The project team designated the barge LABROY 237 as a staging platform for rock-handling operations. Heavy off-road dump trucks would drive onto its deck and deposit rocks weighing up to 4 tonnes, while wheeled loading machinery needed to manoeuvre freely across the surface.

When engineers assessed the existing deck structure, however, they found it could not withstand these demands. Under such loads, the deck would have deformed permanently, creating surface irregularities that would impair equipment performance and introduce operational hazards.

To solve this, the team engaged SPS Technology to design and deliver a deck-strengthening solution. SPS provides far greater strength and impact resistance than conventional single-plate steel, which makes it well suited to the punishing conditions of rock handling.

Critically, the elastomer core absorbs and distributes impact energy, meaning that loads from dropped rocks or heavy machinery spread across a wider area rather than concentrating at a single point, substantially reducing the risk of surface damage.

The strengthened deck demonstrated a 67% increase in load-bearing capacity, rising from 15 to 25 tonnes/m². Structural analysis and computer modelling confirmed the upgraded deck safely accommodated all planned heavy equipment without sustaining permanent damage under normal or overload conditions.

A team at the Arab Heavy Industries Shipyard in Ajman, UAE completed the works in March 2007.

In just eight days, the existing deck of the barge was blasted and cleaned by Keppel Engineers before new 25 mm backing bars and a new 25 mm steel plate were welded in place. The resulting 25 mm airtight cavity was then injected with the elastomer core.

Notably, apart from blasting and cleaning, no interference with the barge structure or underdeck services was required. Moreover, the advantages of the SPS system extended beyond this.

By using SPS to strengthen the deck, the deck:

• withstood the intense point loads imposed by earth-moving plant, where conventional stiffened steel structures remained vulnerable
• provided a consistent, flat deck surface, eliminating weak points associated with traditional repairs
• had significantly improved durability under heavy operational use.

Repairs were completed quickly, minimising downtime and shortening repair schedules. Sandwich Plate System enabled rapid return to service with minimal interruption to operations.