1. INTRODUCTION

This request for quotation is for the replacement of a shell segment with fixation for girth gear based on the existing kiln in the Holcim plant in Kujawy.

The replacement is planned for the kiln shutdown in 2026.

The bidders are invited to quote replacement.

Proposal date of project: January 2026

Place of project: Kujawy Cement Plant 88-190 Piechcin, Poland

 

2. COMMERCIAL PART

2.1 FORM OF OFFER

Offers have to be submitted until 15.03.2025 to:

Holcim Polska Spółka Akcyjna z siedzibą w Małogoszczu adres: ul. Warszawska 110 (28-366)

Category Manager

Sebastian KUSZ

Phone +48 572 700 135

Mail to: sebastian.kusz@holcim.com

 

Preventive Maintenance Manager

Bartłomiej MACIEJEWSKI

Phone +48 502 786 260

Mail to: bartlomiej.maciejewski@holcim.com

 

The offer has to be valid at least 2 months after the deadline.

 

2.2 SCOPE OF WORK

The scope of work shall comprise:

● Engineering & Integration: All necessary engineering work required to integrate the new kiln section into the existing system, including labor, materials, and travel.

Fit & Compatibility: Ensuring the new components properly align and fit within the existing kiln structure.

Quality Standards:

- the kiln shell’s roundness, eccentricity, and total run-out must be at least equal to or better than their pre-disassembly levels.

Reference Data: The actual pre-disassembly values can be found in the file "2025_02_19_Kiln_1 backup" or "2025_02_19_Kiln (K. Zarychta, T. Sobczak).pdf"

- the vibration of main drive must be at least equal to or better than their pre-disassembly levels: 2024_06_07_pomiar_regulacje_2147408634 (1).pdf

● Quality assurance (considering 3rd party inspection at Holcim cost)

● Supervision services for erection and commissioning

● Erection services

● Trial operation and commissioning of the new system

● All technical documentation (WPS, etc.)

The Supplier bears overall responsibility for all tasks connected with the erection of the new system that is necessary for the disassembly and full reassembly of the equipment. The system must be complete in all respects (whether or not this is explicitly mentioned in this tender document).

 

The completion of the project includes, in chronological order, the completion of the following stages:

I Measurement

II Erection, Installation and Commissioning

III Tests on Completion (Dry Run, Trial Operation, Performance Test)

IV Provisional Acceptance

V Warranty Period

VI Final Acceptance

 

2.3 Detailed description

1. Shell replacement from 20.000 mm to 39.100 mm like in attachment: kiln shell.pdf)

2. Girth gear disassembly and assembly after flip 180 deg. (drawing : Girth gear.pdf)

The measurement values after completing the work must be within the permissible limits specified in the documents:

- Checklist_girth_gear.pdf

- Record sheet: girth gear measurement record.pdf

3. Changing bearing of pinion (drawing in attachment Pinion bearings.pdf)

4. Changing inlet plates- 32 pcs (drawing in attachment Inlet plates.tif)

5. Changing outlet plates pos.8 (32 pcs (drawing in attachment Outlet plates .pdf)

6. Check tensioning system on fixation tire no.1 and make correction to design tensioning value (drawing: Pierścień - system mocowania.tif)

7. Cleaning splash lubrication system with paddle wheel. Changing wear pipes on paddle wheel (2.7)l- drawing Pinion bearings.pdf

 

Customer supply:

- Kiln shell section:

• Length determined by the replacement company.
• Acceptance in accordance with the project and standards – the contractor has to confirm that the work has been carried out in compliance with the design and applicable standards-participation in factory acceptance is mandatory

- Girth gear fixation system

- Bearings for pinion

- Inlet and outlet plates with fixation

- Refractories

 

2.4. SPECIFIC REQUIREMENTS

1) The Bidder must provide references from the last five (5) years for completed projects involving the construction or refurbishment of kilns with a diameter of at least 4,800 mm.

2) The bidder must provide references from the last five (5) years for completed projects involving the assembly using the Polysius girth gear fixation system.

3) The bidder must ensure communication in Polish and English during each shift.

4) Mandatory Site Visit: A site visit is required as part of the bidding process to ensure bidders fully understand the project scope and site conditions.

5) The bidder must provide a detailed schedule at least 2 months before the start of work. At least in June the executor presents which part of the plant should be take over for need execution.

6) Provide an HSE coordinator for this jobsite in order to apply our company’s health and safety rules. Note: the HSE coordinator will be present throughout the period of the works

7) Protection while work is carried-out. While dismantling collective protections (walkways, handrails, etc.), provide lifelines, rigid barriers, etc.When the kiln is dismantled, provide protection around the assembling area.

8) The access conditions to the jobsite area at the Kujawy Plant must be clearly identified by the contractor during the costing phase and before work starts.

9) The assembly areas and location of cranes or scaffolding shall be indicated by the Contractor before commencement of works. All these conditions will need to be defined by scheduling the project and shall be subject to approval by HOLCIM

10) Documents to be provided:

- All design calculations which are needed for this project.

- Modelled dismantling-assembly procedure.

- Welding procedure.

- All these points must be included with the items/services supplied.

- List of personnel involved (function and speciality),

- Workers’ medical skills (and specific for work at height and in confined spaces),

- Workers’ qualifications according to activity (electrical, machine operators, welding,etc.)

- Safety training certificates according to activity (wearing of PPE, scaffolding access, confined spaces, etc.)

- Construction site public liability insurance,

- Jobsite team organisational chart.

- Mandatory forms for foreign workers.

- Professional Qualification Certificate for rope access technicians.

- You must inform us of the number of temporary workers, seconded workers and employment contracts.

11) Replacement of kiln and girth gear fixation system according Polysius kiln design,

12) The bidder must provide (in offer) the final length of the segment to be delivered, with the aim of optimizing costs.

 

13) The bidder indicates lead times and the times which asses as being required for these operations in the bid: according to the list of tasks, the replacement method, the technical proposal and the pre-schedule, in compliance with the schedule defined by bidder. We request that you give the minimum times in order to carry out the work as quickly as possible

14) All the equipment needed to carry out the work (cranes, scaffolding, welding machines, bolting machines, etc.), in accordance with the safety rules.

15) The costs incurred in unloading the items supplied (equipment, materials and accessories), their storage at and their removal from the jobsite.

16) The Kujawy Plant will be in continuous operation throughout the whole period of pre-assembly on the ground.

17) All of your supplies will be placed near the site or in a location defined by the Kujawy contact person

18) The refractory lining will have been removed and installed by the refractory bricklaying company Holcim contractor)

19) For the scaffolding estimate, the construction volume in cubic meters (m3) must be calculated.

20) The bidder provides temporary support for kiln lifting.

21) Steel offcuts (Pieces fitted to a standard scrap container.) shall be placed in the scrap yard within a maximum of eight days in allocation defined according to the instructions given by the Holcim contact.

22) For cranage operations, it is essential to provide one person on the ground to manage hoisting safety. For foreign companies: To ensure good understanding and transmission of orders to the crane operator, it is essential to provide a lifting supervisor who speaks Polish and English.

23) The Subcontractor will be responsible for cleaning operations at the end of the construction work. These cleaning operations will need to be inspected and approved by the Client.

24) The subcontractor is required to attend site meetings convened by Holcim or to delegate, after agreement, power to a person responsible to immediately give the necessary orders on the jobsite.

Daily meeting at 8.45 am (during the kiln shutdown), to ensure proper coordination according to the numerous jobsites located around the plant. The site manager must in all cases be present with the Holcim contact person at the site planning meeting (meeting duration: approximately an hour).

Daily meeting at 6 pm (during kiln shutdown), is dedicated to monitoring the kiln site only.

25) Before starting the work, the Contractor will have visited the jobsite to familiarise themselves with the site and its specific characteristics. The services are established with full knowledge of the facts and under their liability.

26) The bidder must specify the number of site containers (tools) required and the number of portable buildings needed for use as offices (or other) so that we can set aside a location in the work area and living area. Determine, with plant representatives, the locations of electric power supplies for cabinets or boxes (planned and provided by the Contractor). All equipment, assembly tools and additional lighting must be connected to these. The bidder must define electric infrastructure needs

27) The work must be carried out in compliance with the Safety rules defined in the https://www.holcim.pl/zakupy and its appendices.

28) All works has to carried 24/7 with supervision on each shifts

29) The Contractor is responsible for all their services, even if some or all of these are performer by subcontractors. They are in particular responsible for:

a) The design, calculations and quality of their service.

b) Modifications which must be made to the work due to errors, omissions or differences in the service they provide, or failure to respond to information they have given or received

30) Responsibility of Kujawy Holcim

- Production shutdown

- Replacement of refractory lining.

 

More details can be found in the attachments.

 

Kind regards,

 

Patrycja Grzecza

Specjalista ds. Zakupów

Holcim Polska S.A.

Cementownia Kujawy w Bielawach

tel. 572 700 442

patrycja.grzecza@holcim.com