Infrastructure Pvt. Ltd.

SINCE 1983

Lift & Weld System

 Statistics show that around 15% of all industrial accidents
are related to working at height and almost a third of these
are caused by a fall of over 2.5m in height.

Any Technology that can Minimise these

Risks is Surely Worth Considering.
Tank Storage Magazine - January 2012

01
Index
Lift & Weld Process 03
Retractable Jacks 05
Automatic Girth Welding Machine 07
Comparison 09
Jack Models 11 Infrastructure Pvt. Ltd.
Range of Services 13 SINCE 1983

Other Lifting Applications 15

Quality Control 16
Manufacturing Facility 17

Innovation has been the key at Bygging throughout its 30 year presence. Bygging strives to
deliver world class solutions to storage tank builders across the globe. With the introduction
of the “Lift n weld” system, we have added SAW automatic horizontal welding solutions for
both external and internal tank peripheries to our basket of tank lifting products. Our mission
is to help our customers build tanks FASTER, SAFER and make LARGER PROFITS.

02
 Lift &
Weld Process

Lift & Weld System

03
Working Principle TOP MOST
SHELL COURSE

STEP-1
ROOF RAFTER
WIND GIRDER

LIFTING LUG
LIFTING ARM

SPACER BEAM
450 mm HIGH

1. Annular plates and bottom plates are laid out and welded. HYDRAULIC JACK

2. Spacer beams (400 to 500 mm height) are placed on the annular plate at a spacing BOTTOM PLATE
of 2000 mm around the periphery of the tank shell. Spacer beams have guide cleats
welded onto them.
3. Top-most shell course (or top two shell courses) are erected on the spacer beams and
fixed roof construction is completed leaving 3 or 4 plates open in the roof for air to
vent through the roof.
4. Jacking equipment is installed inside the tank.
TOP MOST
SHELL COURSE
STEP-2
ROOF RAFTER & PLATE

5. Constructed part of tank is lifted up to a height required for the next shell course to be
placed on spacer beams.

STEP-3

TOP MOST
SHELL COURSE

6. Plates of the next shell course are erected on spacer beams and vertical welds are
completed. Lifted part of the tank is lowered down slightly to sit on the newly erected NEXT LOWER
COURSE
shell course, after which horizontal welding on external face is completed using
Bygging Automatic Girth Welding machine.

STEP-4

7. Once horizontal welds are completed, the tank weight can be released from the
jacks. Lifting and fend off lugs are cut off.
8. Control valve is opened to direct oil flow from powerpack to the retraction
mechanism and shut-off oil flow to the lifting jacks.
9. With the press of a lever, all jacks retract away from the tank shell creating space
between the inside face of tank shell and jack trestles, to allow the use of Bygging
SAW Single side AGW for internal welds.
10.Bygging SAW Single side AGW is mounted on the inside periphery of tank and
internal welds are completed.

STEP-5

11.After internal welds are completed, the AGW is dismounted and the trestles are
brought back hydraulically all at once to their original vertical position, ready to lift
04
the next shell course.
 Retractable
Jacks

05
 TRESTLE IN RETRACTED POSITION
INTERNAL WELDING IN PROGRESS

Retractable Jacks
Once the tank is lifted using our jacking equipment, and a new
course (shell ring) is placed, vertical welds are completed either
manually or using an automatic FCAW welding machine.
Thereafter external horizontal welds are done using our SAW
single side Automatic Girth Welding machine (Root weld can be
done either manually or using our Automatic Girth Welding
machine with the additional use of a ceramic backing strip).

1600 mm
After external welding, the tank load is released from jacks, lifting
lugs and fend-off lugs are cut-off, and with the push of the
operating lever on the same powerpack (which is used for lifting
jacks), all trestles retract away from the tank shell, to allow for
space for the use of the Bygging SAW single side AGW for internal

2500 mm
welds.

This allows optimum utilization of the AGW and considerably

reduces the need to employ manual welders, which would
otherwise be required for internal welds.

Once internal horizontal weld is completed, the jack trestles are

moved back hydraulically all at once to their original vertical
position, ready to lift the next shell course
TANK BOTTOM PLATE

(Patent applied)

Type of Jack & Girth Welding Machine Fast Lifting External welding Internal welding
(40 minutes to lift using Automatic using Automatic
up 2.5 mtr height) Girth Welding Machine Girth Welding Machine

Single Acting Jacks

Double Acting Jacks

Double Acting Jacks + Automatic

Single Sided Girth Welding Machine

Double Acting Jacks Retractable

Type + Automatic Single Sided
Girth Welding Machine

06
 Automatic
Girth Welding
Machine (AGW)

07
Technical Specification:
Welding plate width : For first / top shell - Min. 800mm
For subsequent shells - No restriction.
Tank diameter : Suitable for tanks more than 8 mtr in diameter.
Welding current : From 250 Amps Upto 1000 Amps at 100% duty cycle.
Output Voltage : 44V
Welding Speed : 250 mm to 700 mm/min
Idle Travel Speed : Upto 1000 mm per minute.
Wire diameter : 2.4 / 3.2 mm / 4 mm
Weight of Welding head : 216 kgs (approx.) without flux & wire spool.

Salient Features:
Bygging SAW AUTOMATIC GIRTH WELDER (AGW) for
SINGLE SIDE WELDING
Suitable for horizontal welding of storage tanks built using jacking system:

Make of Power Source - Lincoln Electric, USA.

Make of Wire Feeder - Lincoln Electric, USA.
Weatherproof Electrical cabinet.
Robust DC motor for tractor movement.
Auto flux recovery unit.
Fine adjustable manual cross slide for vertical & horizontal adjustment.
Weld head slide assembly.
Auto sensor for wire feeder speed.
Flux stored in Flux Recovery Unit as well as in Flux discharge hopper.
View glass in flux hopper & in Flux Recovery Unit
Same Power Source can be used for root welds and for FCAW / MIG / SMAW vertical welds.
Two or more FCAW / MIG / SMAW welding heads can be used using one Power Source (by using Multiweld
350) which increases vertical welding productivity by more than double.
Same mechanism can be used for Arc gouging.
Ambient temperature range at which the machine can work : -5 to + 65 deg C.
Machine is compact, light weight & can be handled without the need for a large crane.
Root welding with backing strip possible.
Bygging AGW’s output is equivalent to 6 welders. 08
 Comparison

Conventional Method Plain Vanilla Jacking

Comparision Between Conventional Method, Plain Vanilla Jacking Method and

Parameter Conventional Method Conventional Method
With Manual Welding With Automatic Welding

Method of erection Bottom to top

Crainage cost (cost of crane 30 to 40 ton capacity with 30 mtr boom: us $24,500 per month
rental including fuel) 70 ton capacity with 40 mtr boom: us $50,000 per month
Required for providing access to manpower for alignment of plates,
Scaffolding
welding, painting of underside of roof
Safety of workmen High risk of accidents from workmen falling from heights
Fixed roof construction Roof to be erected at height
Safety of tank shell Since the tank is without a wind girder until top-most shell is erected,
during erection tank shell is subject to stresses due to high winds during erection phase
Evacuation of personnel In case of an emergency during construction, evacuation of workmen working
in case of emergency at heights is time consuming and difficult
Incidence of weld repair High Low
Wastage of electrode butts High Nil
Cost of welding & grinding consumable High Low

Analysis of manpower and time required to erect tank shells of various sizes under d
Conventional
Welding Method Jacking Method of Erection
Erection Method

No. of Auto Days For No. Of Days For No. Of

Welding No. Of
Welding Total Days Placing And Fitters / Placing And Fitters /
Tank Shell Speed Welders And
No. Of Working Required For Erecting Shell Riggers Erecting Shell Riggers
Diameter Thickness Per Machine / Machines Helpers
Weld / No. Of Hrs Horizontal Plates, Aligning And Other Plates, Aligning And Other
(meters) (mm) Per Welder Required
Passes Manual Per Days Welding And Helpers And Helpers
(mtrs/ Min) For Welding
Welders Vertical Welding Required Vertical Welding Required

Mechanised External 4 1 1.26 2 16 4 24 Total days for 1 (one) shell course

0.333 4
Welding Internal 3 1 0.94 Total manpower required
20 10 Manual External 4 4 10 2.33 Total days to erect 6 shell course
0.045 10
Welding Internal 3 4 1.75 Total man days for shell

Mechanised External 5 2 1.18 2 21 4 28 Total days for 1 (one) shell course

0.333 4
Welding Internal 3 2 0.71 Total manpower required
30 16 Manual External 5 5 10 3.49 Total days to erect 6 shell course
0.045 12
Welding Internal 3 5 2.09 Total man days for shell

Mechanised External 5 3 1.31 5 28 8 37 Total days for 1 (one) shell course

0.333 6
Welding Internal 4 3 1.05 Total manpower required
50 20 Manual External 5 6 10 4.85 Total days to erect 6 shell course
0.045 15
Welding Internal 4 6 3.88 Total man days for shell

Mechanised External 7 5 1.76 8 40 11 54 Total days for 1 (one) shell course

0.333 12
Welding Internal 5 5 1.26 Total manpower required
80 24 Manual External 7 12 10 5.43 Total days to erect 6 shell course
0.045 27
Welding Internal 5 12 3.88 Total man days for shell

Notes: (A) Actual working days considered without holidays (B) Data on number of workmen and required working days are acquired from actual job sites and may vary from one job site to another
09
 Lift n Weld

Bygging “Lift n Weld” (Jacking + Automatic Welding) both external & internal
Plain Vanilla Jacking Method Jacking Method With External Lift N Weld
With Manual Welding Welds Using Automatic Machine
Top down method and using automatic
Top down method
girth welding machine for external and
(or top to bottom)
internal horizontal welds
One small 10 ton capacity crane with 8 mtrs boom length
required for handling of shell plates: us $2,000 per month

Not required above 4 mtr level

Zero risk of workmen falling from heights

Roof erected at ground level, leading to saving in erection time of roof by 30%
Top most shell ring and wind girder are erected at first, and therefore tank shell is
Stable against high winds during erection

Evacuation is quick and easy since workmen are working at a maximum of 3 mtr height

High Medium Low

High Medium Nil
High Medium Low

different erection methods

Jacking+External Welds ‘LIFT n WELD” % Reduction in man
Conventional+Manual Conventional+Automatic Plain Vanilla Jacking+ % Reduction Compared
by Auto Welding+ (Jacking+Auto Welding for both days compared to
Welding Welding Manual Welding to manual Welding(C-E)
Internal Welds manually External and Internal Welds) conventional method (B-E)

A B C D E (C-E) (B-E)

8.07 6.20 6.07 5.00 4.20

34.00 28.00 26.00 21.00 20.00 23.08 28.57 Lesser workmen required
48.44 37.21 36.44 30.02 25.21 30.81 32.25 Lesser time for shell erection
1,646.88 1,041.87 947.38 630.46 504.19 46.78 51.61
9.59 5.89 7.59 5.27 3.89
40.00 32.00 33.00 27.00 25.00 24.24 21.88 Lesser workmen required
57.51 35.32 45.51 31.64 23.32 48.76 33.97 Lesser time for shell erection
2,300.59 1,130.32 1,501.98 854.40 583.06 61.18 48.42
16.73 10.36 13.73 10.19 7.36
52.00 43.00 43.00 35.50 34.00 20.93 20.93 Lesser workmen required
100.37 62.15 82.37 61.14 44.15 46.39 28.96 Lesser time for shell erection
5,219.07 2,672.59 3,541.77 2,170.36 1,501.21 57.61 43.83
20.31 14.02 17.31 13.64 11.02
81.00 66.00 67.00 53.50 52.00 22.39 21.21 Lesser workmen required
121.86 84.12 103.86 81.84 66.12 36.34 21.40 Lesser time for shell erection
9,870.48 5,551.66 6,958.47 4,378.53 3,438.03 50.59 38.07

10
 Jack Models

11
 Double Acting Jack Single Acting Jack

The time for lifting tank upto 2.5 meters height is as follows:
Using double acting jacks - 40 minutes
Using single acting jacks - 3-4 hours
Double Acting Jacks work 5 Times Faster than Single Acting Jacks

Jack models in terms of lifting capacity

Model / Description 510-35D 2510-35D 2510-40D 2510-50D
Working capacity (metric tons) 12 12 18 25
Testing load (metric tons) 18 18 27 37.5
Standard arc distance between jacks (m) 2 to 3.5
Max plate height for which jacking
equipment can be supplied (m) 2.5 or 3.0 or more
Min plate height that can be used (m) 0.80
Min safe bearing capacity below trestle base plate (N/mm²) 1.45
Plate thickness range (mm) 5 and above 6 and above
Unitary climb (cm/stroke) 10
Time per stroke (minutes) Approx 5 1 to 1.5
Working pressure (kg/cm²) 120 142 135
Piston retracting system Spring hydraulic
Trestle retractable system to allow internal welds
using automatic welding machine No No No No

Jack models in terms of variants

Jacks that don’t need any welding to tank
Model Code (also order example) 2510-35D S H R Jack Model: 2510-35D-S-H
Lifting Hook: No welding of
2510-35D = Double Acting Jack 12 ton capacity cleats to tank shell
2510-40D = Double Acting Jack 18 ton capacity
2510-50D = Double Acting Jack 25 ton capacity

Maximum height of shell course

S = 2.5 mtrs
B = 3.0 mtrs

Type of contact with shell plate

H = Lifting hook: no welding of lifting cleats to tank shell.
L = Lifting arm: cleats to be welded to tank shell.

R = Retractable system: enables internal welding using

automatic welding machine.

Example: 2510-35D-B-H-R: Double acting jack 12 ton capacity

suitable for 3 mtr width shell plate with lifting hook and with
retractable arrangement. 12
 Range of
Services

13
Bygging offers complete solutions for any storage tank project - be
it erecting a 100m diameter floating roof tank, or lifting a 75m
diameter LNG tank for foam glass replacement, or lifting a 1900
ton blast furnace gas holder, all backed by engineering support.
Our products and services range right from supply of jacks and
welding machines and experienced technicians up to providing
stability calculations, method statements and job hazard analysis.

Sales and Rental of hydraulic jacking equipment and single sided

automatic girth welding equipment
Tank construction companies can either purchase or rent jacks and auto welding machines from Bygging which
takes care of tank lifting and horizontal welding which is a major portion of the tank construction process.

Deputation of tank jacking and auto welding specialists

Specialists with vast experience in tank projects are deputed by Bygging to job sites the world over. Besides doing
the mundane jobs like tank lifting and horizontal welding, these specialists offer useful site tips to tank builders
from the experience they have gathered from working at various geographical locales.

Re-bottoming of tanks
Bygging carries out site survey, submits jacking layout for placing jacks on the outside of tanks and stability
calculations that are essential for any tank repair project.

Retrofitting pre sold jacking equipment to make them retractable

Bygging has sold more than 26,000 jacking units world wide. Existing customers can get their equipment
retrofitted to make them retractable which allows the use of auto welding machine for internal welding as well.

14
 Jacks for

other Lifting Applications

Hydraulic jacks for erecting grain storage silos, dryers and

bolted Tanks
Bygging manufactures and rents hydraulic
telescopic jacks of 5.5 and 6.8 ton capacity
suitable to lift two shell rings of grain storage silos
so that lifting brackets have to be removed after
fixing two rings. These jacks are quickly replacing
the traditional A-frames with chain blocks in the
erection of grain storage silos.
Jacks of 9 ton capacity with synchronized lifting
mechanism are manufactured to lift dryers.

Strand Jacks
Single strand jacks up to 25 ton capacity using 18mm diameter
H.T. strands are manufactured by Bygging. These jacks find use
in lifting of steel flues for chimneys, and to lift horizontal tanks,
vessels and de-aerators. Multistrand jacks upto 180 ton lifting
capacity are used for boiler drum lifts.

15
Quality Control

Ultrasonic Testing Jack Load Testing

In order to deliver a world class quality product, strict quality control

measures are adhered to and extensive checks and tests are conducted
at various stages of the manufacturing process.

Raw materials for critical components are sourced directly from

reputed manufacturers. Only high quality raw material from time
tested and proven manufacturers is used.

Dimensional checks of components are carried out after they are

machined.

Testing : The final products are rigorously tested to ensure trouble

free operation on the job site which means higher productivity for
our customers.

16
 World class infrastructure with well equipped

Manufacturing
Facility

17
01
 5750 tanks constructed using Bygging Jacks
in 55 countries, in more than 320 locations
Finland
United Poland
Kingdom Ukraine
Ireland Denmark
Russia
Canada
The Netherlands
Turkey Kazakhstan
Romania
Cyprus Lebanon
United States Tunisia
Jordan Pakistan
Morocco
Algeria
Mexico Egypt
India
Ghana GCC Countries Vietnam
Libya
Guinea Yemen
Cote D'ivoire Sudan Maldives Singapore Malaysia
Costa Rica Sri Lanka
Kenya
Nigeria D.R. of Congo Indonesia
Brazil Republic of Congo Tanzania
Peru Angola Mozambique
Namibia Madagascar
Australia
South Africa
Uruguay

New Zealand

Bygging Jacking System approved by and used at

02
18
 Infrastructure Pvt. Ltd.
SINCE 1983

Office:
India
BYGGING Infrastructure Pvt. Ltd.
69, RNA Arcade,
Lokhandwala Complex,
Andheri (W), Mumbai - 400 053
+91 22 26364241 / 26368756,
info@bygging.com

Workshop
R-570 & R-571,
TTC Industrial Area,
MIDC Rabale,
Navi Mumbai -400 701

www.jackingsystem.com