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Abfad ltd Company Profile November 2014

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Innovative Project Management and Solution
Development of Rope Access Projects
Abfad Ltd takes a unique approach to Rope Access Services; we focus on developing rope access skills for trade personnel. Time‐ served
welder, for example, can be taught the specific rope access skills however methodologies for actually performing hot work at height need
to be fine‐tuned to carry out welding work efficiently, productively and safely, the same level of expertise can be delivered to all trades by
short in house training.
Many rope access personnel now train on a three day blasting and spraying course through OPITO (Offshore Petroleum Industry Training
Organisation) and promote themselves as blaster/sprayers, they do not have the necessary skills to perform this work safely or provide the
quality necessary for clients. Abfad can deliver scalable trade testing to ensure that personnel mobilising do have the necessary trade skills to
perform the work.
We believe the correct process is to train trades persons to work at height so they can provide a quality service for clients.
Unskilled persons with a rope access level 1 or 2 need to be apprenticed with skilled labour so they can attain the necessary skills to be a
valuable asset to a company. ABFAD Ltd take this approach with our personnel and train necessary skills as required for projects.
Falls from height are the most frequent cause of fatalities at construction sites and continue to be a major concern with the HSE. It is
particularly important that Health and Safety Systems are second to none when working at heights. ABFAD has a remarkable history of safety
during our 16 years in business. Although I have good experience in H&S offshore and onshore over the past 30 years I maintain training in Occupational Health and Safety and am currently finishing an NVQ level 5 in Occupational Health and Safety, modules I am informed are equivalent to Degree Level.
World‐class Technology Solutions
 Abfad have also developed a patented double skin lining system for underground and above‐ground storage tanks.that is currently in the final stages of accreditation from Europe’s most significant assessment arm TUV Nord. The system has already generated huge interest on the worldwide stage, with significant enquiries being generated from as far afield as China, Saudi Arabia, United States and Canada.
 FUELVAC® double skin liner is the most environmentally‐friendly system developed and in use in the UK and, we believe, the World.
The system uses engineered manufactured materials and solvent‐free resins which creates a seamless liner.
A description of the features and benefits of the system is also available on the website.

 Since 2006 to present time over 100 underground storage tanks have been installed within the UK and in 2011 Abfad double skin lined two tanks for Simon Storage. FUELVAC® double‐skin liner installed with vacuum leak detection monitoring is the highest fo

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Abfad ltd Company Profile November 2014

  1. 1. Specialist Rope Access Services A Presentation by Abfad Ltd November 2014
  2. 2. Company History & Profile Providing National & International Services: • Rope Access Multidiscipline Trades • Tank Linings for Diesel, Petrol, Bio‐Fuels, Ethanol and Aviation Fuel (Single & Double Skin with Environmental / Containment Monitoring) • Fast Set Solvent Free Coatings for long term Protection for Steel & Concrete (Single Application up to 2mm + using Plural Hot Feed System) • Civil & Industrial Engineering Services to suit Clients Requirements • Coatings for the Water Industry
  3. 3. Key Personnel Chris Haritou ABFAD Projects / Health & Safety Director. Employed for over fourteen years continuously within the U.K. offshore oil and gas industry. I have been responsible for offshore planning, logistics, administration, materials, and documentation requirements for the various disciplines for the Construction and Maintenance department, which has numbered up to 1200 personnel. Largest project involved with was Third Party Installation of new subsea pipelines and safety valves, installation of new Gas Module with associated pipe work including full commissioning into existing facilities, project cost £600 million. Through a close working relationship with instrumentation, electrical, black trades, painting, scaffolding and rope access department’s I have gained valuable experience in planning, material take off, scheduling and monitoring projects to their completion. Since 1996 to date been involved with establishment and general office management including controlling project and health & safety operations in coordination with Abfad co. Directors.
  4. 4. Key Personnel Alan Fada ABFAD Operations Director Alan has 33 years experience in Blasting / Spraying within shipyards in the United Kingdom, Europe and Offshore North Sea Oil Fields including the Middle East – United Arab Emirates. Specialized in Rope Access Blasting and Spraying Offshore Jackets, Modules and Flare Towers. Developed safety rope methodology whilst blasting and spraying from ropes and trained blast / spray personnel offshore in these techniques. Since 1996 to date been involved with Managing Projects on behalf of ABFAD Ltd consisting of high level engineering activities to application of protective coating for steel and concrete including installation of Double Skin tank liners complete with vacuum leak detection monitoring equipment. Oversees training of apprentices for rope access blasting and spraying techniques including plant maintenance and operation.
  5. 5. Innovative Project Management and Solution Development of Rope Access Projects Abfad Ltd takes a unique approach to Rope Access Services; we focus on developing rope access skills for trade personnel. Time‐ served welder, for example, can be taught the specific rope access skills however methodologies for actually performing hot work at height need to be fine‐tuned to carry out welding work efficiently, productively and safely, the same level of expertise can be delivered to all trades by short in house training. Many rope access personnel now train on a three day blasting and spraying course through OPITO (Offshore Petroleum Industry Training Organisation) and promote themselves as blaster/sprayers, they do not have the necessary skills to perform this work safely or provide the quality necessary for clients. Abfad can deliver scalable trade testing to ensure that personnel mobilising do have the necessary trade skills to perform the work. We believe the correct process is to train trades persons to work at height so they can provide a quality service for clients. Unskilled persons with a rope access level 1 or 2 need to be apprenticed with skilled labour so they can attain the necessary skills to be a valuable asset to a company. ABFAD Ltd take this approach with our personnel and train necessary skills as required for projects. Falls from height are the most frequent cause of fatalities at construction sites and continue to be a major concern with the HSE. It is particularly important that Health and Safety Systems are second to none when working at heights. ABFAD has a remarkable history of safety during our 16 years in business. Although I have good experience in H&S offshore and onshore over the past 30 years I maintain training in Occupational Health and Safety and am currently finishing an NVQ level 5 in Occupational Health and Safety, modules I am informed are equivalent to Degree Level.
  6. 6. Scope of Trade Testing Can include but not limited to:  Rope Access Blasters  Rope Access Paint Sprayers / Hand Coating  Rope Access Substrate Mechanical Preparation to St3  Rope Access Welding / Cutting / Drilling (hot work)  Rope Access Cladding Repairs and Sheet Replacement  Rope Access Instrumentation / Electrical Applications
  7. 7. Clients (but not limited to) • Simon Storage • Shell UK • Total UK • BP Global Alliance • Network Rail • Sabic • Huntsman UK (Refinery / Oil & Gas) • E.ON (Powergen) • EDF • Vestas Celtic Wind Technology Ltd • Repower • Newcastle University • Foster Yeoman (Marine Industry) • Canadian Coastguard • M‐Real (Pulp & Paper Industry) Sir Robert Mc Alpine Amec British Energy Adgas (UAE) Norwest Holst Vinci Vesta Wind Turbine Limited Local Authorities Halcrow Nuttall Nissan AlcanCITB (Construction Industry Training Board) MOD Naval Base (Portsmouth) Raytheon James Hall & Co. (Spar Brand) Center Parcs
  8. 8. Significant Rope Access Projects Undertaken by Abfad  Das Island, Abu Dhabi, Middle East to change out Flare Tip and structural modifications on Flare Tower. Complete blast and coating of another Flare Tower from tip to sea level.  BP Coryton Refinery inspections, mechanical and structural activities.  North Tees Refinery Flare Tip change out / Vertical alignment surveys of stacks / NDT Inspections / Bund Coatings / Stack Coatings, etc.  Jodrell Bank Telescope Coatings and Radio Dish Steel Plate Replacement (designed system to enable plates to be replaced on telescope surface which has been adopted on other telescopes around the World – our design patented by Manchester University.  Set up Company in Canada Nova Scotia and applied solvent free coating to Lighthouse internally and externally and to navigation buoys and sea chains; heating oil storage tanks – ceased trading in Canada 31st March 2005.  Renewable Blade Inspection which ABFAD has performed for E.ON on a large onshore Wind Farm in Scotland. We are currently looking into new technology for blade repairs as these structures are increasing in numbers within the UK.  In addition to the coating refurbishment (rope access blasting and spraying) which we are currently employed on for Climate & Renewable Utilities Company for their 30 Offshore Wind Turbines we also supply rope access trade services to Power Stations throughout the UK.
  9. 9. Power Station Boiler House Roof Fabrication and installation of high-pressure vent cowlings as detailed on roof structure by use of rope access
  10. 10. Power Station Boiler House Roof Fabrication and installation of high-pressure vent cowling and cladding repairs by use of rope access
  11. 11. Power Station Boiler House Roof Fabrication and installation of high-pressure vents by use of rope access
  12. 12. Power Station Transformer Housing Mechanical preparation and coating project by use of rope access. Scaffolding not permitted within area.
  13. 13. Power Station Transformer Housing Full primer applied after mechanical preparation complete ready for mid and finish coat application.
  14. 14. Power Station Auxiliary Boiler Stack Removal of cladding and insulation, inspection of flange joints with coating repairs and reinstatement
  15. 15. New Wembley Stadium Coating and welding by rope access on high-level beams and arch
  16. 16. New Wembley Stadium Coating detail on arch
  17. 17. New Wembley Stadium 60 rope access technicians applying protective coating to all high level beams
  18. 18. Offshore Met-Mast within Wind Farm Rope access blasting with magnet system
  19. 19. Offshore Met-Mast within Wind Farm Rope access spray painting Installation of fabricated clamps and new ladder sections
  20. 20. Offshore Met-Mast within Wind Farm Installation of fabricated clamps and new ladder sections
  21. 21. Offshore Met-Mast within Wind Farm Hydrotight hydraulic securing of clamps
  22. 22. Offshore Met-Mast within Wind Farm Structure painting complete, clamps installed and ladder sections connected
  23. 23. Offshore Met-Mast within Wind Farm Met Mast off the Yarmouth Coast, Scroby Sands. Due to corrosion and mechanical damage to access ladders, a tender was awarded by E·ON Climate & Renewables UK Ltd. Project was to fabricate new ladder sections and eight clamps, blast clean the structure to SA2.5 and apply a protective coating, remove existing damaged ladder sections, install new clamps, tighten using Hydratight hydraulic equipment, then install new ladders to structure. 1 2 Photograph detailing corrosion to underside of main support steelwork of walkway. 3 Close up detail of scale corrosion to main steelwork just below walkway. Photograph also shows blast standard where corrosion has been removed by shot blasting. 4 Blast operations to Met Mast main stem using rope access techniques and revolutionary patented magnets to hold the operative in position during blasting operations.
  24. 24. Offshore Met-Mast within Wind Farm Spray coating steelwork after blasting works complete. 5 6 ABFAD Ltd trained personnel tightening clamps using Hydratight hydraulic equipment. 7 Fully refurbished, picture detailing new clamps and ladder sections installed, all works fully complete and commissioned. Completed project detailing fabricated ladder and clamps installation
  25. 25. Offshore Wind Farm
  26. 26. Project Case Study Scroby Sands Wind Farm is an offshore wind farm located 1.5km off the Norfolk coast. The wind farm consists of 30 Wind Turbine Generators each rated at 2MW, mounted on mono pile foundations. The development has been operational since 2004 and is one of the UK’s first commercial offshore wind farms located at Scroby Sands in Great Yarmouth, owned and managed by E.ON. ABFAD Ltd successfully won this three year contract to refurbish the mono pile steelwork from grating elevation to sea level deploying rope access techniques. Work consists of; 1. Removing gratings and davit arms in stages 2. Blasting steelwork structure to SA2.5 standard to remove corrosion, profiling existing coating and feather back all edges prior to coating application 3. Spray apply protective coating 4. Reinstate gratings and davit arms Phase 1 2012 refurbish area of steelwork as far as Mono pile collar section below grating support steelwork. Phase 2 To refurbish all steelwork down from below collar section to sea elevation. Work has been performed with ABFAD Ltd unique magnetic positioning aid clamp in conjunction with rope access equipment. The magnetic clamps assist rope access blaster sprayers to hold their position whilst suspended from ropes reducing standard time norms when performing their work activities to the highest quality. Grit blasting performed using highly skilled roped access techniques 1 Workboat alongside mono pile carrying all necessary tools and equipment to perform blasting, coating and mechanical works. 2 Removal of gratings and davit arms in preparation for grit blasting. 3
  27. 27. All corrosion removed to blast standard SA 2.5 and sound paint profiled to take new coating 4 New protective coating, airless sprayed applied to the required thickness. 5 New protective coating applied to underside of walkway. 6 New protective coating applied to top sides of walkway. 7
  28. 28. Re-install gratins and davit arms. 8 Phase 1 refurbishment to walkway and underside of mono pile complete. Phase 2 will take mono pile refurbishment from underneath top collar section below gratings down to sea level. 10 9 Re-install gratings.
  29. 29. Offshore Wind Farm Mono Pile Coating Restoration Rope access blasting
  30. 30. Offshore Wind Farm Mono Pile Coating Restoration Before and After shots of restoration project by use of rope access and magnets
  31. 31. Offshore Wind Farm Mono Pile Coating Restoration Refurbished Mono Pile
  32. 32. Offshore Wind Farm Mono Pile Coating Restoration Refurbished Mono Pile also detailing stencilled number of structure
  33. 33. Offshore Wind Farm Mono Pile Coating Restoration Rope access spray painting opposite completed Mono Pile
  34. 34. Ocean Nomad, semi-submersible Rope access services
  35. 35. Ocean Nomad, semi-submersible Removal of steam vent pipe from drilling derrick
  36. 36. Ocean Nomad, semi-submersible Removal of steam vent pipe from drilling derrick and installation of newly fabricated pipe by means of rope access
  37. 37. Ocean Nomad, semi-submersible Mechanical preparation of steelwork by rope access
  38. 38. Ocean Nomad, semi-submersible Mechanical preparation of steelwork by rope access
  39. 39. Light house tower (Canada) fully encapsulated internally and externally with a fast set polyurethane 2mm thick Fast set polyurethane coating, single application 2mm thick to shipping lane navigation aids
  40. 40. Ongoing R & D Providing Innovative, Patented Solutions to Engineering Problems With its engineering experience, the Abfad team have focused on bringing innovative, cost‐effective solutions to common engineering problems. While primarily designed with the offshore industry in mind, these solutions have a multitude of uses and can be applied equally effectively to land‐based operations. A prime example of this is our patented permanent magnet units that have proven invaluable in areas that can only be accessed by rope but need a method of moving the rope technician closer to the substrate to be worked on and anchoring them securely to facilitate the various works to be carried out. The market for these magnets we believe is huge and we have produced our 2013 model recently which provides a superior performance. Abfad’s deployment of this unique magnet system provides a productivity advantage. Its use increases speed of work such as blasting, St3 mechanical surface preparation, welding, drilling , NDT inspections etc. as they secure rope access trade persons to steel substrate providing precision quality work.
  41. 41. Magnet Certification STANDARD TEST ‐ static pull test on 50mm segmented ground plate Serial no 00100 Pull off 368kg Serial no 00101 Pull off 402kg Serial no 00102 Pull off 390kg Serial no 00103 Pull off 422kg Serial no 00104 Pull off 410kg Serial no 00105 Pull off 378kg Serial no 00106 Pull off 364kg Serial no 00107 Pull off 398kg Serial no 00108 Pull off 410kg Serial no 00109 Pull off 402kg
  42. 42. Industrial cleaning of vessel by means of rope access with unique magnet system
  43. 43. Mono Pile Coating Restoration Blasting structure by means of rope access with unique magnet system
  44. 44. Thalassini Kyra Coating repair by use of rope access and magnet system
  45. 45. Thalassini Kyra Coating repair by use of rope access and magnet system
  46. 46. Blister / Ballast Tank Construction Shot showing rope access welder secured by magnet system
  47. 47. BP Schiehallion Cosmetic coating of complete vessel by use of ropes and magnet system
  48. 48. Middle East Flare Structure Rope access blasting
  49. 49. Offshore Oil and Gas Platform Offshore Jacket Spray Coating
  50. 50. Damhead Creek Power Station Mechanical preparation of weld seams, stripe coating, full up-coat of structures by use of rope access and magnet system
  51. 51. HMS Warrior 1860 Coating refurbishment of masts, yard arms, funnels, etc. by use of rope access
  52. 52. Rope access welding
  53. 53. Millennium Stadium, Cardiff Rope access coating, refurbishment
  54. 54. MISSION IMPOSSIBLE… Major refurbishment of concrete ceilings in working Paper Mill Kemsley Paper Mill, Kent ABFAD provide a range of specialist services to industry, but a project to refurbish the ceiling and replace walls in a modern paper mill presented a range of unique and demanding problems. For example: • no disruption to the mill’s 24 hour a day operations was allowed • hostile humidity and temperature (45-60°C) conditions had to be overcome • health and safety of mill employees, ABFAD technicians and applicators, and the safety of sensitive paper process equipment had to be assured Against strong competition from major civil engineering and construction companies, ABFAD secured the contract with an innovative plan involving the design, fabrication and installation of suspended decks and platforms and the use of advanced Copon sealant, polyurethane and finish coat systems. Project highlights Some 5000sq.m of the concrete ceiling running the length of the mill had to be cleaned, repaired and prepared for treatment, and two concrete walls either side of a large skylight atrium had to be removed and replaced with WARD insulated wall panels. To tackle these requirements ABFAD:  created a mobile platform (35.6m x 8m) and installed its two main beams on the mill’s own overhead crane rails using a 300 tonne crane  completed platform fabrication and installation using rope access technology and rigging equipment to secure interconnecting sections  designed and installed a special steel deck, plate by plate, using rope access/rigging to span to 176ft skylight atrium opening  designed a secure disposal system to deal with over 200 tonnes of debris  ensured all ceiling/atrium working areas were sealed to prevent debris spillage and equipped with effective environmental controls Protective coatings The client selected three Copon guaranteed warranty coatings systems to protect the renovated mill ceiling:  Copon 165 sealer – designed especially to penetrate porous concrete and increase its tensile strength, and act as a primer for a range of solvent free urethane coatings  Copon 170 EL – an elastomeric polyurethane rapid cure flexible lining that is impact, abrasion and chemical resistant. It provided a fully waterproof coating to prevent any deterioration in the mill’s humid atmosphere  Copon HBF – a single pack moisture cure polyurethane designed to give a cosmetic but resilient colour fast finish The ceiling was renovated to specification in just 8 weeks – 4 weeks ahead of schedule, with a 100% safety record, and no disruption to mill operations.
  55. 55. Scaffold walkway installed to remove reinforced concrete walls within atrium. Ventilation fans and trunking can be seen to cool area above Paper Mill machine during wall removal.
  56. 56. Photograph details Atrium with concrete walls removed. WARD insulation panel installed.
  57. 57. View of refurbished concrete ceiling, atrium WARD insulation boards. Working platform and atrium deck plates for refurbishment work detailed in photo. Atrium deck panels can be seen spanning between roof sections overhead platform at far end of picture.
  58. 58. Photograph detailing refurbished concrete ceiling, WARD insulation panels and overhead working platform
  59. 59. YEOMAN BRIDGE Cargo Hold Bulkhead Coating Case Study Project was to protect the steel bulkheads from further deterioration suffered from coal and granite loadings. Coal contains sulphur which causes severe corrosion when in contact with the ship’s steelwork. After steel was blast cleaned it was apparent that steel was extremely pitted due to corrosion as detailed in photographs below. The solution after blasting complete was to coat the cargo holds using a solvent free urethane which could be sprayed in one application up to 3mm at the same time, saving valuable time in dock. Resin completely encapsulated the steel providing a barrier for future granite loadings.
  60. 60. Yeoman Bridge Picture detailing scaffold erection and condition of bulkheads. Granite cargo hold, blast and protective coating project of bulkheads
  61. 61. Corrugated Bulkheads blasted to SA 2.5 standard prior to coating application. Fast Set Urethane applied to cargo hold bulkheads and ladder sections to a thickness of 3mm (3,000 microns) in 1 single application using plural component heated spray pumps.
  62. 62. Yeoman Bridge Detail of protective coating to bulkheads at 3mm nominal thickness applied to corroded steel
  63. 63. Lisnave Shipyard, Portugal – location of project. Granite loading into cargo holds. Paint thickness reading detailing readings with little or no wear of the solvent free resin taken 9 months later in the Cargo Holds
  64. 64. Company Accreditations • ABFAD Limited is accredited to ISO 9001:2008 and OHSAS 18001:2007 for Industrial Rope Access; Specialist Coatings including Tank Linings using 100% Solvent Free Epoxy and Polyurethanes. • ABFAD Ltd is also audited to work in the Oil & Gas Industry and have passed all external audits from major clients including Total UK, Shell and BP. • ABFAD Ltd is a full member of IRATA, NESHEP (North East Safety, Health and Environmental Partnership), NECC (North East Chamber of Commerce), APEA (Association for Petroleum and Explosives Administration, PEIMF (Petroleum Equipment Installers and Maintenance Federation and British Standards Institute. • Chris Haritou is a member of the UK BSI Committee to revise the European Double Skin Tank Lining Standard EN 13160‐7, meetings across Europe and in London which is still ongoing. Personnel Training All personnel are trained to IRATA standards Level 1, II, & III. Personnel are also trained for working in Confined Spaces, First Aid, Safety Passport for Construction; Explosive Environments; Network Rail ; Abrasive Wheels; Insulation and Cladding; Steel & Concrete preparation; blasting & spray coating; mechanical preparation to St3 and hand coating using traditional painting techniques as well as Hydracat solvent free coating; double skin lining installation; plant safe operation. Specific training for trade work is performed in addition to basic level of skills.
  65. 65. Accreditation ISO 9001:2008 OHSAS 18001:2007 Full IRATA Member BP HSSE Accreditation
  66. 66. Testimonials Numerous testimonials, including many from Blue Chip companies, are available on request
  67. 67. World‐class Technology Solutions  Abfad have also developed a patented double skin lining system for underground and above‐ground storage tanks that is currently in the final stages of accreditation from Europe’s most significant assessment arm TUV Nord. The system has already generated huge interest on the worldwide stage, with significant enquiries being generated from as far afield as China, Saudi Arabia, United States and Canada.  FUELVAC® double skin liner is the most environmentally‐friendly system developed and in use in the UK and, we believe, the World. The system uses engineered manufactured materials and solvent‐free resins which creates a seamless liner.  To view an animation of the system please visit http://www.storagetankrepairscompany.com/fuelvac/install‐process/ scroll down on the home page and the animation will run. A description of the features and benefits of the system is also available on the website. The animation details single skin coating application in storage tanks using solvent free resins and the double skin installation process.  Since 2006 to present time over 100 underground storage tanks have been installed within the UK and in 2011 Abfad double skin lined two tanks for Simon Storage. FUELVAC® double‐skin liner installed with vacuum leak detection monitoring is the highest form of monitoring that exists.
  68. 68. brought to you by T. +44 (0) 191 543 7166 ‐ E. info@abfad.co.uk Directors: Chris Haritou & Alan Fada Registered Office: Unit 8, Teal Park Way, Teal Park Farm, Washington, Tyne & Wear, NE38 8BG

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