CONSOLIS

- Consolis Malaysia
- Consolis Regional Office Korea
- Bonna Indonesia
Table of Contents

1. Consolis Group 3. Installation (Onshore)

2. Bonna Indonesia 1) Installation

2) Jointing
1) Business Area and Services
2) RCCP 4. Reference Projects
3) Production Line
4) Benefits

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 CONSOLIS is a leading European Group
in building solutions, civil works and rail
infrastructure, specialised in
manufacturing high-performance
concrete building elements.

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10 500
1,31 bn
*2015

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 History - More than a Century
PARTEK
Launched New shareholders New shareholders
concrete Creation of CONSOLIS Group
INDUSTRI KAPITAL Since 2007, LBO France and
products INDUSTRI KAPITAL
Creation and co-founders merged co-founders are majority shareholders,
PARMA Finland CONSOLIS Oy and
Creation BONNA SABLA
along with management
PARTEK Finland
Creation
WPS
Acquisition
Poland

1782 1890 1948 1958 1997 2001 2002

Post war reconstruction
Consolis Oy
2005 2007 2008 2016
Bonna Sabla

1868 1924 1975 1978 1988 2001 2002

SATEBA
Creation
Maroc Consolis Malaysia
Consolis Korea
New shareholders SPAENCOM
SABLA As part of an MBI, Acquisition
BONNA SATEBA joins CGE
CGE hands over Denmark
Creation Acquisition Bonna Sabla to the
by Aimé by BONNA BONNA
and co-founders** along ASA
Bonna France with Axa Private
France SABLA Acquisition
BONNA ECPC merged Equity
Hungary
Acquisition Creation Romania
by CGE* Egypt Ukraine

(*) Compagnie Générale des Eaux

(**) Pierre Brousse and Philippe Milliet
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3 Business Areas
RAIL, BUILDING, INFRASTRUCTURE

Mars 2014 Consolis Corporate 5

Rail
Solutions for HSR, Main Lines, Urban Networks, and
Heavy Haul & Mining

• Heavy Haul Line

(Sweden)

• TGV(France) Sleepers

• Mining (Sweden)

Consolis Rail is a European leader in designing and manufacturing concrete

sleepers and bearers for railways. Consolis also provides a range of
engineering services
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Building
Solutions meeting the 21st Century needs

Shopping mall, Emporia, Malmö, Sweden Museum MuCEM, Marseilles, France

Alexandria Library , Egypt Non-residential Residential

We contribute to increase concrete’s awareness as our solutions

answer economic efficiency, urban design and environment.
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Infrastructure
From civil works to large infrastructure projects

Bridges Water treatment Cemetery, France

Cooling systems High pressure pipes Beams

We offer solutions for urban and rural planning, sustainable development,

water treatment, transportation routes (roads, railways, airports), cutting-edge
infrastructures (bridges, tunnels, water pipes) and energy management.
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2. Bonna Indonesia

1) Business Area and Services

2) RCCP

3) Production Process

4) Benefits

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 1) Business Area and Services
SECTORS
• ENERGY : HYDRO, POWERPLANTS & WATER SUPPLY
• OFFSHORE : OIL & GAS, MINING
• INDUSTRY : FERTILIZERS, CHEMICALS, PETROCHEM
• INFRASTRUCTURE : ROADS, RAILWAYS, Tunnel segments
PRECAST CONCRETE PRODUCTS and SOLUTIONS
BONNA® RCCP pressure pipe concrete technology for
conventional /nuclear power plants circulating/cooling/safety
system or drinkable water supply pipelines.
Railways sleepers, conveyor belt supports
Tunnel segment linings
Offshore products (ballast collars, annular rings, mattresses)
CAPABILITY
• CUSTOM-MADE PRECAST CONCRETE SOLUTIONS
• DESIGN, ENGINEERING & MANUFACTURING
• DOMESTIC SALES & EXPORTS to SEA since 1993
Industrial site (created in 1993)
Location : Gunung Putri, 30 km South Jakarta
Total land acreage 75.000 m2
Covered building 12.700 m2
Office & lab buildings 400 m2
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 1) Business Areas and Services
- Conventional/Nuclear/Hydro Power Plants -

 COOLING PIPELINES :

INTAKE PRESSURE

DISCHARGE / OUTFALL

 Additional circuits :

Flue Gas Desulfurization

 OFFSHORE :

INTAKE HEADS

DIFFUSERS
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 1) Business Area and Services
BONNA® pressure pipes - CUSTOM-MADE integrated SOLUTIONS
for POWER PLANTS owners & EPC Contractors

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 1) Business Area and Services
Special Works – Pipe Jacking & Micro Tunneling

AREAS of EXPERTISE Exemple : Capability to design PIPES for JACKING

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 2) The BONNA®
Reinforced Steel Cylinder Concrete Pressure
(RCCP) Pipe

 STEEL
 CEMENT
JIS G3101 SS400 or eq.
Type-V Sulphate Resistant

A Very Smooth Steel Bar

Concrete Reinforcement
Inner Surface

Embedded Superior Outer

Welded Steel Reinforced
Cylinder Concrete Wall

Pipe Design can be customized for every project specifications

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 2) Bonna® RCCP pipes - BENEFITS of SELF-ANCHORING
absence of massive anchor/thrust blocks

THRUST
FORCE

With RCCP, massive

concrete thrust (anchor)
blocks are NOT required Welded
restrained joint
W W
GRP
W W

W
W

Welded or Fitted /
W/F flexible joints

W/F

W/F

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 2) BONNA® - RCCP
COMPLETED PRODUCT RANGE
Standard Pipes Specials Fittings / Accessories
Flange
Connections to
any Standards &
Suitably Protected

Stainless Steel
Rings to be fitted
Diameters on any end to
Range from cope with
settlements,
ID 800 mm expansion,
rotation,
Up to or seismic
ID 5000 mm movements

Intake Head with

Easy Assembly &
Easy Expedition

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Sand Washing and Aggregate washing is
performed for 100% of the Aggregates in
the PT Bonna Indonesia plants.
Aggregates are conforming with ASTM C33.
Operation and Control is performed 24/7 as
per internal quality procedures

PT. BONNA INDONESIA

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 3) Production Process
BONNA® RCCP

ROLLING & BENDING WELDING

Steel Plate

ASSEMBLING Steel Cylinders + End Rings

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 3) Production Process
BONNA® RCCP

FULL WELDING & Test

HYDROTESTING for
Every Steel Cylinder

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 3) Production Process
BONNA® RCCP

Steel Bar REINFORCEMENT FITTING The CAGE

ASSEMBLY & Inspection Over Steel Cylinder

Finished RCCP
READY for
FINAL INSPECTION Vertical
& DELIVERY CASTING

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 4) Benefits
BONNA® RCCP RESISTANCE to
External CLIMATIC
CORROSION Conditions
RESISTANT
LOW FRICTION +
ABRASION RESISTANT

Resistance to
Resistance to
EXTERNAL LOADS
DEFORMATION
DURABLE

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 4) Benefits
BONNA® RCCP Solution
for Cooling Water System

STRONG/ROBUST  BONNA® RCCP pipes avoid the need of

Expensive Reinforcement rings while Steel Pipes needs
Reinforcement Rings/Stiffener to avoid ovalization (pipe
become oval) or Plastic pipes need Concrete Blocks/
Reinforcement to avoid the pipe become oval.

DURABILITY  Strong & sustain to climate and any loads

(i.e. soil backfill, mobile loads–crossings, or even earthquake/
Seismic design considerations).

CORROSION FREE  No steel will contact to the water (even for sea water intake
parts; we use always cement type-5 Sulphate Resistance for
sea water); RCCP will be covered by concrete inside & outside.

MAINTENANCE FREE No need Cathodic Protection at all;

Maintenance Cost for piping = 0 (zero).

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 4) Benefits
BONNA® RCCP Solution
for Cooling Water System

EASY TO INSTALL  No Heavy Lifting Equipment needed.

20 ton sections can be lifted, positioned & welded within hours.

QUICK & EASIER WELDING JOINT 

Only needs single Filet Weld or maximum 2 phases of welding joint & very easy to do (No
Butt-welding needed like in the case of thick steel pipes), faster welding and testing of the
welds and joints which reduces the installation cost and time.

FASTER BACKFILLING  No Need Soil Compaction every 30 cm.

COMPARISON

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3. Installation

1) Installation in 7 fast and easy steps

2) Jointing

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1) Installation
- 7 steps installation for Inland Cooling System (Onshore)

1. Dig the trenches

i. Reinforce if needed with Sheet piles
ii. Prepare base level.
• Soil strength verification (geotechnical study defines the solution)
• Choice of Gravel base or stone ballasted column
• Self compacting sand (withor without Geotextile)
2. Place the pipes in the trenches
i. Fit the pipes with chain block
3. Adjust position and check alignment with surveyor
4. Tack Weld and hold in position
5. Filet Welding and quality control
6. External grouting and internal masonry
i. Hydrostatic Pressure test (if selected)
7. Backfill

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1) Installation (Onshore)

Step 1 – Prepare the trench : excavation + bedding

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1) Installation (Onshore)
2 positioning solutions

Crane Loader

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1) Installation (Onshore)

Step 2 – Fit the pipe -> chain blocks

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1) Installation (Onshore)

Stpe 3 – Adjust and check with surveyor

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1) Installation (Onshore)

Step 4a –Tack Weld and lock in position

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1) Installation (Onshore)

Step 4b – Full welding 1 or 2 passes -> filet welding 6mm

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1) Installation (Onshore)

Step 5 – Welding Inspection – weld-through capillary test

Wait Check inside :

overnight
(12h) Red stain =
leakage -> Repair
and retest
No Red Stain =
Conform
White Inside Red outside QC passed
EN571-1
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1) Installation (Onshore)

Step 6 – Fill gap with filling mortar

Grouting outside

Manual Masonry
Inside

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1) Installation (Onshore)

Step 7 – Backfiling simple material push

No Need for
Compacting !

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1) Installation (Offshore)
: 2 methods for installation
1 -> Dredging

• One dredging barge open the trench and prepare

installation bedding in advance.

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 2 -> Segments preparation
• Need working area, one team on land to prepare the pipes into
segments: similar jointing work to onshore installation.

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 2 -> Segments preparation
• Need working area, one team on land to prepare the pipes into
segments: similar jointing work to onshore installation.

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 3 -> Transfer to installation barge

• For the project on the pictures the offshore contractor

chose to use transfer ramp:

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 3 -> Transfer to installation barge

• For the project on the pictures the offshore contractor

chose to use transfer ramp:

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4 -> Install the pipes with hydraulic jack

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5-> Backfilling

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Pipe burried just below sea bed level
Pipe laying at sea bed level
 OFFSHORE COOLING WATER SYSTEMS

Installation Method B

Bonna lead and special design for Ramp

and Launch method

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Shore based Installation

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Shore based Installation

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Shore based Installation
connecting onshore and pushing into
sea

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 HANDLING & SHIPPING - full export capability
full stackability is possible due to BONNA pipes inherent robustness

4/13/2017 52
31 mars 2014 Consolis Corporate 53
2) Jointing and connection options

Only inside or
only outside
Filet Weld

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 Benefits for EPC building a Power Plant
CAPEX investment includes:
Tee, Reducer, manholes, Seismic
SMJ …
Pipe (std units)
Reinforced Ring
Thrust Block
Installation time for Welding and
jointing
Backfilling(Compadting)
OPEX Benefits include
Vacuum resistance
Maintenance and inspection costs
EPC benefits
Cost effective, quality and reliability
Quality and reliability
0 need for RCCP (competition needs Every 2.5m)
0 need (avoidance of a 50Ton to 150Ton cost of
civil work per elbow, and altitude change)
Fast as Filet Welding(1 pass)
Basic skilled workers can be hired
0 compacting needed (not every 30 cm)
Resist to full vacuum, protects pumps and pipes,
no ovalization.
0 cathodic protection, 0 lining

RCCP is 5~15% cheaper with materials cost + installation cost,

RCCP is a better TCO solution 55
 Benefits for Power Plant owners
Owner Benefits
CAPEX investment includes:
Tee, Reducer, manholes, Seismic SMJ … Lower CAPEX
Pipe (std units)
Reinforced Ring Lower CAPEX
Thrust Block Less civil work is faster completion and ROI
Installation time for Welding and jointing Earlier installed is faster ROI
Backfilling(Compacting) Lower CAPEX, using Native Backfilling
OPEX Benefits include
Vacuum resistance Full vacuum resistant
Electrical cost 0 cathodic protection
Pumping cost Reducers and smart manifolds avoid limit
pressure losses and reduce pumping power
Maintenance and inspection costs 0 relining, 0 repainting
Offshore maintenance Avoidance of annual diver inspection

RCCP is 5~15% cheaper with materials cost + installation cost,

RCCP is a better TCO solution 56
4. Some Reference Projects

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 CONSOLIS - Energy & Power Plants
COOLING WATER SYSTEMS in BONNA® pipes
Recent references in ASIA

Project Owner EPC Work Scope Country

Quezon SBPL
Meralco Daelim(Korea) Power Plant Cooling Water System Philippines
550MW CFPP
3B Jimah Hyundai(Korea) Power Plant Cooling Water System Malaysia

Manjung-V Daelim(Korea) Power Plant Flue Gas Desulfurization Pipe Malaysia

Nongsaeng
Gulf Energy MHI(Japan) Power Plant Cooling Water System Thailand
2x300MW CFPP

Batangas Refinery Petron Toyo(Japan) Power Plant Cooling Water System Philippines

Adipala 660MW PLN CNEEC(China) Power Plant Cooling Water System Indonesia

Merak 2x60MW Merak Energy Daewoo(Korea) Power Plant Cooling Water System Indonesia

Tanjung Awar 2x350

PLN CNEEC(China) Power Plant Cooling Water System Indonesia
MW CFPP
Taishan 1&2 2x1600M
TPNJVC CGNP-Areva Security System 3rd Generation Nuclear Power Plant China
W NPP
Pelabuhan Ratu 3x35 Shanghai Electric
PLN Power Plant Cooling Water System Indonesia
0MW CFPP (China)
Tanjung Jati B 2x670
PLN Toshiba (Japan) Power Plant Cooling Water System Indonesia
MW CFPP
Glow Energy 3&4 675
Suez (France) Black & Veatch Power Plant Cooling Water System Thailand
MW

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 CONSOLIS - Energy & Power Plants
COOLING WATER SYSTEMS in BONNA® pipes
Recent references in Vietnam

No Project Owner Main Contractor Description

1 Ca Mau 750 MW 1&2 PETROVIETNAM Torishima Water Cooling System 350m

(2006 & 2007) ND2200 to ND500
Pipe and Fittings
6 bar pressure
2 Phu-My 2-2 (2002) EDF Lilama 18 Water Cooling System 822m
ND1800 & ND700
Pipe and Fittings
4 bar pressure

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 BONNA® Reinforced Concrete Cylinder pipes (RCCP) :
over 4000 WORLDWIDE REFERENCES in ENERGY, INDUSTRY & WATER SUPPLY

NUCLEAR APPLICATIONS
(17% worldwide market share)

China Japan Korea S.E. Asia

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 The end !
Any Question?

For more information please contact us at

Harry.kim@consolis.com
www.consolis.com

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