The project
Assembly tooling
Assembling °ÄÃÅÁùºÏ²Ê¸ßÊÖ requires tools to lift, tools to suspend, tools to transport, tools to assemble, tools to adjust ... over 100 custom devices have been designed for the assembly phases of the °ÄÃÅÁùºÏ²Ê¸ßÊÖ machine.
Gallery
Things in reverse
2023-08-29
The "upending tool" had to turn into a "downending tool" in order to remove sector #8 from the sector sub-assembly tool where it had been positioned. This unplanned for operation required study and measurements.
Same tool, different operation
2023-08-29
The assembly of sector module #7 was almost finalized when the decision to stop the process and to dismantle was taken at the end of 2022. The reverse operation—the disassembly of the different elements making up a sector—is underway to prepare for repair work. (/newsline/-/3882
Manipulator arms: super strong and ultra precise
2023-01-10
This is the in-vessel tower crane developed by CNIM Systèmes Industriels, a remote-controlled mobile manipulator that travels 360° around the interior of the vacuum vessel on dedicated rails. It can carry internal components weighing up to 5 tonnes and position them at any location inside the vacuum vessel to better than 0.5 mm accuracy. Two of these manipulators are planned.
Tools for in-vessel component installation
2023-01-10
At this Trial, Test and Training Facility at CNIM Systèmes Industriels (Toulon, France), bespoke mechanical handling solutions have been developed for the installation of components on the inner wall of the °ÄÃÅÁùºÏ²Ê¸ßÊÖ vacuum vessel. In 2022 and early 2023, the entire suite of tools passed acceptance testing ''with flying colours.'' (Read more at /newsline/-/3835.)
To be transferred to °ÄÃÅÁùºÏ²Ê¸ßÊÖ
2023-01-10
This scale-one Trial, Test and Training Facility reproduces one-third of the °ÄÃÅÁùºÏ²Ê¸ßÊÖ vacuum vessel and a single port cell corridor. It will be transferred along with all tools and mockups to °ÄÃÅÁùºÏ²Ê¸ßÊÖ for operator training and procedure development.
Sturdy
2022-09-09
The in-pit assembly tool enters action for the first time, supporting the sector module built around vacuum vessel sector #6.
Tools galore
2022-09-08
In this view from the rafters, major pieces of the assemlby "toolkit" are laid out before us.
Busy cranes
2022-09-06
A 110-tonne central solenoid module hangs from one set of overhead cranes. The Assembly Hall is equipped with two sets: the heavy-duty 750-tonne cranes that work together to lift loads of 1,500 tonnes, and a smaller set of 50-tonne auxiliary cranes.
Early engineering studies in Korea for an important tool
2022-07-18
Before °ÄÃÅÁùºÏ²Ê¸ßÊÖ's giant vacuum vessel sector sub-assembly tools could be manufactured, the team at SFA Engineering Corp., Korea, built this 2010 mockup at one-fifth scale to perform structural and functional tests, and to demonstrate the global kinematics of the system. See the story here: /newsline/-/3778
A particularly complex rigging
2022-05-11
Particularly complex rigging is on display during the transport of the first vacuum vessel sector module into the pit. Between the blue cable hooks and the component itself (deep in the pit) we see the Dual Crane Heavy Lifting Beam (DCHLB, in yellow) that synchronizes the four hooks of the cranes into a single lift point and enables the rotation of the load, and the grey Sector Lifting Tool. This last rigging attachment connects to both the DCHLB and the radial beam to precisely align the load with the cranes.
Showing their numbers
2022-05-05
During sector module lift tests on 5 May 2022, the overhead bridge cranes display their numbers—each of the crane's four hooks is supporting a load of approximately 345 tonnes (only two of them are visible in this image). The total weight of the sector module plus its rigging apparatus is in the range of 1,380 tonnes—the equivalent of four fully loaded Boeing 747s. See the story at: /newsline/-/3754.
A gripping tool for central solenoid assembly
2022-03-17
This unique tool was designed by US °ÄÃÅÁùºÏ²Ê¸ßÊÖ to clutch 110-tonne central solenoid modules and hold them in its grip by exerting a strong radial force. The modules cannot be lifted in a traditional manner because it is impossible to add hooks and other lift fixtures to the superconductors.
Working at height
2022-01-19
Scaffolding surrounds the docked sector to give access to every level of the giant component. Still, a bucket truck can be useful ...
Two tools in a row
2021-12-21
In December, for the first time, each sector-sub assembly tool (SSAT) had its own vacuum vessel sector...
Complex rigging
2021-12-20
The rigging for a vacuum vessel sector (440 tonnes) is particularly complex. For more information, see this article: /newsline/-/3592
Up and into the SSAT tool
2021-12-20
A vacuum vessel sector is slowly lowered into a sector sub-assembly tool (SSAT #1). Two identical tools allow the assembly team to go twice as fast.
The well-named column tool
2021-12-20
The central column of the in-pit column tool is in place. The nine radial beams will arrive next, each one designed to support a vacuum vessel sub-assembly by sharing the weight of the load between the central column and the concrete wall of the pit.
Horizontal to vertical
2021-12-08
The upending tool raises °ÄÃÅÁùºÏ²Ê¸ßÊÖ's heaviest components (vacuum vessel sectors and toroidal field coils) from horizontal to vertical. In this photo, it is sector #1(7) from Korea.
A purpose built tool for cylindrical magnets
2021-11-04
In yellow, the purpose built central solenoid lift tool. Manufactured by Robatel (France) for the US Domestic Agency, it will move soon from storage in the Cryostat Workshop to the central solenoid work station in the Assembly Hall.
Different types of rigging
2021-10-21
For each lift, the rigging is adapted to the load. Here the rigging (in yellow) for this bottom correction coil allows for a smooth and balanced transfer, with no tilting.
Over the top
2021-10-21
Once completed, the sector sub-assemblies will be lifted vertically out of the SSAT tool. The required height above the tool for this operation helps to explain the height of the bridge cranes in the Assembly Hall. © Les Nouveaux Médias/SNC ENGAGE
Central solenoid assembly platform
2021-10-20
The assembly platform for the °ÄÃÅÁùºÏ²Ê¸ßÊÖ central solenoid has been positioned in the Assembly Hall (load capacity: 1,300 tonnes). Six modules will be stacked on top of this platform inside of a strong supporting structure. © Les Nouveaux Médias/SNC ENGAGE
Testing a radial beam
2021-09-07
Radial beams will arrive in the pit supporting each vertical vacuum vessel sub-assembly as it travels by overhead crane. Their precise positioning is paramount for the alignment of the machine torus. A test operation, in September, demonstrated that tolerances were respected.
°ÄÃÅÁùºÏ²Ê¸ßÊÖ's largest tools
2021-09-07
This tall three-pillared sector sub-assembly tool (SSAT) weighs 700 tonnes, and is capable of supporting a vertical vacuum vessel sector (440 tonnes, centre) and two toroidal field coils (2 x 350 tonnes, left and right). Impressive.
Central column in place
2021-09-01
Formed from a central column and nine radial beams, the in-pit column tool will support, align and stabilize vacuum vessel sub-assemblies as they are joined and welded. The tool is designed to support a nominal weight of 5,400 tonnes.
First building block takes shape
2021-08-30
With the scaffolding now removed, the three constitutive components of the first sub-assembly are revealed in all their technological splendour and complexity: to the right, the 40° vacuum vessel sector encased in its silver-plated thermal shield panels; to the left, toroidal field coil #12. (Toroidal field coil #13 is only partly visible through the sector's D-shaped opening.)
First coil in tool
2021-06-09
In a series of operations that started on 9 June and concluded six days later, TF12 was successfully attached to the left wing of one the twin sector sub-assembly tools (SSAT-1). The 320-tonne coil will be moved to SSAT-2 in about a month for the actual pre-assembly operations.
Stabilizing attachments
2021-04-26
A special lift attachment between the load and the bridge cranes ensures that this component, poloidal field coil #6 (PF6), is kept stable (no tilt) for the duration of the transfer.
First sector safely docked
2021-04-06
Supported by a radial beam above, vacuum vessel sector #6 is now safely docked in the sector sub-assembly tool (SSAT#2).
First piece
2021-03-27
The bottom cylinder of the tool was installed in the pit on 27 March 2021. Four other segments will be added to form the +20-metre-tall central column.
A 90° tilt in mid-air
2021-03-26
The first vacuum vessel sector is upended on 26 March 2021, the culmination of close to one year of planning and rehearsal.
Upending operation
2021-03-25
This specialized upending frame will be used to raise two types of large components—vacuum vessel sectors (440 tonnes) and toroidal field coils (360 tonnes)—from their horizontal delivery configuration to vertical for subsequent installation on the sector sub-assembly tools. The "tilt" operation is carried out in coordination with the overhead cranes.
Strong hands
2021-03-25
The heavy-lift bridge cranes have been operating in the complete assembly space (Assembly Hall + Tokamak Building) since March 2020.
Heavy base for a strong task
2021-03-20
Close to 6 metres tall and weighing approximately 70 tonnes, this is the first segment of the in-pit column tool, the bottom cylinder. Hollow inside, it will permit access to different levels of the vacuum vessel during in-pit welding operations. Four other segments will follow to build the full column.
In-pit assembly tool
2021-03-09
Formed from a central column and nine radial beams, this tool is installed inside of the Tokamak pit to support, align and stabilize vacuum vessel sub-assemblies as they are joined and welded. With the central column anchored to the Tokamak Building basemat and the radial beams supported between the column and the concrete bioshield, the in-pit assembly tool is designed to support a nominal weight of 5,400 tonnes.
Major tools, all in a row
2021-03-01
Some of the major assembly tools are visible in this photo: the sector sub-assembly tools (22 metres tall, right); the upending tool (in its raised position, left); and the °ÄÃÅÁùºÏ²Ê¸ßÊÖ bridge cranes.
3 handling devices
2021-02-28
Under the overhead crane, the 90-tonne "dual crane heavy lifting beam" (yellow) provides a single connection for the next-layer of lifting attachment. The second layer—the sector lifting tool—interfaces at three points with toroidal field coil lifting beam. The lifting beam (also called a radial beam) connects directly to the top of the vacuum vessel sector (which is represented here by the dummy load).
Just right
2021-02-16
The success of another trial operation: the two wings of the sector sub-assembly tool are rotated inward with their two outboard segments of vacuum vessel thermal shielding, and the precision of their alignment is measured.
Double load trials
2021-01-12
Testing continues with two dummy loads.
Putting the tool through its paces
2021-01-12
Operators are practicing with a dummy load to prepare for the upending operations to come—the tilting from horizontal to vertical of vacuum vessel sectors and toroidal field coils.
Next tool to be installed
2020-12-22
In December, part of the central column of the in-pit assembly tool is moved to the antechamber of the Assembly Hall. © Les Nouveaux Médias/SNC ENGAGE
A new tool arrives from Korea
2020-11-02
The "sector lifting tool" is one of the interfacing components between the heavy lift cranes and some of the heaviest °ÄÃÅÁùºÏ²Ê¸ßÊÖ components. The tool is equipped to perform horizontal-plane adjustments along the X and Y axis (longitudinal and transverse) in order to balance the loads before each lift.
Functional tests conclude on sector lifting tool
2020-10-14
Functional tests on the "sector lifting tool" have demonstrated that the tool's controller and actuators are ready to implement operator commands during the delicate lifting operations of vacuum vessel sectors, toroidal field coils, and the finalized sector sub-assemblies.
Practicing with the upending tool
2020-04-10
The upending tool is brought to vertical by the overhead cranes during commissioning tests in the Assembly Hall.
A big beam for a heavy load
2020-03-28
The double overhead bridge crane comprises four such 47-metre-long, 155-tonne steel girders, or beams. Arranged in two pairs and working in tandem, they can lift up to 1,500 tonnes. The double overhead bridge crane was tested at 125 percent of its capacity (1,870 tonnes) in December 2017.
Testing the path before the real loads
2020-03-28
Totaling approximately 1,000 tonnes, the mock loads are ready to undertake their 170-metre-long journey from the entrance of the Assembly Hall all the way to the opposite end of the newly created crane hall. Testing the load path, and carefully monitoring building inflection as the loads go by, are part of the last commissioning activities before machine assembly.
1,000 tonnes
2020-03-28
The 840-tonne double load on the "north bridge" of the crane (right) is complemented by a 156-tonne load on the "south bridge," bringing the total to a little more than 1,000 tonnes. Calculations and modelling are used to extrapolate the effect the actual 1,500-tonne loads will have on the building's structure.
Like a steel cradle
2020-03-02
Procured by Korea, the upending tool is a 250-tonne steel "cradle" designed and equipped to handle vacuum vessel sectors and D-shaped toroidal field coils throughout the "pre-assembly" phase.
First steps
2020-03-02
An important step for every tool, once assembled, is testing and commissioning. This step verifies that the tool is performing according to specification and also serves to train operators.
Teamwork
2020-03-02
Early tests on the upending tool are carried out under the supervision of the °ÄÃÅÁùºÏ²Ê¸ßÊÖ Organization. The operation was coordinated by MOMENTUM (°ÄÃÅÁùºÏ²Ê¸ßÊÖ's Construction Management-as-Agent) and involved Apave (security), contractors from the assembly consortium DYNAMIC, an operator, and an engineer from crane manufacturer REEL.
Preparing all processes
2020-02-25
°ÄÃÅÁùºÏ²Ê¸ßÊÖ specialists and contractors involved are testing "processes"—not just lifting systems and the loads to be handled, but their interaction and the whole kinematics of upending, transporting and manipulating charges that can be as heavy as four fully loaded Boeing 747s. Here, we see the upending tool in testing.
Up in the rafters
2020-02-18
Soon, these bridge cranes will be able to travel double distance—not only the length of the Assembly Hall, but that of the adjacent building as well. Crane commissioning activities over the Tokamak pit will start once the temporary wall comes down.
Back in service
2020-02-14
Two 360-tonne test loads are back on the main tools of the Assembly Hall. With extra weight added, they will be used to commission the overhead cranes in the new crane hall of the Tokamak Building. The temporary wall between the buildings is coming down now.
Next to test: the upending tool
2019-12-13
Tool commissioning is an important activity, during which the all specified functional requirements are demonstrated. Also, for tools sourced outside of the European Union, it is the occasion to show compliance with EU regulations.
Load tests conclusive
2019-11-27
The commissioning phase for the twin sector sub-assembly tools (SSAT) in the Assembly Hall is over. The final verification tests—with test load (photo)—demonstrated that both tools are performing to expectation.
Upending tool arrives
2019-11-14
The two halves of the upending tool (right) are headed for installation in the far right corner of the Assembly Hall, on the area of floor that has been painted.
The doors open and ...
2019-11-07
... the segments of the upending tool, delivered by Korea, enter. This large structure is designed to "upend" °ÄÃÅÁùºÏ²Ê¸ßÊÖ's largest components (toroidal field coils and vacuum vessel sectors) from horizontal to vertical.
Shift of weight
2019-09-30
In late September, the second 360-tonne load (at left) was transferred to SSAT tool #2 (on the right). After one month of functional tests on the second tool, the loads will be removed and stored until needed for the testing of the "upending" structure that has been shipped by Korea.
Two mounted
2019-07-23
Two mock loads were built in Scotland by Doosan Babcock and shipped to °ÄÃÅÁùºÏ²Ê¸ßÊÖ for assembly. They represent a combined weight of 700 tonnes, now mounted on the tool SSAT#1. Rotational tests begin late in July.
Two mock loads
2019-07-11
Two mock loads weighing 350 tonnes have been constructed from steel and concrete (far left) to represent the D-shaped toroidal field coils that will be mounted on the wings of the assembly tools. Lifting and installation will begin soon.
Open arms
2019-07-03
Standing in front of one of the sub-sector assembly tools is Swiss photographer Luca Zanier, who spent two days at °ÄÃÅÁùºÏ²Ê¸ßÊÖ in July in pursuit of "unusual" perspectives in industry.
Loads prepared
2019-06-12
Load tests are about to start on the twin sector sub-assembly tools (SSAT). The mock loads in the foreground—weighing 350 tonnes each—will be installed on the tool "wings" to measure their capacity to rotate inwards and adjust to within millimetre tolerances.
Mechanical testing underway on SSAT tools
2019-04-25
With both sector sub-assembly tools (SSATs) now erected, mechanical load testing can start. In April, teams begin testing the movement of upper alignment units. Load testing is schedule for June.
A pair of hands is still useful
2019-01-10
Lessons learned from the first tool have reduced assembly time for SSAT-2 by approximately one-third. Still, some manual operations are still required...
Heavy machinery
2018-02-20
Two pairs of hands will manoeuvre the °ÄÃÅÁùºÏ²Ê¸ßÊÖ components from above in the Assembly Hall—the 1,500-tonne crane (on higher rails) and the 50-tonne crane, both visible in this photo. The cranes were supplied by the French firm REEL as part of European procurement contributions. © Les Nouveaux Médias/SNC ENGAGE
After-hours load tests for the crane
2017-12-18
Late at night in December the principal crane of the Assembly Building was subjected to loads that were +10%/+25% of nominal—all part of commissioning tests for the important equipment.
It's midnight, but these teams are at work
2017-12-18
Observers during the load tests include representatives of the crane manufacturer Reel, the °ÄÃÅÁùºÏ²Ê¸ßÊÖ Organization, the architect-engineer Engage, and the safety controller Bureau Veritas.
Complex machinery
2017-11-22
Trolleys and cranes of various capacities fill most of the space in the Assembly Hall rafters. Like a catwalk in a theatre, they host the invisible machinery that makes the production possible.
Cranes galore
2017-11-22
Cranes galore This striking view takes in the whole lifting system installed in the Assembly Hall: the massive double overhead bridge crane, with a lifting capacity of 1,500 tonnes (top), and its much smaller sibling the 50-tonne auxiliary crane sitting on rails three metres below.
2017-11-22
Load tests are scheduled to begin in the first week of December. A final test at 25 percent over-capacity (1,875 tonnes) will verify that the flexion of the 43-metre-long bridge crane girders remains within specifications.
A full view
2017-11-08
Looking down across the full 97-metre length of the Assembly Hall. The travelling cranes are approximately 45 metres above floor level.
Looking up
2017-07-12
The two large overhead cranes of the Assembly Hall are currently undergoing functional tests.
Modular tools for in-vessel assembly
2016-05-15
In order to carry out the installation of the °ÄÃÅÁùºÏ²Ê¸ßÊÖ in-vessel components—such as the diagnostic looms, in-vessel coils, blanket shield blocks and first-wall panels—the °ÄÃÅÁùºÏ²Ê¸ßÊÖ Organization will require a set of specifically engineered tools. The °ÄÃÅÁùºÏ²Ê¸ßÊÖ Organization is working with CNIM (Toulon, France) for a trial, test and training facility that demonstrates that the tooling can achieve the required in-vessel assembly tasks.
The sub-assembly of the nine vacuum vessel sectors
2014-11-15
The °ÄÃÅÁùºÏ²Ê¸ßÊÖ "toolkit" for assembly will include very large, heavy, strong, expensive and precise tools.
Extremely specialized sub-assembly equipment
2014-11-14
This 22-metre-high sector sub-assembly tool will assemble components weighing a combined mass of 1,250 tonnes: one 40° vacuum vessel sector; two toroidal field coils; and thermal shields. Most of specialized purpose-built tooling for °ÄÃÅÁùºÏ²Ê¸ßÊÖ assembly will be supplied by Korea, as part of its procurement commitments to °ÄÃÅÁùºÏ²Ê¸ßÊÖ.
The vacuum vessel Sector Sub-Assembly tool
2014-11-13
Standing shoulder to shoulder, two Sector Sub-Assembly tools will suspend the vacuum vessel sectors from the top while carefully positioning and installing—via the rotary motion of the "wings"—the vacuum vessel thermal shielding and two toroidal field coils.
Upending the largest components
2014-11-13
"Upending" the vacuum vessel sectors Appropriately termed the "upending" tool, this specialized tool will lift the 40° vacuum vessel sectors from the as-delivered horizontal orientation to vertical orientation for sub-assembly with two toroidal field coils and thermal shields. This tool will also be used to upend toroidal field coils.
Work platforms in the vacuum vessel
2014-11-13
Modular platforms at four levels are planned to provide access for in-vessel installation activities. As a highly adaptable modular structure, the staging can be broken down into 10-degree sections to allow for the movement of in-vessel cranes and other handling tools.
Perfect
2014-11-13
The lifting of this 440-tonne vacuum vessel sector and its positioning in the sector sub-assembly tool was a master class of coordination and precision.
The °ÄÃÅÁùºÏ²Ê¸ßÊÖ Tokamak Building bridge cranes
2014-11-13
In their tandem configuration of two trolleys carrying two 375-tonne cranes respectively, the °ÄÃÅÁùºÏ²Ê¸ßÊÖ bridge cranes will be capable of lifting loads of up to 1,500 tonnes.
How the upending tool works
2014-11-13
The loads will be suspended several metres above the ground as one side of the upending tool is winched to vertical. The tool will then be lowered and secured as the vacuum vessel sector (left) or the toroidal field coil (right) is lifted up and away to be delivered for pre-assembly activities.
Lifting configuration for poloidal field coil #5
2014-11-13
Most of the °ÄÃÅÁùºÏ²Ê¸ßÊÖ components with large diameters, like the poloidal field coils or the cryostat segments, will be handled by the synchronous use of four universal lifting beams connected to as many 375 tonne crane hooks.
In-pit assembly tool
The in-pit assembly tool is made up of a central tower and a series of beams. This tool will support the vacuum vessel sub-assemblies and align them while the vacuum vessel is assembled.
On the inside of the vacuum vessel
During assembly of the °ÄÃÅÁùºÏ²Ê¸ßÊÖ vacuum vessel—11 metres tall with an interior diameter of 6 metres—temporary floors, ladders and bridges will be set into place for the teams.
1200
tonnes heaviest component
22
metres tallest tool
100
custom devices
1500
tonnes bridge crane capacity
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Assembly tools
°ÄÃÅÁùºÏ²Ê¸ßÊÖ BRIDGE CRANES
Two sets of bridge cranes installed at a height of 46 metres are the major lift and transport tools for delivering components from the Assembly Hall to the Tokamak pit. The heavy-duty set (two 750-tonne cranes) can work together to lift loads of 1,500 tonnes—or the approximate weight of four jetliners. The system is complemented by two smaller 50-tonne auxiliary cranes. (Procured by Europe)
SECTOR SUB-ASSEMBLY TOOLS
Standing six storeys high in the Assembly Hall, the 800-tonne tools suspend the vacuum vessel sectors while carefully positioning and installing—via the rotary motion of the "wings"—thermal shield panels and two toroidal field coils. Actuators will permit the components to be positioned with the highest degree of accuracy (1.5 mm for the toroidal field coils) and adjusted to six degrees of freedom (up and down, side-to-side, forward and backward, swivel, tilt, and pivot). The completed "sector sub-assembly" to be transported to the Tokamak pit weighs 1,200 tonnes. The operation must be carried out nine times, for nine vacuum vessel sectors. (Procured by Korea)
IN-PIT ASSEMBLY TOOL
Formed from a central column and nine radial beams, this tool is installed inside of the Tokamak Pit to support, align and stabilize vacuum vessel sub-assemblies as they are joined and welded. With the central column anchored to the Tokamak Building basemat and the radial beams supported between the column and the concrete bioshield, the in-pit assembly tool is designed to support a nominal weight of 5,400 tonnes. (Procured by Korea)
CRYOSTAT INSTALLATION AND ALIGNMENT TOOLS
Purpose-built transportation and lifting tools have been designed for the installation of each cryostat section (base, lower cylinder, upper cylinder, top lid). Once installed, the sections are brought into alignment with the tokamak global coordinate system through hydraulic jacks. (Procured by the °ÄÃÅÁùºÏ²Ê¸ßÊÖ Organization)
TOROIDAL FIELD COIL ALIGNMENT TOOL
The in-pit installation tool for toroidal field coil pairs moves the D-shaped superconducting coils a few millimetres along three axes and ensures their precise positioning inside of the Tokamak pit to within 1/10th of a millimetre. It also performs the final adjustment of the Tokamak's nine sectors. (Procured by the °ÄÃÅÁùºÏ²Ê¸ßÊÖ Organization)
POLOIDAL FIELD COIL ASSEMBLY TOOLS
This group of tools includes, for each coil: a transportation frame, purpose-built survey tools, lifting adapters to interface with lifting beams, and installation tools and adjustable supports. (Procured by Korea)
CENTRAL SOLENOID TOOLS
Assembly of the six central solenoid modules into an 18-metre-tall stack (including support structures) requires a dedicated space in the °ÄÃÅÁùºÏ²Ê¸ßÊÖ Assembly Hall and specialized tooling including an assembly platform designed to support 1,300 tonnes and a module lifting fixture. (Procured by the US)
