Project Overview
In 2019, the 400,000 DWT Very Large Ore Carrier (VLOC) ORE ZHANJIANG was delivered from Beihai Shipbuilding, marking the completion of a major VLOC newbuilding program for which FBR supplied HMPE mooring ropes across a fleet of 20 vessels.
The project formed part of a long-term iron ore transportation initiative involving Vale, one of the world’s largest mining companies, and several leading Chinese shipping operators. The vessels were constructed by four major shipyards in China, including Shanghai Waigaoqiao Shipbuilding, Beihai Shipbuilding, China Merchants Heavy Industry (Jiangsu), and Yangzijiang Shipbuilding. FBR was selected to supply HMPE mooring ropes for the entire fleet.
The Challenge
VLOCs are among the largest bulk carriers ever built. Their extreme displacement, high berth loads, and dedicated iron ore trade routes place demanding requirements on mooring systems.
To ensure safe and efficient operations, mooring ropes must provide:
- High strength-to-weight ratio
- Low elongation characteristics
- Reliable handling performance
- Compliance with international marine regulations
- Compatibility with major ore terminals, including Vale-operated facilities
Recognizing these requirements, FBR began dedicated research and product development for ultra-large ore carriers as early as 2007, building technical expertise specifically for VLOC applications.
The Solution
FBR supplied complete HMPE mooring rope sets for all 20 vessels in the program.
The ropes were manufactured in accordance with the requirements of major classification societies, including LR, DNV GL, and CCS, and complied with relevant ISO standards and international maritime regulations.
The supplied mooring systems were designed to satisfy operational requirements at major iron ore terminals, including Vale’s Ponta da Madeira terminal in Brazil.
Supporting Vessel Operations
Beyond rope supply, FBR provided ongoing technical support throughout the vessels’ early operational period.
Whenever a vessel returned from loaded voyages between Brazil and China, FBR technical engineers conducted onboard visits to assist crews with:
- Rope inspection procedures
- Maintenance and storage practices
- Operational guidance
- Performance monitoring and feedback collection
Information gathered during these visits was incorporated into manufacturer inspection reports submitted to vessel owners, helping support long-term rope management and operational safety.
Achievement
The 20-vessel VLOC fleet represented one of the largest ore carrier construction programs of its generation.
Compared with earlier vessel designs, the new VLOC series was developed with a strong focus on efficiency, environmental performance, and operational safety. The vessels achieved significant reductions in transportation costs per tonne of iron ore while increasing cargo transportation efficiency.
The successful completion of the project demonstrated the suitability of HMPE mooring technology for ultra-large bulk carriers and further strengthened FBR’s experience in supplying mooring solutions for some of the world’s largest commercial vessels.
