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Portal power
China’s rapid economic growth in the past decade has resulted in a big increase in freight traffic through the country’s seaports . Old ports are being expanded and new ports built to handle the large growth in container and bulk cargo traffic all along the Chinese coastline.
China’s port expansion programme has provided a strong boost to the domestic port equipment industry, which has enjoyed a strong increase in demand for port cranes of various types, including container cranes and portal cranes along with bulk cargo handling equipment.
State-run China Harbour Engineering (group) Corporation Ltd, established under the ruling State Council, is China’s largest supplier of port cranes and bulk cargo handling equipment. The organization controls both Shanghai Zhenhua Port Machinery Co Ltd (ZPMC),the world’s largest manufacturer of quayside container cranes, and Shanghai Port Machinery Plant (SPMP), which specializes in the manufacturer of portal cranes and other cranes used in ports along with dry bulk cargo handling equipment.
SPMP’s main market is China, although the company is looking to expand its overseas sales. Although less well known than its associate ZPMC, SPMP also operates large manufacturing facilities, and is due to move part of its production shortly to Changxing Island near Shanghai where ZPMC already operates a large container crane fabrication plant.
Portal and other harbour cranes are SPMP’s major production item. During the past two years, the corporation has won contracts for 145 portal cranes from port authorities throughout China, both from new ports under construction and ports undergoing expansion.
In recent years, SPMP has also supplied portal cranes to the United States, Iraq,and Myanmar.The port Rangoon of Myanmar in has purchased a 47m,40t portal crane while BIW of the United States has purchased three cranes-15t,150t, and 300t portal cranes. Elsewhere, SPMP has supplied 12 portal cranes to several ports in Iraq since the end of the Saddam regime.
In China, SPMP’s recent major orders for portal cranes include eight 40t, 45m radius cranes for Tianjin Overseas Mineral Terminal, while Yan Tai Port Bureau in Guangdong in southern China has purchased six 40t, 45m radius cranes. Other large orders include seven 10t, 25m radius cranes for Zhenjiang Port Group and an order of 1025t, 33m radius cranes from Fangcheng Port Bureau, while the Yingkou Port Group has ordered 1325t,35m radius cranes along with two 40t, 44m radius port cranes.
MANY CRANES BUILT TO ORDER
SPMP also supplies other cranes used in ports and harbours, many of which are built to order for clients. Quayside container cranes have been supplied to a number of foreign clients including Bangkok Port in Thailand, Kaohsiung Port in Taiwan, and Port of Vancouver in Canada. In China, SPMP has supplied quayside container cranes to Shanghai Port, Tianjin Port, Yin Kou Port, Yan Tai Port and others. The company also supplies rubber-tyred container gantry cranes to domestic and overseas clients.
Customers for other cranes used in ports include Guangzhou Port in Guangdong, which purchased a 25t floating crane while Zhonggang Port has bought two double trolley 125/63t gantry cranes, along with a700t overhead crane, In 2003 Zhonggang Port awarded a contract to SPMP for a 2,600t floating crane, whichi is the largest crane the company has made in recent years.
Other customers include Zhongyuan Nanytong Shipyard of Jiangsu Province has purchased two 300t goliath cranes for use in its shipyard, while Shanghai Waigaoqiao Shipyard uses two of SPMP’s 600t goliath cranes for its shipbuilding operations. SPMP has two factories. The Shanghai plant employs 2,000 workers while a factory in Jiangsu Province employs 1,500 workers. The combined total of 3,500 workers includes 800 technical and management staff involved in designing, developing, and building portal and other cranes along with dry bulk cargo loading and unloading equipment.
Currently, SPMP is preparing to vacate its Shanghai factory site as the company’s existing plot of land is part of a riverside area earmarked by the Shanghai Expo in 2010. SPMP’s Shanghai factory will close at the end of 2006, and move to a new site on nearby Changxing Island.
“The new factory will be much bigger than the present plant,” Li said. “Phase 1 will be ready for us when we move at the end of 2006.”
In addition to moving the Shanghai factory to a new site, SPMP expects future business operation with ZPMC.
Officials at China Harbour Engineering (Group) Corporation are understood to have told SPMP of plants for SPMP and ZPMC to co-operate more in bidding for projects in future. Both companies are expected to retain their individual manufacturing capability, however, with precise details of future co-operation still some way from being finalised.
Meanwhile, SPMP associate company ZPMC is strengthening its position as the world’s largest manufacturer of ship-to-shore container cranes, supplying slightly more than half the annual international container crane market. In addition to operating four crane production complexes for its crane manufacturing and other businesses.
ZPMC’s full range of products includes quayside container cranes, rubber-tyred gantry cranes, bulk material ship loaders and unloaders, bucket-wheel stackers and reclaimers, portal cranes, floating cranes, and engineering vessels. The company has also diversified into manufacturing other large steel structures including large steel bridges.
ZPMC EXPANDING PRODUCTION
ZPMC’s cranes and other products are in use at over 150 shipping terminals in 37 countries and regions worldwide. By the end of December 2005, ZPMC had supplied 705 quayside container cranes, and had orders in hand to deliver another 128 quayside container cranes in 2006. In addition, at the end of 2005 ZPMC had delivered 1,148 rubber-tyred gantry cranes to customers worldwide and had orders in hand to deliver 308 rubber-tyred gantry cranes to customers in 2006.
ZPMC is expanding production facilities in expectation that the volume of orders will grow in future. The company owns four crane production complexes in Shanghai and the surrounding area at Jiangyin, Changzhou, Zhangjiang and Changxing Island.
The Changxing production site, which was completed in 2001, covers one million sq m, and has a 3.5km coastline. The facility is capable of manufacturing 160 quayside ship-to-shore container cranes each year along with 300 rubber-tyred gantry cranes and 200,000 metric tons of large steel bridge structures.
Plans call for a futher 3 million sq m of land to be reclaimed at Changxing, which ZPMC will develop to become its largest production centre.
Korea looks inward
In a fragmented global port crane industry, Korean manufacturers are being forced to look for more business in their domestic markets
South Korea’s container crane and port crane equipment manufacturing industry has become more focused on the domestic market in recent years as manufacturers have faced tough price competition from ZPMC of China in major foreign markets. The problem is the same as that faced by other port crane manufacturers around the world, none of which account for more than about an 8% share of the world container crane market.
As well as ZPMC, competition from European and Japanese equipment suppliers is also strong, both for quayside container cranes and for rubber-tyred gantry crane contracts. While South Korean firms-including Hyundai Heavy Industries, Samsung Heavy Industries, Doosan Heavy Industries, and Hanjin Heavy Industries – continue to bid for international contracts, winning large orders has become increasingly rare.
Doosan Heavy Industries & Construction Co Ltd is believed to be the only South Korean port crane maker to have won a large container crane contract during the past few years, with most orders booker by Korean manufacturers being for less than 10 crane units.
Doosan recently completed delivery of a 42-unit rubber-tyred gantry crane (RTGC) order to the Port of Singapore Authority PSN that was awarded in 2004. Including a recent contract. Doosan has received orders to supply the Port of Singapore with a total of 120 RTGCs since 1997. The recent batch of RTGCs is designed for increased safety. Esch of the RTGCs is fitted with 16 wheels instead of the usual eight.
“We have supplied container cranes locally and overseas. Most projects are one or two units, but Singapore has been 120 units,” commented a source in Doosan Heavy Industries’ material handling equipment division. “Container cranes can lift one or two containers depending on the client, but the twin spreader design is normal now. Our biggest contract before was with Pusan Port for over 10 container cranes.”
BUILDING POWER PLANTS
Doosan Heavy Industries’ major activities include the design and construction of power plants. Apart from supplying protection equipment, Doosan also manufactures turbines and generator sets. Doosan has a large castings and forging division. Other major activities include the construction of desalination plants in the Middle East.
Container port handling equipment is produced by Doosan’s material handling equipment division, which supplies coal handling equipment and bulk cargo handling facilities for other industries.
Port of Singapore Authority is the largest customer for RTGCs. Other recent clients include Southern Gateway Terminals in Colombo, Sri Lanka, and Korea Express in the Port of Pusan.
Doosan also supplies ship to shore container cranes. Recent quayside gantry crane clients include Jakarta Container Terminal in Indonesia, Jawaharlal Nehru Port near Mumbai in India, and Frazer Terminal in Vancouver.
“Prospects for our port crane sales are not bright. ZPMC is dominating the world market due to price,” the source commented. “We are looking for projects not invoving ZPMC as they are not concerned with all projects. We got contracts in Singapore in 2004 and 2005. We had no success anywhere else, but we are still bidding on various tenders.”
Doosan is expected to be one of the bidders for container cranes to be installed in South Korea’s planned Kwangyang Bay Port expansion. The company’s R&D division is involved developing new automated controls that will be required for quayside container cranes installed in the port expansion.
“Container cranes are well developed in technical terms. There is nothing else to develop except for automation,” the source said. “We are developing more automated controls, but the new features are not commercialized yet.
Our government has a plan for Kwangyang Bay 3-2 terminal project, which they announced will be developed as an automated terminal. We have to adapt to this. The tender has been postponed for about six years. We expect the project will be tendered again in 2007 or 2008.”
South Korea’s other container crane manufacturers also are expected to bid for the Kwangyang Bay project, which is likely to be awarded to a local supplier. Hyundal Samho Heavy Industries will be among the bidders having recently commissioned five automated rail mounted gantry cranes (RMGCs) also known as automated transfer cranes at Pusan East Container Terminal (PECT) .
The terminal has become the first terminal in Korea to install automated cranes, which are in service at new berths four and five .
The cranes stack nine-wide between a 28.5m rail gauge, and have dual cantilevers covering two road lanes . Stack height is 1 over 6 by 9ft 6in high and operational speeds are 150m/min for the gantry , 120m/min for the trolley and 75-80m/min for the empty hoist .
Among other recent orders that Hyundai has won is a contract for four quayside container cranes from Hutchison Port Holdings and one for Uam Port.
Competition from ZPMC remains the main challenge in winning overseas contracts according to Hyundai Heavy Industries sales manager Lee Yong Tae : “ We are trying to get more projects , but ZPMC has a very low price . We will try to cut our price but we think it will lead to a bad situation in future . ”
“ if customers think that quality is important then we are ok , but if they just think about price we cannot win the project . We have experience of building cranes to lift one or two containers .We buy the main crane controls system from ABB and then use a Korean fabricator .”