80m Clear-Span Arch Vault Bulk Sheds at Indonesian Deep-Water Port: Defying Marine Salt-Spray Corrosion and Wet-Season Demurrage Deadlines

Located at a critical deep-water maritime logistics hub in Indonesia, this mega transit complex handles millions of tons of dry bulk cargo annually, transferring materials directly between ocean-going bulk carriers and processing centers. For the port authority and EPC construction team, the project had two major commercial stress points: astronomical ship demurrage costs and extreme tropical marine corrosion. Berth space at the terminal is leased at premium rates; every extra day spent installing roof arches above active ship loaders risked halting conveyor trials, which triggers demurrage fines of up to tens of thousands of dollars per vessel per day. Furthermore, the equatorial coastal site exposes steel to constant saline sea breezes, high humidity, and abrasive bulk mineral dust, which can cause unprotected steel structures and standard zinc roofing to rust within two to three years.

Shijie Heavy Industry implemented a modular, high-rigidity structural system using spatial tubular barrel-vault arches and C5-M marine-grade protection. By pre-assembling arch truss segments with self-locating bolted sleeve connections in the factory, Shijie eliminated on-site welding near flammable bulk conveyor belts. Every steel member received a composite duplex coating—hot-dip galvanizing paired with thick aliphatic polyurethane—backed by 4-mil fluorocarbon-coated corrugated metal sheets. Transported in phased container and flat-rack packages matched to berth crane radius charts, the arched bays were lifted directly into position. The entire warehouse complex was completed 20 days ahead of the monsoon berthing window, enabling immediate commissioning of the enclosed conveyor galleries without incurring demurrage penalties.