availability.

By loadout day, the vessel was 1,500 tons heavier but still within equipment capacity. The first step involved positioning SPMTs under the vessel, confirming load distribution, center of gravity and operation. All three hydraulic groups measured the same weight. Once confirmed, the barges were aligned to the dock and the port was closed to maritime traffic. Alignment required 20 hours, using 30-ton winches, spacer barges, ramps and ballasting.

The vessel was then moved slowly over ramps onto the barges, with constant checks on vessel stability, SPMTs, winches, barges and tugboats. Once in position, the vessel lowered its jack-up legs into the water and transferred weight from the SPMTs to the barges. This step was challenging due to hydraulic and electronic connections spread across three moving platforms. Continuous communication ensured safety.

Fagioli sourced axle lines and power packs from its U.S., European and Asian fleets, with a few rentals in the U.S.

Once load transfer was complete, SPMTs rolled off the barges, and tugboats repositioned the barges and spacers to reopen the port’s navigational channel. The project finished well within the 72-hour window.

The vessel traveled about 1,000 feet from land to barge, all within the shipyard. Ground bearing pressure was mostly 2,000 psf, except for a soft spot that was bridged with steel ramps. The Ro-Ro ramps had to bridge an additional 12-foot gap from the jetty face.

Among the project’s key innovations were the hydraulic and electronic integration of 880 axle lines and 28 power packs from different generations moved together by a single remote control, both on land and on three separate barges.