At the end of 2021, a unified team of salvors finished removing the wreck of capsized car carrier Golden Ray in St Simons Sound, Georgia
T&T Salvage completed one of the most complicated and expensive wreck removal projects ever in Q4 2021 after acquiring a specialised heavy-lift vessel and employing a fleet of tugs, workboats and barges.
It took two years to remove the Golden Ray wreck from St Simons Sound, Georgia with weeks of potential work lost to the Covid pandemic, weather and equipment wear. But responders lifted the last remnants of the capsized car carrier from the seabed on 25 October 2021, completing the main offshore operational elements of the project.
Golden Ray grounded and capsized in September 2019 while fully laden after leaving the Port of Brunswick unbalanced and with insufficient ballast.
Emergency responders, salvors and eventually wreck removal experts were mobilised to assist with salvage plans. T&T Salvage’s plan was seen as the most effective in removing the wreck from this environmentally challenging area.
Costs are estimated to have risen beyond US$1Bn on this challenging project, including preparation of a unique cutting and lifting vessel, VB 10000.
The response Unified Command (UC) worked with T&T Salvage, North P&I Club, Gallagher Marine Systems and the coastal resources division of the Georgia Department of Natural Resources to remove the rusting hulk of the ship, its vehicle cargo and any environmental pollution for more than two years.
VB-10000 lifted the final section (four) from the sea ready to go onto a cradle system on a Crowley barge ready for its departure in October 2021.
Then wreck-removal experts stowed the final section on its cradle and three tugs assisted in its transport it to a local facility, near Mayor’s Point Terminal, for partial dismantling. These parts were then transloaded to container barges and shipped to a recycling facility in Louisiana.
T&T Salvage president Mauricio Garrido explained the challenges at the Salvage & Wreck Removal Conference in London, in December 2021.
One of the challenges was the extreme tides and currents at the wreck site, he said. There was dynamic scouring and ecosystem concerns in the protected Golden Isles of Georgia.
Other challenges were restrictions due to the Covid 19 pandemic, oversight by federal, state and non-government organisations, engaged local communities, hurricanes and US flag restrictions.
“The biggest challenges were Covid, the scale of the project and the infrastructure and vessels needed,” said Mr Garrido. “Jones Act limited our capabilities to source a heavy lifting vessel.” VB 10000 was sourced from the offshore industry, where it was employed to lift platforms in the US Gulf.
VB 10000 is a pontooned floating crane with dynamic positioning class DP3, a mooring system and a 7,500-tonne lift capacity and height of 78 m, which meant it could not go under bridges.
T&T Salvage ordered 16 lifting lugs of 32 m length and 3.7 m height from shipyards in the US and Germany. It had trouble sourcing the drydock pontoons needed to transport lifted sections to the recycling centre.
The only resource for these was the MARS naval drydock pontoons, which were connected to make one drydock with support pieces. Other floating assets also required refurbishment.
“Barges were outfitted with containment and sea fastenings and cradles for the salvage sections,” said Mr Garrido.
The initial response was from September 2019 to January 2020. There was a long period until the first section was cut and lifted in November 2020. When operations were underway, they were hampered by cutting equipment breaking and hurricanes coming in from the Atlantic.
Environmental protection
T&T Salvage project manager and naval architect Matthew Cooke said there was “a lot of welding and fabrication work” on the wreck, which had a 10° list, in preparation for the cutting and lifting.
An environmental protection barrier (EPB) was erected around the wreck site “to mitigate pollution of floating oil, vehicle cargo and debris from the wreck.”
This EPB was positioned in a diamond formation with the piles into the seabed and a mesh “enabling marine life to go through while stopping cars getting out of the site,” said Mr Cooke.
“There was a floating protection boom to retain hydrocarbons and scour protection around the piles.” There were also gates to the north and south of the EPB to allow vessels and barges into and out of the site.
Wreck removal involved cutting the hull seven times using a chain and then lifting the eight sections. They were loaded on to the drydock barge and transported to the local facility, near Mayor’s Point Terminal. Derrick barge Thor broke up remaining parts of the wreck into smaller 200-tonne to 500-tonne pieces before they were transloaded onto container barges and shipped to Louisiana for scrapping.
Tugs were heavily involved in the barge transport and lifting operations. Crosby Star, Caitlin and Kurt J Crosby assisted a drydock barge loaded with sections to a local facility and tugs helped to transfer sections on to Crowley’s Julie B and towed it to Louisiana.
Overcoming challenges
Mr Cooke said the tidal range and currents meant scour protection, using embedded containers with rock inside, was needed around the EPB piles and “around the bow and stern of the wreck to prevent more keel over.”
Once this was in place, a liftboat with a drilling unit was brought in to horizontally drill five tunnels below the wreck to thread the cutting chain through.
“We used 3-inch anchor chain for cutting but had to increase the grade as we saw wear on the chain,” said Mr Cooke.
To overcome challenges from the Covid pandemic the salvage team was split into three tiers of importance. Tier 1 were the critical positions and had the strictest social distancing rules. Tier 2 were the tug and salvage crews and tier 3 were the support teams.
T&T Salvage hired accommodation for these teams and prevented social interaction between tiers to reduce the risk of infections, particularly in the tier 1 personnel, said Mr Cooke.
Q4 2021 work
In October and November 2021, wreck removal teams and a flotilla of small vessels continued to recover debris from inside the EPB, which will be dismantled and removed when all work is completed.
On 11 November, UC said personnel had recovered 151 vehicles and 15 partial decks during operations to clear wreck debris and scour mitigation measures from inside the EPB. Additional equipment, including a 176-tonne hydraulic grab, was mobilised inside the EPB to recover larger sunken pieces of the wreck.
Engineering teams conducted hydrographic surveys using sonar each week to assist the debris removal process. Survey analysis confirmed there was no debris along the seafloor outside of the barrier.
Engineers used Edgetech 6205 side-scanning and CodaOctopus Echoscope multi-dimensional sonar equipment to map and monitor the seafloor weekly throughout the Golden Ray removal process.
Outside the EPB
Around the EPB there was a 137-m safety zone, which was increased to 183 m for any non-response vessel transiting outside the shipping channel.
UC developed a multi-layer approach for observing, surveying, documenting and mitigating any release of oil or debris during cutting and lifting operations.
Recovery personnel were stationed at the EPB, at the shoreline and on the water around the Golden Ray wreck. On-water response teams maintained a 24-hour watch around the shipwreck and deployed prestaged equipment and personnel to mitigate any oil discharges, sheens and debris observed.
Survey teams continued to recover debris along 161 km of shorelines and marsh areas in the vicinity of the wreck site. All debris is sorted, catalogued and disposed of according to the response debris plan.
Responders evaluated, surveyed and recovered any reported shipwreck debris in addition to their daily surveys of the water and the shoreline.
Wildlife assessment teams continued to survey marsh areas and beaches throughout St Simons Sound for any potential wildlife impact. Personnel also continued to measure air quality in the community using stationary and mobile air monitoring equipment.
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