The Berkan B ship seized in the port of Ravenna was dismantled in early October2017, the ship literally split in two. The sad saga of the Berkan B finally came to an end that very year, when the Fagioli Group was commissioned to remove the wreck. Fagioli entrusted Marine Consulting of Ravenna with the task of completing the cutting up of the ship. The project presented several challenges, including the large size of the wreck and the difficult environmental conditions. Given the urgency and complexity of the work, Marine Consulting turned to Diamond Pauber, asking for a diamond wire that was both fast and resistant.

SKB-V diamond wire

The selected SKB-V diamond wire has proven to be particularly suitable to meet the technical and environmental challenges of the project thanks to its advanced features. Designed for special applications, such as maritime decommissioning and salvage operations, the wire integrates Diamond Pauber’s double action bead technology, which combines protection and cutting ability, in a single design. The rounded shape of the beads allows the shock, generated in this case by the passage through an object with many empty spaces, to be absorbed by the protective shield, keeping the remaining part of the bead ready for cutting. This is designed to optimise operational efficiency, reducing wear and prolonging the life of the wire. 

Another distinctive feature of the SKB-V wire is the nickel binder, which can be modulated according to the specific needs of the project. Thus, it is possible to adapt the wire to different working conditions by exploiting the versatility of the EMP (Engineered Manufacturing Procedures) protocol to modify the nickel binder. The SKB-V can therefore deliver high performance even in particularly difficult environments, significantly improving the duration and effectiveness of the cut. The superior resistance of the product is the result of an advanced assembly process, also compliant with the EMP protocol, which gives the wire exceptional durability.

One of the main advantages of the SKB-V wire is said to be its ability to offer high performance even at low peripheral speeds, a particularly critical factor in the most complex cutting activities. The ability of the SKB-V wire to adapt to the different machines used not only solves the problem by optimising operational efficiency, but also reduces consumption and wear experienced by the machines themselves. This offers a considerable advantage in difficult working environments, extending the useful life of the equipment. Thanks to these characteristics, the SKB-V wire is said by Diamond Pauber to be ideal for complex technical applications, setting a new standard for cutting precision and efficiency. 

Diamond Pauber’s CEO, Mr. Stefano Bernieri, played a crucial role in the cutting operations, offering supervision and technical support directly in the field. His presence demonstrated Diamond Pauber’s commitment to providing not only cutting edge products, but also high level operational support, fully embodying the spirit of ‘Cutting Experience’, the company’s distinctive trademark. This further underlies the practical and customer oriented approach that has made Diamond Pauber a true pioneer in this industry.

Cutting and removal

In the first phase of the operation, Fagioli managed the waters around the wreck to avoid pollution during the cutting and removal operations. Containment barriers and a skimmer system were installed to suck up any pollutants. Before proceeding with the dismantling, thorough inspections of the quay and underwater checks were also carried out to ensure the safety of the structure.

The Berkan B wreck was 106m long, 17m wide and between 7m and 11m high, and laid on a murky seabed, with a fractured hull. Given the poor visibility, and the difficult conditions of the site, it was decided to perform the cutting from the quay, positioning the cutting machine above it. The SKB-V diamond wire played a key role in ensuring the success of the cutting operations thanks to its high reliability and resistance. This tool proved essential for the completion of the work, conducted by a team of specialist divers and assisted by a ROV (Remotely Operated Underwater Vehicle) to constantly monitor the underwater conditions. 

The cutting operations were divided into different phases: the first cut was performed on 24 August 2021. Initially estimated to last between four to five days, the cut was completed in just two days, which involved 26h of cutting, without any complications being experienced. The second cut proved more challenging as it involved an area of the wreck with preexisting fractures. This forced the wire to follow unwanted paths, consequently complicating the cutting action which was however completed satisfactorily. The third cut took place at the beginning of September 2021. During this phase the movements of the structure caused problems, but the SKB-V wire successfully completed the cut in 14h. 

On 15 October  2021, thanks to the technical support and the experience gained during previous operations, the operator was able to make the most of the features of the wire, managing to complete the fourth cut in just seven hours. Finally, the fifth cut, necessary to reduce the bow, was completed in 16h of cutting. 

Lifting the cut pieces

Once the cutting was complete, Fagioli began lifting and transporting the wreck sections. The first five sections were recovered with a 600t crane positioned on a pontoon, while the stern section, whose 800t exceeded estimates, was recovered using three crawler cranes with a total capacity of 1,750t. An alternative method was then used involving two barges, one for lifting and another for transporting the sections, with constant monitoring for any leaks. Once the recovery was complete, the sections were transported to Piombino for unloading. Subsequently, Fagioli performed a thorough cleaning of the seabed, including bathymetric surveys with control sonar, underwater video inspections, and sampling to ensure the absence of residues and contamination. Finally, the mooring poles and temporary barriers were removed successfully concluding the recovery operations.

Results achieved

During the demolition operations of the Berkan B, the SKB-V diamond wire proved its versatility and cutting ability, successfully tackling a complex structure with numerous empty spaces. The wire provided a combination of resistance and cutting speed, delivering optimal results even in the most problematic areas. A significant advantage of the SKB-V wire was the absence of interruptions experienced during the operation. The wire never broke, thereby avoiding delays and any associated problems such as additional costs for barges and tugboats. This helped maintain high efficiency and continuity of the dismantling process. 

The initial set up also provided valuable insights into the behaviour of the wire during operations on large structures. This experience provided a better understanding of the dynamics and specific needs experienced in large scale demolition operations, leading to an update of cutting methodologies and techniques. In particular, the ‘SafeGuard’ technology of the SKB-V diamond wire proved to be highly reliable, thereby opening new possibilities for use in industrial applications. “The cutting and removal project of the Berkan B wreck was an emblematic example of what we call the ‘Cutting Experience’ of Diamond Pauber. This term does not only represent the physical act of cutting but encompasses an entire operational philosophy that pushes us to overcome the traditional limits of our sector,” said Diamond Pauber’s CEO Stefano Bernieri.