EBAPs Manufacturing – Vila Velha/ES

The Engport Group was hired by Paulitec to manufacture and assemble all the necessary metal structures for the five Stormwater Pumping Stations (EBAPs) in the municipality of Vila Velha. This project represented one of the company’s greatest technical challenges in the civil public works segment: working exclusively with Stainless Steel AISI 316 on a large scale – over 150 tons of noble material in an aggressive marine environment.

THE CRITICAL CONTEXT

Vila Velha, a coastal municipality in Espírito Santo, faced chronic flooding problems in its main neighborhoods during the rainy season (November to March). The solution from the City Hall was to build five strategically positioned Pumping Stations: Foz do Costa, Marinho, Marilândia, Cobilândia, and Aribiri.

Each EBAP functions as an intelligent drainage system: it collects rainwater accumulated on the streets, pumps it to drainage channels, and prevents flooding in homes and businesses. The heart of each station is the suction pipes – large metal pipes that carry water from street level to underground pumps.

THE TECHNICAL CHALLENGE: STAINLESS STEEL ON A LARGE SCALE

The project specification required Stainless Steel AISI 316 – a premium alloy with high corrosion resistance in marine environments and permanent contact with water. Working with this material on a large scale presents unique challenges:

• High cost (3-4x more expensive than carbon steel)
• Specialized welding (GTAW/TIG procedures to avoid contamination)
• Strict contamination control (no contact with carbon steel allowed)
• Impeccable surface finish (chemical passivation after welding)
• Careful transportation (scratches compromise corrosion resistance)

ENGPORT METHODOLOGY

Our team developed specific procedures to ensure absolute quality:

1. Receiving and Storage:

• Exclusive segregated area for stainless steel (zero contamination)
• 100% dimensional inspection of plates and tubes
• Storage on racks with plastic protection

2. Workshop Fabrication:

• Dedicated workbenches (exclusive tools for stainless steel)
• Certified GTAW (TIG) welders according to ASME IX
• High purity gases (99.999% argon)
• Chemical cleaning after each step

3. Quality Control:

• 100% visual inspection according to AWS D1.6
• Non-destructive testing (liquid penetrant) on critical welds
• Chemical passivation on all parts
• Ferrite test (ensuring absence of contamination)

4. Transportation and Assembly:

• Transport over 1,000 km (São Sebastião → Vila Velha)
• Assembly with non-ferrous tools (to avoid scratches)
• Field welding with argon protection and subsequent cleaning

SCOPE EXECUTED IN THE 5 STATIONS

EBAP Foz do Costa:

• 08 (eight) suction pipes Ø 1,200mm x 8 meters
• Support and fixing structures
• Manufacture and installation of a monorail in Carbon Steel ASTM A36, with a capacity of up to 5 tons for lifting the suction pumps.
• Mechanical assembly of the entire discharge line in Cast Iron of Ø1,200mm
• Mechanical assembly of all flap valves in the discharge lines
• Mechanical assembly of all containment gates

EBAP Marinho:

• 08 (eight) suction pipes Ø 1,200mm x 8 meters
• Support and fixing structures
• Manufacture and installation of a monorail in Carbon Steel ASTM A36, with a capacity of up to 5 tons for lifting the suction pumps.
• Mechanical assembly of the entire discharge line in Cast Iron of Ø1,200mm
• Mechanical assembly of all flap valves in the discharge lines
• Mechanical assembly of all containment gates

EBAP Marilândia:

• 04 (four) suction pipes Ø 1,200mm x 8 meters
• Support and fixing structures
• Manufacture and installation of a monorail in Carbon Steel ASTM A36, with a capacity of up to 5 tons for lifting the suction pumps.
• Mechanical assembly of the entire discharge line in Cast Iron of Ø1,200mm
• Mechanical assembly of all flap valves in the discharge lines
• Mechanical assembly of all containment gates

EBAP Cobilândia:

• 04 (four) suction pipes Ø 1,200mm x 8 meters
• Support and fixing structures
• Manufacture and installation of a monorail in Carbon Steel ASTM A36, with a capacity of up to 5 tons for lifting the suction pumps.
• Mechanical assembly of the entire discharge line in Cast Iron of Ø1,200mm
• Mechanical assembly of all flap valves in the discharge lines
• Mechanical assembly of all containment gates

EBAP Aribiri:

• 02 (two) suction pipes Ø 1,200mm x 8 meters
• Support and fixing structures
• Manufacture and installation of a monorail in Carbon Steel ASTM A36, with a capacity of up to 5 tons for lifting the suction pumps.
• Mechanical assembly of the entire discharge line in Cast Iron of Ø1,200mm
• Mechanical assembly of all flap valves in the discharge lines
• Mechanical assembly of all containment gates

THE SCHEDULE PRESSURE

Like any high-visibility public work, the deadline was critical. The City Hall set an absolute deadline for October/2021 – the stations needed to be operational BEFORE November, when heavy rains begin in the region.

City Hall inspectors personally monitored multiple stages of manufacturing and assembly. The pressure was enormous: a delay would mean another year of flooding in the neighborhoods, with direct political impact.

EXECUTION IN TWO PHASES

PHASE 1 – WORKSHOP FABRICATION (18 MONTHS):

30 professionals working simultaneously:

• Cutting of plates and tubes (guillotine, saw, plasma)
• Forming (bending, folding)
• Drilling and chamfer preparation
• GTAW (TIG) welding with multiple passes
• Finishing and polishing
• Chemical passivation
• Inspection and release

PHASE 2 – ON-SITE ASSEMBLY (6 MONTHS):

Assembly teams:

• Transport of 150+ tons on special trailers
• Lifting of large pipes and structures (up to 5 tons/piece)
• Precise positioning and leveling
• Field welding with special protection
• Installation of auxiliary systems
• Hydrostatic tests and commissioning

HSE MANAGEMENT (HEALTH, SAFETY, AND ENVIRONMENT)

Works in urban environments close to residences and businesses require special care:

• Mandatory DDS (Daily Safety Dialogue)
• Safety signage around the entire perimeter
• Noise control (welding and cutting)
• Waste management (plates, electrodes, gases)
• Communication with local residents

ON-TIME DELIVERY

OCTOBER 2021 – exactly as established:

All 5 stations with installed structures
Approved hydrostatic tests
Successful commissioning
Operational systems before November

ACHIEVED RESULTS

Strictly met deadline: 2 years of fabrication/assembly
Zero accidents: In 48,000+ man-hours worked
 Premium Quality: 100% of inspections approved on the first attempt
 Customer Satisfaction: Governor, Mayor and Paulitec praised publicly
 Proven performance: 4+ years operating perfectly

QUANTITATIVE DATA

• Material manufactured: 150+ tons of AISI 316 Stainless Steel
• Rework rate: 0%
• Accidents: 0

LASTING IMPACT

The five EBAPs in Vila Velha represent critical infrastructure for more than 100,000 inhabitants living in the benefited areas. The AISI 316 stainless steel structures manufactured and installed by the Engport Group continue to operate flawlessly after 4 years of exposure to the harsh marine environment of the Espírito Santo coast – definitive proof of the technical quality of our deliveries.

This project consolidated our reputation in the large-scale public works segment and demonstrated our ability to work with high-quality materials on an industrial scale, maintaining the highest standards of quality and safety.