6
Worldwide specialists in heavy lifting and transport
2006
MAMMOET WORLD
Our Red Men ...
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Coke drums moved by Mammoet First job PTC III
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Relocating a complete steel factory Offshore lifting in the Caribbean Transformer transformed
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Our Red men … Forty years ago last April, my father, Jan van Seumeren senior, set up Van Seumeren Kraanbedrijf SKB and laid the foundations for today’s Mammoet. His modest ten-man company in De Meern has grown into a leading player on the world stage. We now have 60 companies in 30 countries and more than 1,800 employees, working in such varied markets as petrochemicals and civil engineering, power and offshore, marine and equipment rental. Roderik van Seumeren, Despite the enormous growth in President & CEO. size, our activities have essentially remained unchanged, although we have established a name for ourselves in really complex projects in recent years. We are and will remain service providers and problem solvers with heavy lifting and transport solutions as our core activities, as illustrated by the many projects featured in this edition of Mammoet World. A 40-year history is nothing to be sneezed at – especially if you think that a company’s average life expectancy is just 12½ years, regardless of its size. It makes you wonder why Mammoet has lasted so long. For me, the answer lies in ‘our red men’, as our counterparts in the business call us. Those red men represent the Mammoet feeling, the Mammoet style, the Mammoet heart, loyalty and enthusiasm. They approach their work with an attitude that can best be described as precisely the right kind of guts. The kind of guts that has got nothing to do with recklessness, quite the opposite. It is made up of professional skill, love for the job and enterprise. It is the sort of guts my father and of course especially his successor, my brother Frans, had: the enterprising professional who always had both feet firmly on the ground. Frans also had the drive to undertake new challenges, to dare to propose different and original solutions and the courage to change course when necessary. I am convinced that his way of doing business – being an expert service provider who constantly makes a creative contribution to solving the client’s problems, no matter how big the company – is the key factor in Mammoet’s current reputation. The last two years, a new generation of Van Seumerens is at the helm Patrick, Jan Junior and myself. Together with Siem Kranenburg, we are Mammoet’s management team. We want Mammoet to grow further and become even more professional, building on what we have achieved in the past 40 years. We might have grown in size, but the world in which we operate is changing faster than ever before and making new demands on the way we work. That is why we will continue to invest in resources, especially in people who have the right kind of guts. The guts that are needed to look at ‘tried and tested solutions’ with fresh eyes: can we make it better, can we do it smarter, can the best solution to one challenge be used on a comparable project and can we work just that little bit more efficiently? In a changing world, it’s the people who matter most. People who have a nose for innovation, who never get stuck in routines, who have the courage to shoulder their responsibilities and use their own common sense – and you can be sure that common sense takes guts. All our crew have personal veto rights. Even with very thorough pre-engineering and preparation, some details might turn out to be different in practice. Every Mammoet employee has the right to stop any operation that they feel is potentially unsafe. That calls for the kind of determination and confidence that is first nature to professionals who not only know that they have final responsibility for the work but also enjoy the continuous support of the management. It is our job to encourage that kind of guts by constantly proving our own commitment. It is better to stop an operation once too often than regret not doing so later. The challenge for the years ahead is to grow the company and adapt it where necessary while retaining the Mammoet feeling, Mammoet style and Mammoet heart. So that we are known as that unique heavy lifting and transport solutions company with ‘our red men’, carrying out everything from equipment rental and straightforward engagements to the most complex projects that draw on our specific know-how and innovative skills. We are pleased to present this year’s edition of Mammoet World, featuring some of the eye-catching projects we have carried out in the past 12 months.
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‘customer decides what quality is’
Patrick van Seumeren, Vice President & COO.
Siem Kranenburg, CFO.
Jan van Seumeren jr., CTO.
We have seen some tremendous changes in recent years. Mammoet has enjoyed a huge increase in its business while the market has demanded competitive quotes, outstanding quality and prompt services. Commercial and operational excellence is essential if we are to continue to grow in this dynamic and demanding market with both multinational and local customer profiles. The management team, made up of Roderik van Seumeren (President and CEO), Patrick van Seumeren (Vice-President and COO), Jan van Seumeren Jr. (CTO) and Siem Kranenburg (CFO), explains how Mammoet pursues excellence by continuously working on the critical success factors of technical skills, innovative management, service, quality and safety. Mammoet has worked hard on strengthening its foundations in recent years. ‘Our employee skills, safety policy, management structure and corporate systems such as SAP are key to our competitive edge. That’s why we are investing in them,’ says Roderik van Seumeren. ‘We always have done, and we always will. This philosophy reflects the Mammoet way of working and underpins our position as a strong global firm with a very good financial standing and an attractive revenue stream.’ The same approach underlies the market strategy. Patrick van Seumeren: ‘We invest three-tier: to serve the top segment of heavy lifting and transport, to improve the regional operations, and to consolidate our basic market: equipment rentals. These investments reinforce each other because the segments are so closely linked.
Safety has top priority Continued investment in state-of-theart technology and equipment is extremely important but in the final analysis it’s the people who work with those investments who make all the difference. ‘They decide the final quality and, much more important, the customers’ satisfaction. Our pursuit of quality therefore focuses on continuously improving our customer services, both in our operational working processes and in our information and administrative processes. In other words, we are pursuing operational excellence. Throughout the world, we recognize the importance of internal training, safety awareness and development based on uniform professional standards. Every member of every
Shared knowledge and best practices Mammoet’s solid position and the effective customer support provided by its operations are due in part to the highly dedicated ICT team that provides the ‘glue’ in the organization. The SAP Enterprise Resources Program, for instance, now covers well over 95% of our organization. ‘It enables very fast communication, standard procedures, delivery of financial and other management information, and fully auditable consolidations. It is important not
Projects in the top segment, for example, gain high exposure for our expertise, professionalism and reliability. That feeds through into the regional and local markets and strengthens our position as an attractive partner.’ Striking the right balance in this three-tier strategy calls for careful judgment, if only because of the long leadtime between the investment decision and the creation of added value for the customer. ‘We have to rely on our understanding of the market and anticipate future demand as accurately as possible. Several markets are booming at the moment or have enormous potential and we have to match our investment decisions to them,’ says Roderik. Patrick adds: ‘One example of this is the growth of our portfolio with Mammoet Salvage. Others, described elsewhere in this edition of Mammoet World, can be found in our Equipment Management Department.’
crew, and every office worker too, must promote transparent service levels, knowledge and safety awareness. ‘Only such an integrated approach to safety makes you less prone to accidents,’ Roderik reiterates. Mammoet’s renowned safety regulations meet the highest industry standards. That is why safety always has top priority. The theoretical basis is laid through internal e-learning courses. New employees and externals working for Mammoet through a subcontractor are obliged to follow the courses. Then the real work begins: before an operation begins, Mammoet holds toolbox meetings and crews on the job are supervised by certified senior
only as a mean to share knowledge and generate information but also as a learning tool,’ says Siem. The intranet is available throughout the Mammoet organization. Managed by the SAP system, e-learning has been put in place and people are very enthusiastic about it. Many courses are now supported by electronic materials, examples, exams, videos and documentation. Achievements are registered and drive the certification of Mammoet’s employees. The program includes a wide range of courses for technical
employees. Jan van Seumeren: ‘They transfer experience and best practices to their teams because taking real decisions on-site requires more than just theoretical know-how.’ As well as having supervisors, Mammoet’s safety teams check the status on-site. Employees are even interviewed on-site to test their knowledge and safety awareness. ‘And, of course, we are constantly developing internal training programs and campaigns that vigorously and vividly remind us of the really important issues. We have just kicked off the “Mammoet Minds” Safety Campaign, for example, which is featured elsewhere in this Mammoet World.’
operators but there are also many practical courses for office staff and we are constantly adding to the range. Siem: ‘By rolling out the training program, we are living up to our ambition that shared knowledge and best practices should be available to all within our organization.’
Investing in a multicultural workforce
management development are tackled as global issues. Roderik: ‘Only then can you create recognizable quality and present Mammoet as a leading brand.’ Training is provided at local level and colleagues from all over the world come to the Netherlands to participate in study exchange programs. Mammoet provided five scholarships in 20062007 so that students from India could study at Delft University in combination with a
To put the theory into practice, on-the-job training programs managed by qualified supervisors are being implemented in several locations and in Kuala Lumpur a fully-dressed CC 1800 crane is available for dedicated learning purposes. For an international company like Mammoet, it goes without saying that language skills and
traineeship within Mammoet. Siem Kranenburg: ‘These investments create many career opportunities for the people concerned and also improve Mammoet’s resource planning. The same is true of our dedicated management development programs. We run these cross-border and in doing so we create the well-qualified managers we need for our future. Similarly, our standardized training and development program adds to the mobility and flexibility of our workforce. Qualified operators from Malaysia, for example, can be added to our teams in Sakhalin. Training & Development contributes to the concept of One Mammoet, worldwide!’
because in the end our customers have to be satisfied with our performance. An uneventful execution of a job is probably the best compliment we can get. It means that our preparations have paid off, that we could cope with all the circumstances and that our crew made the right decisions,’ Roderik concludes.
‘Although we have grown into a mature, professional, global firm, we have managed to preserve the basics that made Mammoet a great company: doing what we do well and constantly working on doing it even better, even smarter and even safer to serve our customers even better. And that is what we are going to focus on in the future, too,
Mammoet Minds MAMMOETMINDS
MAMMOETMINDS
MAMMOETMINDS
Mammoet employees sharp and focused on workplace health and safety, Mammoet periodically launches new safety campaigns.
Management support statements Themes linked to day-to-day operations
!
!
WE CARE!
KEEP THINKING
We Care! Keep Thinking! Look out! Mammoet’s performance is the result of a carefully maintained balance between man and machine. When handling heavy cargo and equipment representing huge investments, often on sites where operations continue and traffic keeps on moving, a disruption in the scheduled activities may lead to losses and
! LOOK OUT!
extra costs. What is more important, even a slight oversight can lead to a potentially dangerous situation that could harm people who are on the site or nearby. Every Mammoet employee is trained in safety awareness and knows what his individual responsibilities are, from giving feedback to colleagues, to stopping operations immediately. To keep
busy. It is better to schedule specific contact moments.
Mammoet recently developed a new campaign under the name ‘Mammoet Minds’. It will run at least three years, with a different theme being highlighted every three months. To avoid routine and put the message across clearly, the concept summarizes the core message using three icons – a house, a cloud and a warning sign – symbolizing We Care!, Keep Thinking! and Look Out! The concept will be rolled out using several channels and will be integrated into the regular training and learning programs and into the toolbox that supports safety awareness on the sites. The themes are a perfect reflection of the day-to-day operations. One of the first themes will be the cell phone. In some situations, especially in the petrochemical sector, cell phones have to be switched off to prevent interference with electronic equipment. In other cases, a cell phone conversation can distract an operator and stop him from concentrating on his work. The campaign illustrates the risks in order to remind on-site operators about the regulations and safety issues and also to make office staff more aware of how to use cell phones. They should not call operators when they are
The campaign’s sharp focus on safety awareness and safe conduct is inspired by the conviction that safety is an important issue for your own well-being and that of other people. The campaign will emphasize on a personal and pro-active approach for which different cross-cuts of the personnel will be reached. The whole campaign will be supported by a strong and striking lay-out. Management also believes the campaign must be a long-term undertaking. The safety messages will be repeated over and over again, but each time using a different theme and in a different form to fit the target group best. Mammoet’s managers are strong supporters of the safety campaign, and CEO Roderik van Seumeren has formulated a series of statements that express the concept of We Care!, Keep Thinking! and Look Out!: 1. We make sure that knowledge and experience can be shared via the Training & Development Program (We Care!). 2. If you think a situation is so unsafe that you cannot comply with our safety rules, stop the work. I will always support you (Keep Thinking!). 3. When I discover a potentially unsafe situation on site, I will personally draw your attention to it (Look Out!).
Mammoet Salvage Mammoet Salvage: Smart Solutions, United Experience In essence, salvage work is no more than a complicated lifting job (especially when wrecks have to be recovered). This is a perfect application for Mammoet’s expertise. The best example is still the recovery of the Russian submarine, the Kursk. With its distinctive engineering approach, Mammoet has the potential to successfully complete salvage
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operations that some people think are impossible. Mammoet has been working in the marine sector for many years and at the beginning of this year we strengthened our position by setting up Mammoet Salvage B.V., a joint effort with various experts from the international salvage scene. The company has a clear ambition: to rank among the top three specialized salvage companies worldwide within three years. To achieve this goal, a dedi-
cated team of specialists from a wide range of disciplines is concentrating on competitive bids. The difference between two bids often lies in the basic approach: ‘the smartness of Mammoet solutions’. This approach is rooted in the conviction that many proven Mammoet techniques and solutions will also work on salvage operations as long as we are smart enough to adapt to the specific circumstances. Patrick: ‘Mammoet Salvage is not
starting from scratch but is actually an extension of an area in which we want to demonstrate our operational excellence. We started from our headquarters in Schiedam but we are also seeking customers from our offices in Houston and Singapore.’
Mammoet’s think tank EMD
Jan van Seumeren jr., CTO.
MSG Crane Koeweit
The Equipment Management Department (EMD) is one of the most important departments in the Mammoet organization. It is responsible for the complete management and maintenance of the equipment fleet. The articles on this page show why part of EMD is known as Mammoet’s think tank. It is responsible for ‘inventing’ equipment for new solutions and adapting components that are already in service. Its valuable solutions include easy transportation, usually fully containerized, and low Total Cost of Ownership. The department manages a large stock of spare equipment and components. Its delivery processes run 24 hours a day, 7 days a week.
New software ensures high accuracy in positioning, more efficient moves with the load, and absolute assurance that all operations will stay within the design limits. The number of power packs has been reduced to one, eliminating the need for complex hydraulics and valves and auxiliary electrical power at the top of the crane. The container concept is still mandatory for all our technical developments, so the building blocks are fully containerized and can be dispatched overseas easily by road or rail. It is a fully self-supporting concept. All that is needed, from ballast to power packs and support equipment,
is kept together. The result is that the MSG is now more versatile than ever before and the upgrade meets the demand for fast and efficient logistics.
Double stacked boom concept Innovations are often the outcome of practical experience and know-how but they are also inspired by exploring new ideas in mechanical engineering. A good example of this is the Platform Twin Ring Containerized Double Stack (PTC DS), which could even be hailed as a trend-setting innovation.
Safety first, better performance, enhanced efficiency It is the careful balance between man and machine that makes the difference in delivering the best services with the most attractive price/ performance ratio. Mammoet’s strategy is therefore directed at continuously improving that balance. A shining example of this is the recent MSG upgrade. Mobilizing this type of lifting gantry is a challenge, especially in remote areas or in crowded spaces. So we came up with an innovative upgrade program that simplifies the mounting. Our solution has the twin advantages of making our logistics more flexible and it also makes a positive contribution to the crew’s safe working conditions. EMD put a lot of practical experience and knowhow into the upgrade. It reviewed the existing configuration and redesigned the components to make the MSG a better machine. MSG Upgrade
Tonne-meter reveals crane performance What exactly is the performance of a crane? From basic mechanics it is easy to understand that the lifting capacity of a crane depends on the distance between the crane centre and the position of the hook, the operating radius. When the crane has to reach far, the capacity will be lower than when lifting nearby.
PTC DS concept extended The Mammoet fleet will be enlarged with a fourth PTC DS in the course of 2006. The investment is being made to meet market demand for the enormously successful PTC concept. It offers a great deal of value for money and customers are very happy with its performance and flexible applications. The greatest advantage of the PTC concept is that all crane sections can be transported in standard 20 ft or 40 ft containers, with a maximum weight of 30.4 tonnes. Since there is no need for special transport, considerable savings can be made on transport times and costs. The fourth PTC – the number eight ring crane in Mammoet’s fleet – is expected to be operational in late 2006/early 2007, and will be one of the world’s largest mobile cranes.
CRANE DUTY GRAPH 1,600 1510
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PTC
Filtered mb: 49m
CC8800-1 Filtered mb: 0m
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CC12600 Filtered mb: 54m
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To maintain balance, the product of force and radius at the working side must be equal to the counterweight side of the crane. When using enhanced configurations such as Super Lift, the counterweight can be moved to a larger radius to provide more counter effect, which in turn increases the available capacity on the crane’s hook.
1292
1,300 1,250 1,200 1,150 1,100
Capacity (ton)
1,050
When specifying a crane’s lifting power, the numbers usually specify the maximum capacity based on the minimum lift radius which is limited by the sheaves in the hook block or the boom head. However, at more practically usable radius, the capacity depends on the counterweight system, the boom/jib configuration and other parameters.
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Ideas triggered by customer needs Other striking additions to the Mammoet fleet include another 170 axle lines and the containerized winch concept for a winch with a capacity of 650 tonnes. This concept has been designed especially for very high-end jobs, such as lifting operations in nuclear power plants. The current plans involve two of these winches, which will first be used on a job in the US. The idea itself was triggered by customers.
900 850 800 750 700
When examining various crane profiles, it turns out that a “lighter” crane may outperform a “stronger” crane at a larger radius. To provide more transparency in its technical communications, Mammoet now uses the ‘tonne-meter’ number to work out which crane is the best for the job. This allows customers to compare competitive quotes. The tonne-meter figure is based on the weight of the lift and the operating radius, which is dictated by the crane’s position. The crane’s performance can be read from a graph showing the lift capacity at increasing radius.
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650
The same is also true of innovations such as the crawler system for the Platform Twin Ring and PTC, and the flat racks added to Mammoet’s container concept. The development of 20 strand jacks of 900 tonnes to elevate pontoons rock-steady and thus create a very stable metal island in the Caspian Sea was also inspired by customer needs. The entrance channel to the Caspian Sea is too small to transport a prefab oilrig, so customers need a clever solution that can be constructed quickly and at a modest price.
600 550 500 450 400 350 300 10
15
20
25
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Radius (m)
50
55
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Each one of these innovations illustrates Mammoet’s ambitions to be market leader: to continue providing the safest and best solutions, in part through continuous innovation based on practical experience, technical know-how and feedback from customers.
Mammoet Footsteps The Hunger Project for a world without hunger developing new expertise to guide this process effectively. For more than 28 years, it has been a pioneer in the field of sustainable and structural development. THP is a professional organization. As a member of the UN Task Force on Hunger, it is a leading player in the UN Millennium Project led by Kofi Annan. In the past twenty years, THP has developed an effective and integrated strategy to achieve all eight Millennium Goals by 2015. No fewer than 189 countries have signed up to the Millennium Project.
Partnership and respect
Mammoet supported a technical school in Indonesia for three years. Inspired by the project’s success, it went in search of a new global project with a social goal. It settled on The Hunger Project because this organization’s core principles seamlessly match the Mammoet brand feeling. Our core activities are tailor-made heavy lifting and transport solutions, with the added value of the unparalleled know-how and experience of our staff. Key concepts that run throughout all our work are problem solving, innovation and professionalism. The same core concepts and priority for people are also a hallmark of The Hunger Project (THP).
People-driven problem solvers THP is an international development organization whose mission is to create a world in which everyone is able to live a healthy and productive life. The organization is people-driven in all respects. It does not see people in need of food as helpless victims but as the key to solving the problem of hunger.
Innovative and professional THP’s vision and methods are innovative because every part of the organization is imbued in word and deed with a bottom-up approach to solving hunger. THP never provides money or resources top-down but invests in the empowerment of poor populations and the creation of opportunities so that they can shape their own destiny. THP is constantly learning and
THP believes a world without hunger is possible. In every country, the organization seeks equal partnerships and mutual respect. Everyone works on local solutions that suit their own culture and country. The THP staff in developing countries are always made up of local people and the THP offices in western countries are staffed chiefly by unpaid professionals. In the donor countries, therefore, the organization does not cost any money. THP’s approach could have been written for us. THP is a front-runner that dares to stick its neck out and rises to find unique solutions to one challenge after another. Where others stop, THP keeps going. That is why we are convinced that by sponsoring THP, we can make an effective contribution to the sustainable development of the global society. For more information: www.thp.org
Close to the customer in Antwerp Like Rotterdam, the port of Antwerp ranks among the busiest and largest ports in the world. It is home to many of Mammoet’s well-known customers, including those in the petrochemical sector, power industry and general port business. Since February 2006, Mammoet has been able to provide these customers with an even better service from an office right in
the center of the port area. The current facilities include dry docks, crane capacity, weighing stations, platform trailers and much more support equipment. The site can accommodate the assembly of modules, ship conversions and the dressing of columns and vessels, while also providing capacity for temporary storage. From here, Mammoet supports local and
EH&S Contractor Award for Mammoet Dow Benelux B.V. of Terneuzen, the Netherlands, has presented the Environment Health & Safety (EH&S) Contractor Award 2005 to Mammoet. Dow’s Global Vice-President, Mr. David Graham, and the Chairman of the Board of Executives of the Terneuzen site, Mr. Gerhard van Harten, personally honored their best performing contractor. Wouter van Noort, Mammoet’s Director Cranes Benelux, accepted the Award saying it was “A great compliment to us all”, and noted that Mammoet had also won the 2004 Award, a very unique situation indeed. He emphasized that Mammoet will continue to seek improvements, delivering even better results with an unerringly sharp focus on Quality, Safety and Environmental issues, because this will ultimately be to everyone’s benefit: customers, fellow contractors, employees and the Mammoet company itself.
regional maintenance operations and carries out specialized jobs for customers as well as for itself. Mammoet shares the site in partnership with Antwerp Ship Repair. Together the two companies are preparing for a very demanding engagement that will commence later this year. Mammoet will perform lifting and transport services for the construction of a large bridge.
Number 1 in Transport 50 The Transport 50 Index is a listing of owners of specialized and heavy transport equipment around the world that the industry can consult to gain a clear picture of a company’s capabilities. Companies are listed according to their transport capacity, which is calculated by counting all the modular and specialized trailers in their fleet. The Transport 50 Index also says something about the importance and influence of modular trailer systems, especially Self-Propelled Modular Transporters (SPMT). They have a great impact on the list, and it is therefore not surprising that Mammoet is ranked number 1. Even if the fleets of the second and third placed companies were combined, Mammoet would still be bigger. The data for the Transport 50 Index are supplied by the companies themselves. They must complete a detailed questionnaire to provide information on heavy haulers that are used chiefly on sites and projects and on heavy and specialized road haulers.
Black Empowerment for Mammoet South Africa economic inequalities and underdevelopment that arose during the apartheid era. The ultimate objective is to achieve a substantial increase in the participation of black people in the economy and the business community. Black Economic Empowerment is quantified using a scorecard of seven items and a maximum score of 100. Companies achieving a score of at least 40 are entitled to refer to themselves as Black Empowered, a qualification that is necessary to be eligible for orders from the Government or organizations such as power companies and petrochemical companies. Since the end of apartheid in 1994 the Government of South Africa has taken a number of steps to achieve a greater diffusion of economic power within the black community. This legislation, Black Economic Empowerment, is intended to overcome the
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Compliance guaranteed To ensure compliance with the Black Economic Empowerment legislation Mammoet has sold 50% of its stake in Mammoet
Southern Africa (Pty) Ltd to Tlou Heavy Lift Solutions, a company owned by James Ngobeni, Phumelele Siphayi and Noor Hendricks. The sale of the shares has also resulted in changes in the organization of Mammoet Southern Africa (Pty) Ltd. The Board of Directors has been expanded from the former three directors to six, and in addition to the three partners mentioned above now includes Roderik van Seumeren, Siem Kranenburg and Martijn Kuipers. Martijn Kuipers (Managing Director) and Noor Hendricks (Director Operations) are responsible for the day-to-day management of the company. About 90 representatives from our clients and the Government, including South Africa’s Minister of Transport, Mr. Jeff Radebe, attended the official announcement of the share sale and the signing of a Letter of Intent by all partners in Johannesburg.
Petrochemical Driven by the optimization of performance ratios, the scale of petrochemical plants is increasing. In close cooperation with its clients’ engineering departments, Mammoet stretches the design limits by providing high capacity transport and lifting equipment. This enables clients to design modules that can be moved and lifted more cost effectively.
For both Mammoet and the client, minimizing down time, space restrictions, and safety procedures are a matter of course. The cases illustrate the extensive specialist expertise that Mammoet has developed to serve the petrochemical industry.
Crane ballet for low cost, smart & safe solution
C
MAMMOET
Location
EUROPE
Job Challenge
Cleves, Germany, and Schiedam, the Netherlands Transporting reactors weighing 420 and 683 tonnes Offering the client the most economical solution through the judicious use of equipment
Highlight:
In Cleves, Germany, two reactors weighing 420 and 683 tonnes were built for a project in Jubail, Saudi Arabia. The vessels were constructed upright and our first job was to lay them on their sides so they could be finished. They then had to be jacked up and placed on pontoons to be shipped down the River Rhine to Rotterdam. Loads of these weights and dimensions would normally be lifted by lattice boom cranes such as a CC 2800. But with careful study and professional ingenuity, it proved possible to use two AC 650 cranes instead of one CC 2800 crane. This had significant advantages for the client. Firstly, disruption at the site was kept to a minimum because the cranes arrived in the morning and left in the evening. A CC 2800 would have needed two days to assemble and two days to dismantle, in addition to the lifting day. Secondly, this solution was a lot cheaper.
Customized slings The AC 650 cranes with a 25.5-meter main boom and 160 tonnes of counterweight were positioned on each side of the reactor. Both cranes were jacked up 60 centimeters to provide the clearance and lifting height needed. Once they had been jacked up using 10-centimeter beams under the outrigger pads, an additional support was built under the slewing ring using 10-centimeter beams. We also used 12.2-meter-long slings made especially for this job, with a capacity of 150 tonnes and small loops that could be hitched in the breech around the lifting bollard. A 400-tonne spreader beam was mounted in between; the shackles, all based on a load of 300 tonnes, were hitched to the beam.
The crew carried out these preparations using a 70-tonne auxiliary crane, since the weights were far too great to be lifted by hand. At the same time two Demag AC 500 cranes were erected, each with a 42.5-meter main boom and 100 tonnes of counterweight, to bring the base of the reactor towards the cranes. The four cranes then maneuvered the reactor into a horizontal position and lowered it onto the saddles standing ready to receive the unit. The second job was to jack up the reactors and load them both onto a pontoon. The water level in the Rhine, however, was too low and it was decided to use two pontoons. The 10 kilometers to the RoRo was bridged using SPMTs for the 683-tonne reactor and a conventional trailer for the 420-tonne reactor. After arriving in the Port of Rotterdam they were loaded onto the Jumbo Vision for the last leg of the journey to the final destination, where Mammoet again came into action for the two reactors.
Ants in Antwerp Location Job Challenge
Antwerp, Belgium Transporting and lifting during the simultaneous shutdown of nine plants Simultaneously using many people and resources at the same site
Highlight:
The client, one of Europe’s largest refineries, had already worked with Mammoet and this time asked us to carry out transport and lifting work during the simultaneous shutdown of nine plants. The scale of the job, the changeable crews and equipment required during the project (which also changed during the day, at night and in the weekend) and the limited space for the logistics necessary for such a substantial project required meticulous planning. In collaboration with our
client, Mammoet began the preparations, such as the crane configuration plans, several months before the project began. In total some 30 main cranes were involved, together with some 10 cranes for sundry jobs, 15 tractors and 20 trailers with a range of capacities and lengths. The work began and ended with a 20-strong crew but in the peak period (during the vacation season) 90 people were working on the job.
Made-to-measure efficiency Location Job Challenge
Highlight:
An oil refinery in Finland had to expand to increase its production capacity, primarily for oil originating from Russia. Mammoet won the contract to transport and install four reactors with lengths of 52 meters and diameters of five meters – and weights of no less than 1,254 tonnes! The client had been smart enough to place the reactors at just nine meters distance from each other. Mammoet took advantage of this by offering a solution that minimized the conversion time. The solution entailed installing the reactors using a lifting portal stabilized with guys and two MSG lifting towers, connected by two 10-meter beams. The preparations consisted of converting the single 15-meter beam unit into two 10-meter beams to connect the two MSG towers, carried out at Schiedam. The work at the site was a challenge for even experienced operators: the reactors had to be moved over hilly terrain, lifted using a portal stabilized with guys and tailed with minimal space for the SPMTs and the tailing frame.
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Porvoo, Finland Transporting and installing four reactors at an oil refinery Offering the most effective solution in minimal space
Four seasons in one day! Location Job Challenge
Reydarfjordur, Iceland Installing heavy units using four six axle line SPMTs and a CC 2800 crawler crane Extreme weather conditions
Highlight:
An aluminum factory is being constructed in the east of Iceland. Two production halls will be built parallel to each other, both no less than 1,200 meters long. Mammoet was engaged to transport and lift 45-50 pre-assembled modules with weights ranging from 60 to 350 tonnes and ten trafos of between 181 and 262 tonnes, to install four overhead 122-tonne cranes, to place a 78-meter stack and to lift a 380-tonne silo roof with 16 strand jacks. All these units arrived by ship and were carried to the site using SMPTs. Mammoet used a Demag CC 2800/1 and a 24 axle line Scheuerle 2004 at the site.
What made the job so special was the variable weather on Iceland, which sometimes presented the crew with four seasons in just one day. Snow storms and the combination of frost and wind meant extra attention had to be paid to safety. At wind speeds of 20 meters per second, a couple of degrees of frost will freeze fingertips and ear lobes within 15 minutes. In addition to all-weather suits and thermal boots, hats and winter gloves are essential. And because it could be very slippery on the site, boots and vehicle tires were fitted with spikes. Alertness and good equipment kept disruptions and delays to a minimum.
Full service at Rafnes Rafnes, Norway Installing a 105-tonne column, exchanging three-pressure-stage turbine and more Challenge Time pressure Location Job
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Mammoet Germany won the contract to unload, temporarily store, dress support and install up to 70 items during a total shutdown at a refinery in Rafnes, Norway. Most activities had to be completed during the “hot” shutdown phase, lasting only a few weeks. The centerpiece was the installation of a fully dressed 105-tonne column using a Demag AC 500 as the main crane assisted by a 400-tonne crane for tailing. The cranes, with the column in between them, had to be placed in one of the narrow plant streets.
At the same time, up to 45 machine fitters, assemblers and riggers were needed for another essential job: the complete exchange of a turbine with three pressure stages and one compressor motor. Despite the narrow time frame, the installation of the elements and the machine exchanges were accomplished smoothly and technically perfect.
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Efficient crane mobilization Location Job Challenge
Dartmouth, Nova Scotia, Canada Carrying out various heavy lifts using a CC 4800 crawler crane Multi-deployability of equipment over large distances
“Personal excellence makes the difference in
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In 2005, a refinery in Dartmouth, Nova Scotia, Canada, contracted Mammoet for the replacement of a catalytic cracker head, for which a CC 4800 was used. Mammoet then won an additional contract to install a new diesel hydro treating reactor that was required to comply with new Canadian low-sulfur limits in accordance with the Kyoto protocol. The CC 4800 was on stand-by rental for two months until it was used to erect and install the ULSD reactor. An interesting aspect of the job was that the crane was mobilized entirely by railway from another recently completed project in Indiana, an overland distance of 3,000 kilometers. This logistical simplicity produced a considerable saving for the client.
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what we achieve”
Tim Sittler CEO, Mammoet Canada
Anchored rock-steady Sarnia, Ontario, Canada Transporting 44 process modules using two 12 axle line SPMTs Challenge Offloading using a self-designed mooring system Location Job
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This job began in the Port of Windsor, located directly across the Detroit River from the city of Detroit, where a geared vessel delivered 44 process modules for the Suncor Refinery in Ontario, 100 kilometers further up. With two 12 axle line SPMTs, Mammoet unloaded the modules from the ship and put them in temporary storage at the port. Since it is not feasible to transport large modules by road over long distances in Ontario, Mammoet loaded them onto a 76-meter-long and 22-meter-wide barge 10 to 12 at a time.
SMPTs conquer ten percent slope The 44 modules reached their destination in four consecutive barge shipments while the tireless
Coke drums moved by Mammoet Fort McKay, Alberta, Canada Transporting four 413-tonne coke drums using an 800-tonne gantry system and two 150-tonne climbing jacks Challenge Preventing delays for the client through meticulous and thorough preparation of the transport schedule Location Job
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Four coke drums, drums for removing solid particles from crude oil, weighing 413 tonnes each, had to be moved from Edmonton to Fort McKay, Alberta. The operation demanded a careful selection of the transport configuration, because regular highways and bridges had to be passed on the way to the Canadian Natural Resources Ltd. Horizon project site, a distance of 775 km. In addition, an ambitious transport schedule meant the drums had to be shipped in the current shipping season. Otherwise, they would have to wait until the following winter shipping season, which would seriously delay the project for the client, Coordinating an exceptional convoy The drums were moved in pairs, supported by saddles, trailers, trucks and of course the dedicated Mammoet Canada Western crew. Loading was done with an 800-tonne gantry system and two 150-tonne climbing jacks, with a double-wide 10 line road style under each end of the drums. The total convoy was over 200 meters long, almost 12 meters high and more than 10 meters wide, so a significant part of the job was to scout and prepare the road. Several utility companies were involved – all coordinated by Mammoet – to lift power lines, turn traffic lights, remove street furniture and control traffic. Once outside the city, the two trucks covered the route at two-day intervals in order to limit the impact on highway traffic. Traveling at 30 km/h, a one-way trip took five days. Some passes over bridges were very close to the structures’ design limits. Once on site, the jacking crew took over and the empty vehicles returned to Edmonton to collect the next two drums. After insulation, the drums have been lifted onto their foundations by Mammoet’s PTC crane, completing the factory-to-foundation service. Although many industry experts thought the transport schedule far too ambitious, Mammoet lived up to its promises, to the clients benefit. Only one drum incurred a delay of one day when the ambient temperature dropped below –35° Celsius, which was too cold for safe operations. At such extremely low temperatures, hydraulic systems do not work properly, despite the use of arctic hydraulic oil, and steel can become brittle.
Rings from Japan to Canada Location Job Challenge
Fort McMurray, Alberta, Canada Inland transportation of two hydro treating reactors On-time delivery of three shipments by rail and road
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With the assistance of Mammoet Japan, Mammoet Canada Western won the contract for the inland transportation of two hydro treating reactors for the Horizon project in Alberta, Canada. The reactors were supplied by Kobelco and Japan Steel Works, and the material arrived in the Canadian Port of North Vancouver in three shipments. The first one consisted of ten rings, ranging in weight from 50 tonnes to 67.5 tonnes, crated accessories and fabrication rollers. Using the ship’s cranes in tandem, these were loaded onto rail cars. The rail loads were then transferred to highway transport equipment using Mammoet’s gantry near Fort McMurray, Alberta. This first load was delivered on site the moment the assembly hall was completed and when the overhead crane that is part of the complex was being tested.
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The second shipment, consisting of eight rings, five skirt sections with 5.3-meter diameters and two vessel heads with 4.3-meter diameters, arrived a couple of months later. A special license was needed before the skirt sections could be transported over the road because loads exceeding 4.75 meters are allowed only in special circumstances in mountainous British Columbia. In close cooperation with the authorities, Mammoet also made sure the license was issued on time. The last shipment of material was delivered in two truckloads after the assembly of the reactor vessels had been completed. Mammoet erected them using a PTC. The size of the total job was 1,422 tones in weight and 3,435 CBM in volume.
Mammoet crew traveled back and forth between the Port of Windsor and the Suncor site as they performed the load-outs, sea-fastenings, load-ins, and site transport services. The offloading operations were a special challenge. The narrow dock facilities extend out into the fast-flowing St. Clair River and have few suitable mooring bollards. To moor the barge rock-steady, Mammoet designed a complex system with on-shore mooring points. The dock’s 10% grade could have been an extra complication if not for the fact that SPMTs are ideally suited to climbing such grades due to their superior traction abilities. The modules were therefore offloaded in a very expedient and professional manner.
First job for PTC III Sao Paulo, Brazil Maiden PTC III project, replacing a 654-tonne reactor head Challenge Restricted space in a live refinery, overload permit needed Location Job
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In the third quarter of 2005, Mammoet brought its third Platform Twin Ring Containerized crane (PTC III) into operation. After the customary tests in the Netherlands, the PTC III was immediately disassembled and transported to Brazil for its maiden project. At the refinery in Cubatao, the crane and crew had to overcome another challenge before tackling the first real job. Because there was not enough space in the live refinery to erect the boom/luffing jib and back mast from the ground upwards, part of the PTC
was erected “in the air”. A temporary structure was constructed to position the entire boom and back mast horizontally over a live pipe rack. Large mobile cranes then lifted the boom/luffing jib and back mast into the air in a truly spectacular manner. The PTC III was used to replace the 654tonne reactor head of the UFCC unit at the Petrobras refinery. The additional weight of the rigging, block, spreader, etc. required for the lift meant the load eventually weighed 722 tonnes. The PTC’s manufacturer
therefore first had to issue a special 8% overload permit. In the standard procedure that was carried out, critical parts of the structure were analyzed and the configuration was recalculated. Only when the manufacturer had determined that the excess weight would not cause any technical malfunctions and safety was guaranteed could written permission be given. Replacing the reactor head took six weeks in total. The PTC was then also dismantled in the air.
Integrated logistical transport solutions
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Sakhalin Island, off Russia’s eastern coast and north of Japan Participating in preparations to construct a refinery from a local Mammoet base Challenge Difficult job in remote area Location Job
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Preparations are being made to exploit the huge gas and oilfields on Sakhalin Island. An international consortium that is building a refinery engaged Mammoet for integrated logistical transport solutions. Mammoet has established a local base to carry out the job, Sakhalin OOO, and is using its hydraulic cranes, barges and multi-axle transport systems on the project. One of the first jobs was to unload and transport 58 components to the site for the Sakhalin II project. The first transport comprised 23 heavy modules, varying
in weight from 700 to 1,800 tonnes, three slug catchers, three flares and many other items. Twelve equally heavy modules then followed, one being no less than 84 meters long, four finger racks and other materials. For the roll off, transport from the temporary harbor to the construction site, and setting of the cargoes Mammoet used 356 axle line Scheuerle SPMTs. A triplewide 60 axle line SPMT was used to move the heaviest modules across an 800-meter-long bridge. . This unique combination had never been seen before but it guaranteed the efficient and safe transport of the modules.
Supervising converging cargo flows Gove, Australia Enlarging a bauxite refinery Challenge Moving vertical 350-tonne tanks over a site with slopes of up to 6% Location Job
Brand new equipment in India! Jamnagar, India Shutting down a refinery using two brand new CC 2200s and one new LR 1750 crawler crane Challenge Ensuring the entire crew had the right standard of knowledge to operate new equipment Location Job
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A refinery shutdown in Jamnagar, India, in the fourth quarter of 2005 formed the maiden job for three brand new CC 2200 crawler cranes and a new LR 1750 crawler crane. Before the job began, the crew underwent additional and special training at the crane manufacturer, Terex Demag, in Germany. To assist with the first time assembly, several service engineers from both Liebherr and Terex also traveled to the project. The cranes were used to replace a reactor dome, to remove crude oil exchangers and many other items and, after the necessary maintenance work, to reposition them. Since the work was performed 24 hours a day, Mammoet provided a double crew for each crane.
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To meet the growing demand for aluminum, the owner of a bauxite refinery in Gove, in the Northern Territory of Australia, has decided to expand and double its export capacity. On this project, Mammoet is the contractor and supervisor for the load-in and load-out operations as well as the site moves and final installation. The equipment for the project consists chiefly of pre-assembled modules (PAMs) from production locations in Sattahip (Thailand), Newcastle and Darwin (Australia), Kuantan (Malaysia) and – later in the project – Chan May (Vietnam). In total, there will be hundreds of items with a total estimated weight of 49,000 tonnes, possibly rising to 70,000 tonnes. In Sattahip, Mammoet carried out the site moves and the load-out. In Kuantan and Darwin, it also took care of the transportation. In Newcastle, third parties carried out the load-outs. The major challenge in this project is to move vertical 350-tonne tanks with a height of 38 meters and a diameter of 14 meters over a site with up-hill slopes of 6% and down-hill slopes of 5%. The actual jacking down, performed with climbing jacks, takes place on a slope of about 3.5%. When this article was being written, the first transports out of Thailand had been discharged successfully and most of the PAMs had been installed, either with SPMTs or with mobile cranes.
World record in the desert
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Ras Laffan, Qatar Heaviest lift ever using a land crane Challenge A Mammoet Sliding Gantry especially modified for this job Location Job
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The North Gas Field was discovered on the northeast coast of Qatar in 1971. Since the 1990s, the emirate has been developing all the industries involved in worldwide gas exports. This has had a major impact on Qatar’s economy and is creating many jobs for Mammoet in this tiny state. It is working chiefly on plants that liquefy LNG (Liquid Natural Gas) before it is shipped. One of the projects being carried out here is the Oryx project, a second generation LNG plant that will become the world’s largest. Mammoet assisted in the expansion of the plant, the climax being the installation of two reactors, each weighing more than 2,200 tonnes. A crew of 25 experts from Mammoet carried out the work using a Mammoet Sliding Gantry (MSG) especially configured and modified for the job. In doing so, it set a new record: the weight per reactor represented the heaviest lift ever using a land crane.
Unique lifting factory The MSG can best be described as an enormous lifting factory consisting of completely computer-controlled hydraulic lifting units that the crane driver operates from his control room. Especially for this job, the crane was fitted with a 75.5-meter main boom, a 15.4-meter jib and 2,600 tonnes of counterweight. Four 900-tonne strand jacks (160 strands each) were attached to the boom head and another four 600-tonne strand jacks (144 strands) were fitted to the back mast. During the lifts a tailing frame supported the base of the reactor as the stack moved into position along
Gas, gas, gas... Ras Laffan, Qatar Lifting heavy installations for various gas producers Challenge Smart use of state-of-the-art equipment Location Job
the Mammoet skid system. The MSG operated at a radius of 34 meters and placed the reactors on the foundations in one smooth movement. The MSG is the only crane capable of lifting something as heavy as these reactors and, thanks to its compact design, the location in the middle of the plant posed no problem. Other operations at the site could continue as usual.
High in the sky Jubail, Saudi Arabia Heavy-equipment transport and erection Challenge Use of MSG 50 II Location Job
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At Jubail, Saudi Arabia, Mammoet contributed to the successful completion of the JUEG 2 project to construct an ethylene oxide/ethylene glycol plant. Mammoet won the contract to transport and erect the heavy equipment using the MSG 50 II.
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The heaviest structure to be erected and positioned on its foundations was a wash tower weighing 1,250 tonnes; it had a height of 87 meters and a diameter of 7.6 meters.
The Ras Laffan area of Qatar has become a familiar workplace for Mammoet. As well as the now completed Oryx project, Mammoet has been involved in two other projects in the Ras Laffan area. One, Ras Gas train 5, has now been completed. The other, the Dolphin project, is still ongoing. For the Ras Gas project, Mammoet carried out only the transport work; for the Dolphin project, Mammoet was awarded both the lifting and the transport contract. The first items to be moved were two boilers, both weighing 300 tonnes. Double Cometto 12 axle lines were used to transport and install them on the foundations. The area between the foundation legs was backfilled, so that the trailer could be maneuvered between the foundations and lower the boiler. With only 15 centimeters’ clearance on both sides, the Mammoet crew had to demonstrate all their driving skills.
Project completed, work goes on Throughout the entire contract period ships regularly arrived with heavy vessels for the two projects. Once, Mammoet even had to carry out two substantial jobs in one week: the installation of two 545-tonne Amine absorbers for the Dolphin project and the installation of a 300-tonne demethaniser for the Ras Gas project. The crew had to pull out all the stops because the fleet in Qatar at the time was not as large as it is now. Nevertheless, both jobs were performed smoothly and successfully using the same trailer configuration: double 12 axle lines on the front and double six axle lines on the back. Mammoet’s CC 4800 crawler crane was used to install the Amine absorbers. The Ras Gas train 5 has now been completed. The Dolphin project is still ongoing but that’s not the only reason that Mammoet is still hard at work in Qatar: Ras Gas trains 6 and 7 and the Qatar II project start this year. Mammoet has been contracted to provide transport for both projects.
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“The Middle East market is booming and will face their biggest challenge in history and Mammoet is proud to take part in these exciting times.” Willem Dekkers Managing Director Mammoet Middle East
Civil Experience in multi-modal transport by road, rail and water together with facilities for lifting, skidding and jacking heavy loads ensure Mammoet’s position as a full-service provider in the civil market. Mammoet crews manage all cargo handling from factory to foundation, with a combination of skill, professionalism and state-of-the-art equipment. The cases reflect
Mammoet’s thoroughness in a field that extends from handling heavy prefabricated elements such as concrete girders and steel structures that are assembled on site to constructing, relocating or dismantling buildings and industrial facilities.
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Mega bridge installed in one night! Highlight:
Location
Elevated highway sections are often assembled using pre-fabricated elements. In most cases the site itself is too small to set up a temporary manufacturing facility. Many prefab constructions are thus produced at yards and have to be transported. This final phase includes not only the transport but also the assembly and/or positioning of the construction. It inevitably has an impact on traffic flows. To minimize the inconvenience, customers draw on Mammoet’s experience and turnkey solutions for engineering, logistics, route surveys, negotiations with local and political authorities and documentation.
Typical SPMT job In Zoetermeer in the Netherlands, for example, Mammoet was engaged to place a complete, almost 140-meter-long cyclist and pedestrian bridge over the busy A12 highway. To disrupt
Job Challenge
Zoetermeer, the Netherlands Positioning a 1,000-tonne bridge Timeframe
the traffic on this major highway in the west of the country as little as possible, the work was carried out at night. The road was closed to all traffic at 9.30 p.m. and the first phase of the transport began. It consisted of the Mammoet crew driving the bridge transversely from the construction site along the A12 onto the highway. At about 1.00 a.m. the engines of the 40 axle line SPMT were started and the 1,000-tonne colossus slowly began to move. The wheels of the SPMTs then rotated longitudinally to the road and the bridge was slowly moved to its final destination. The procession passed a railroad gantry, after which the bridge – with an additional 12 axle line SPMT at the
northern end – was jacked up to the required height for installation on the abutments. With the sun about to rise on the Sunday morning, the Mammoet crew lowered the curvaceous structure safely and precisely onto its foundations. The client was satisfied and treated everyone to champagne as the first cars once again raced past Zoetermeer and its new landmark: an elegant white construction designed by architect Edwin Megens. Mammoet’s nighttime activities were photographed and recorded by hundreds, perhaps even thousands of spectators and the cameras of several TV stations and press photographers.
Concrete beams in convoy Location Job Challenge
Amsterdam, the Netherlands Lifting and transporting more than 600 concrete beams and girders Main contractor to execute and supervise all transport
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Netherlands Railways constructed a high-speed link for the Amsterdam-Utrecht route. The “Utrechtboog” is a 15-meter-high and 1800-meter-long viaduct on which high-speed trains will travel to and from Germany in the future at speeds of up to 160 km/h. The construction called for the transport of more than 600 concrete beams and girders. Mammoet was the main
contractor, executing and supervising all of the transport, which took place over several years. The beams were more than 33 meters long and weighed in excess of 144 tonnes. Various tractor/trailer combinations were used for the transport. Mammoet partner MVS was responsible for the assembly work using two Liebherr 300-tonne telescopic cranes.
The Water-train Location Job Challenge
Amsterdam, the Netherlands Positioning a railroad coach on the deck of a boat Very special transport solution during one of the world’s largest boat shows
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During last summer’s ‘Sail’ – one of the world’s largest boat shows – in and around the Port of Amsterdam, Netherlands Railways came up with a playful transport solution: a water-train. It consisted of a railroad coach from the Regiorunner series on top of an old ferry that had had its superstructure removed. Mammoet used two 200-tonne telescopic cranes to place the coach and its bogies on the deck. After the event, the same two cranes made the reverse move. First the carriage – weighing more than 56 tonnes – was lifted from the bogies and set down on the ground to one side of the track. The two cranes then lifted the bogies onto the railroad tracks and the carriage back onto the bogies. Netherlands Railways then only had to make the necessary connections for the train to be used for regular passenger transportation again.
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Bone chilling Location Job Challenge
Bergfriede, Germany Placing a 460-tonne bridge Not getting stuck in the ice
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After East and West Germany were reunited, the replacement of old bridges was one of the main priorities. Mammoet contributed to the installation of many bridges in Germany. The most recent job, won by Mammoet Germany, involved a 460-tonne bridge built for Wasser- und Schifffahrtsdirektion Mitte, Neubauamt Helmstedt. The customary procedure on a job like this is for the crew to first jack up the bridge and remove the building supports and position the skidding material underneath. Mammoet’s hydraulically-driven skid shoes then push the bridge as far as possible until it hangs far enough over the water for the barge to accept it. Both the bridge and the barge are then
pushed across the channel until the bridge reaches its final position. The only difference now was that it was extremely cold during the actual skidding operation – it was even unusually and unpredictably cold for this region! A challenge indeed for the well experienced crew because the tug and pontoon operated by BTS under Mammoet’s supervision nearly got stuck in the ice. An icebreaker and a mobile digger had to come to support. In spite of the harsh conditions, the bridge was positioned exactly on schedule. The channel remained closed for some time and two icebreakers from Wasser- und Schifffahrtsdirektion had to support.
Delivering 80 beer tanks in Seville Seville, Spain Transporting and installing 80 beer storage tanks ranging from 17 to 35 tonnes Challenge Compensating for the very high center of gravity with special equipment Location Job
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“You comply with safety issues not because the management wants it, but because you personally believe it is mandatory to do” Bryan Cronie Corporate QSE Director, Mammoet Holding
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In Seville, Spain, Mammoet transported and installed eighty 17-35 tonne beer tanks of various diameters and heights for a newly built brewery. The challenge in this project was formed by the tanks’ exceptionally high centre of gravity. For a secure and safe operation, the six axle lines of SPMT that we used for the execution was fitted with a special frame supplied by the client. They then drove underneath the tank and chains were fixed to it to secure it on the trailers. To lower the center of gravity on the transport combination the trailers also carried about 25 tonnes of steel ballast. Nevertheless, the tilt margins were very small. The SPMTs therefore had to be maneuvered very carefully when it was driven into the factory. The tank was then positioned above the foundation plates and installed just as carefully. The experienced crew successfully repeated the sequence of picking up a tank, driving it to the factory, installing it on the foundations and driving the SPMTs out again about eight times a day.
“Our current leading position in many
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markets, illustrates we’re doing the right thing”
Jan Kleyn Managing Director, Mammoet USA
Relocating a complete steel factory Louisiana and Trinidad Relocating a complete steel processing plant Challenge Big job, unstable ground conditions Location Job
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Move a complete steel processing plant (DRI plant) from Louisiana, USA, to Trinidad. That was the challenge that was presented for Mammoet USA. Execution of this project started with the preparation of a plan to split up the plant into modules. This plan formed the basis for the transport plan and the choice of equipment for the relocation. The greatest challenge was the construction of a temporary bridge over Highway 44 and the Mississippi River Levee, a lifeline in Louisiana’s complex infrastructure in the Mississippi delta. In addition, major utility lines had to be relocated and a busy railroad line had to be crossed. Mammoet was given responsibility for engineering and developing a plan that would be acceptable to all the relevant agencies and the local community. After several design changes, the solution that was finally agreed was of a magnitude never attempted before in the state.
Unstable ground, restricting water level There is virtually no stable ground in the Mississippi delta. Ground surveys also found that transportation would only be possible if several layers of existing topsoil were first removed and replaced with a specially-designed compactable fill.
Sliding a container crane Montreal, Quebec, Canada Relocating a container crane Challenge Skidding operation on the edge of a quay Location Job
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Mammoet was contracted to relocate a container crane at the Port of Montreal. The crane had recently been constructed to increase the handling capacity at the Termont Container Terminal. The client had built the 900-tonne crane away from the quayside so that the construction work would not disrupt the operation of the other cranes on the site. On completion, the crane had to be moved a distance of about 100 meters to its final position on the quayside. A 1,000-tonne skidding system was the best solution but an inspection of the jobsite found there was not enough space between the edge of the quay and the crane to perform the necessary jacking work. This challenge was solved by using a steel working platform that the client had built in consultation with Mammoet. The relocation of the crane was then completed very quickly and efficiently. Mobilization, equipment assembly, crane skidding and demobilization back to the Cambridge yard were all accomplished well within one week.
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This work was carried out by a local contractor with the necessary expertise in dealing with these types of soil conditions. After the permits were granted, the utilities relocated, and the railroad crossing completed, loads of up to 1,100 tonnes could be moved down the heavy haul road, over the levee bridge, to the seagoing barges. The Mississippi River posed another challenge. The varying water levels restricted the opportunities to transport heavy loads onto the levee and the surrounding areas. Every ‘i’ had to be dotted and every ‘t’ crossed if the seagoing barges were to be loaded out in these narrow windows of opportunity. In close cooperation with the client and all the other involved parties, the dismantling and shipping phase was successfully completed and was immediately followed by a new phase: reassembly in Trinidad. Here, too, another challenge was waiting for Mammoet because the ground conditions in Trinidad were very similar to those in Louisiana. A sizeable amount of site work was required before any equipment could be mobilized. The relocation of the DRI plant required 2 XCC 2800, 72 axle lines SPMT, as well as jacking and sliding equipment. Overall, the entire project, including the Trinidad operations, has been successfully completed.
Offshore Mammoet’s activities in the offshore industry include the accurate and safe execution of transport solutions, load-ins and load-outs, and the assembly of very large and heavy items. The services Mammoet offers seamlessly match the industry’s desire to assemble oil and natural gas production
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platforms almost to the point of completion just before their final positioning at sea. The cases show how the offshore industry benefits in all kinds of ways from Mammoet’s special services and its ability to move and lift large and heavy items at the yard.
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Jacket load-out with a difference Location Job Challenge
Flushing, the Netherlands Combined upending and load-out operation Complex ballasting operation
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Mammoet was contracted to position the Wellbay Structure for the “De Ruyter” field, weighing approximately 815 tonnes on its gravity base. The solution was a combined upending and load-out operation. The main crane for the upending was Mammoet’s LR 1750, in SSL configuration, assisted by three of our client’s crawler cranes. The hinge point for the upending was on the edge of the floating GBS. To keep the base level end at the correct height despite tidal movements throughout the operation, Mammoet’s computer controlled Ballasting System was installed on the GBS. Since the tidal range in Flushing
is approximately four meters and the GBS measured 63 by 70 meters, a total of 16 tanks had to be ballasted. This was a particularly complex operation for the ballast crew, especially because the GBS deck, unlike a normal barge, was covered with cable trays, pipes and stringers. In spite of the harsh conditions, the crews finished the preparations for this operation on schedule and the upending was completed in just three hours’ time. After the lay-out the “ DeRuyter” was brought to Mammoet’s Heavy Lift Terminal in Schiedam, The Netherlands. With the help of a 650-tonnes crane and a 500-tonnes crane a crane was placed on the upper deck of the “de Ruyter”.
The early bird gets the worm? Location Job Challenge
Amelia, Louisiana, USA Loading out several modules of between 3,800 and 5,600 tonnes Bridging the height difference between the storage location and the barge
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Mammoet loaded out a series of modules last year. The last three modules were part of the Atlantis semi submersible. Ready for load-out at the yard in Amelia, USA, were the production module (4,800 tonnes), the generation module (3,800 tonnes) and the compression module (5,600 tonnes). Mammoet used 192 lines of SPMT and Goldhofers at the site. A particular challenge was the modules’ location almost three meters above the ground but still 50 centimeters lower than their position on the barge. The Mammoet engineering department in Rosharon designed a load spreading arrangement on the trailers that would accommodate the height, the jacking and the different beam spacing under each module. This solution worked excellently: the first module was loaded out one day ahead of schedule. The load spreading was reconfigured, and the second module was jacked up and moved to the bulkhead all in one day! The third module went equally fast. For the client, this meant the job was completed three days ahead of schedule.
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“Any change starts with yourself.
Offshore lifting in the Caribbean Location Job Challenge
Caribbean Sea, Venezuela Lifting a 500-tonne jacket and placing it on a 1,500-tonne platform Combination of late award and reduced time window
If you do not believe in a change, then it is useless to convince others.”
Darren Adams Managing Director, Mammoet UK
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Balanced ballasting
In the Caribbean Sea, Mammoet contributed to the Coro Coro project to construct an offshore platform for the extraction of oil and gas in shallow waters. The first phase, lifting a 500-tonne jacket and placing it on a 1,500-tonne Weld Head Platform (WHP), immediately presented a real challenge. The limited window to execute the operations and the late award of the project to Mammoet made it very difficult to get all the necessary solutions and resources on site on time.
The jacket was picked up from the transport barge and set onto the seabed with less than one degree of tilt from the final orientation. A four-man ballasting crew and three trailer/jacking operators were lined up for the next steps: the transfer and float-over of the 1,500-tonne WHP. It was carried on a single barge and transferred onto two submersible pontoons previously sunk in place with adequate space for the single barge to fit in between. By ballasting the main barge with the WHP and simultaneously de-ballasting the two pontoons, the WHP weight was transferred to the two pontoons. The two loaded submersible barges were then conveyed over the jacket resting on the seabed. With the WHP right above the jacket, the two pontoons were gradually ballasted again to deliver the WHP over the jacket.
Part of the plan was a float-over operation in the open waters of the Gulf of Paria between Trinidad and Venezuela, using the RG 912 crane fixed on a large barge that was grounded to the sea bottom by 25,000 tonnes of water. Additional work called for the installation of 70-meter-high, 100-tonne piles in the seabed using the RG 912 equipped with a 58 to 86-meter boom for pile driving and hammering. A Lima crawler crane assisted as tailing crane.
These operations were performed non-stop despite the tidal movements during the day.
Using 28 hydraulic pumps, the operations, once started, could not be reversed. After a series of meetings and studies of the tide charts, Mammoet and the client agreed to start at eight p.m. and finish the next day at five p.m. According to the chronogram, the critical part was during the float-over and it was scheduled to coincide with the best tides, which were expected during the afternoon. The transfer, changing from one pontoon to two pontoons, and the rearrangement of the pumps could be completed during the evening and the next morning. Good coordination between the people at Mammoet and the client is essential in an operation like this. Several meetings were dedicated to step-by-step walkthroughs of every activity and the allocation of specific tasks to each team member. The logistics to supply the crew with food and water without interrupting the operations also had to be perfectly planned.
Smoothest load-out of the year Location
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MAMMOET
ASIA
Job Challenge
Pasir Gudang, Malaysia Loading out a 2,500-tonne jacket The tidal variation
Highlight:
The Geographe and Thylacine gas fields lie 55 and 70 kilometers respectively offshore from Port Campbell, Australia, in the Otway Basin. The Otway jacket was designed especially for these gas fields. It weighs some 2,500 tonnes and is over 100 meters long, nearly 30 meters high and 30 meters wide. The contract to load out this jacket, one of the biggest and heaviest in the project, was awarded to Mammoet Singapore, which used two of Mammoet’s 900-tonne strand jacks for the operation. Ballasting services were provided by a subcontractor with a team of Mammoet engineers monitoring and coordinating the process. After the briefing, the load-out began
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around midnight. The tide was much lower than predicted in the tide table owing to local channels. The load-out began as planned but the strand jacks could not pull at full speed on account of the tidal variation. Furthermore, alternatively pulling and waiting for ballasting made the process a long and tedious one. The crossover stage could not start until about five o’clock the next morning. The Mammoet team worked relentlessly throughout the operation. Men in red overalls were popping up from under and over the jacket, here and there on the barge, making sure that no detail was overlooked. In the end it was one of the smoothest load-outs ever. The client was very impressed and satisfied, as was the Mammoet team.
Pulling & Skidding Pasir Gudang, Malaysia Transporting a 2,300-tonne jacket from jetty to barge Challenge Timing the operation to the tides Location Job
Highlight:
Mammoet was awarded the contract to transport a 61-meter, 2,300-tonne jacket from the jetty to an ocean-going barge. Mammoet deployed two 900-tonne strand jacks with two x 18 120-meter strands to carry out the load-out in a two-phase skidding operation. In the first phase, the jacket was pulled fifteen meters to a location five meters from the edge of the quay; in the second phase, the jacket was pulled from the quay onto the barge. Loading the jacket onto the barge took about six hours. The jacket had to be loaded while the tide was rising, and for this reason the load-out began early in the morning. The calculation of the necessary ballast in anticipation of the operation and the monitoring of the ballasting during the operation were also part of Mammoet’s job. The work also involved transporting three smaller
modules weighing between 220 and 350 tonnes, the largest being 91 x 7 x 9 meters in size. These modules were transported from the construction site to the jetty and loaded onto two barges using 24 axle lines of SPMT.
14,000 tonnes on 32 skid shoes Location Job Challenge
Pasir Gudang, Malaysia Assisting in building a spar Tried and tested skills prove themselves again
Highlight:
At Pasir Gudang in southern Malaysia, Mammoet is helping to build a 14,000-tonne spar as part of the Kikeh Spar project. The structure is similar to one Mammoet Dubai loaded-out at Jebel Ali a year or two ago. Building the spar is the first assignment for the Kikeh Spar project. Mammoet is supplying 32 skid shoes and the crew occasionally moves one of the spar sections to the next location on the skid track. Beside the skid system Mammoet is supplying craneage to assemble the spar segments. The towers are used to place the top sections on the bottom sections. The yard operater, another manufacturer of offshore structures, is also located in Pasir Gudang. Mammoet is providing craneage here for the assembly of the modules.
A clearance of just five millimeters
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MAMMOET
Jebel Ali Port, Dubai Transport and load-out of a 850-tonne module from Jebel Ali to Hartlepool Challenge A clearance of just five millimeters Location
Highlight:
Mammoet Dubai won a contract to transport and load-out an 850-tonne module for the Encana Buzzard North Sea Project North. The module was constructed at Jebel Ali Port and had to be shipped to Hartlepool, UK, on the Condock 5 barge but the construction yard wasn’t on the waterfront. Many competitors claimed that the job could only be done with SPMTs but Mammoet convinced the client that semi self-propelled trailers could do the job just as well. Its advice was based on extensive expertise and experience. Mammoet Dubai has been operating this type
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Job
of trailer for the past seven years, during which time they have proven their value in both the load-out and inland transport markets. The module was loaded onto two 18 axle line units and after a problem-free journey arrived at the port where the Condock was waiting to receive it. To overcome the steep slope of the jetty when loading the module, Mammoet Dubai designed, supplied and installed a special ramp. The load-out supervisor observed that there was only minimal clearance between the module and the pre-installed grillage. While bystanders scratched their heads, Mammoet’s calm and confident employees scraped in between the grillages with a clearance of no more than five millimeters on each side!
Power Modules for power plants are highly specialized facilities that are manufactured by just a few firms. In many cases, the heavy and outsized modules need complex transportation to reach their destinations, be it by road, rail or sea. For such demanding jobs, customers prefer an end-to-end, safe solu-
tion, so that’s what Mammoet offers. These cases highlight several aspects of Mammoet’s strong reputation in the power industry and its wealth of experience in all segments, from fossil fuel and nuclear power plants to facilities using sustainable energy sources such as wind.
500 km journey to the middle of a Scottish mountain
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MAMMOET
Location
EUROPE
Job Challenge
Newcastle, United Kingdom; Cruachan, Scotland Transporting and installing two 115-tonne transformers The power station’s location demanded a unique design and transport solution
Highlight:
Scottish Power commissioned two 115-tonne transformers from Nijmegen, the Netherlands. They were first carried by boat to Mammoet’s Heavy Lift Terminal in Schiedam, where they were transferred to a seagoing boat for the journey to Newcastle, UK. Upon arrival, the transformers were unloaded onto two 9 axle line trailers and prepared for a 500-kilometer journey across the Scottish Highlands, a rugged and unspoiled mountainous region. The trip to their final destination, the Cruachan Power station, took two days. Then came the most exceptional part of this job, the installation of the transformers into a hydroelectric power station in the middle of a mountain that could be accessed only via a specially-constructed one-kilometer tunnel.
Impressive professionalism The plan of the contractor and Mammoet devised to solve this exceptional challenge was worked out in every detail. Preparations began after the design phase had been completed, two and a half years before the actual transport operation. A 100% exact copy was made of the transformers designed especially for this location in order to test the installation process. Only when the test with this dummy was successfully completed the design was approved and work could begin on building the transformers themselves. On arrival at the power station the transformers were reloaded precisely according to plan onto a Mammoet girder bed combination, which ferried the cargo through the narrow tunnel. At the end of the tunnel the trailer’s hydraulics were applied to place the transformers on a turntable. After rotating the table 90 degrees, the transformers were skidded 50 meters along a passageway. They were then turned again, skidded alongside the foundations and jacked down into position. Both transformers were installed in just five days.
Reaching for the top Location Job Challenge
Various locations, Germany Replacing a 33-tonne wind turbine drive unit and windmill blades Meeting the specific demands of the wind power industry with a LTM 1500
Highlight:
The German wind power industry is making intensive use of Mammoet Germany’s LTM 1500. The crane is exceptionally good at meeting the specific demands of installing and maintaining wind turbines. The complications in this sort of work are the height and the radius of the windmill blades. The LTM 1500 has a normal boom of 50 meters but when configured with an 84-meter boom and a fly jib it is perfectly suitable for the wind power industry. One of the most recent jobs on which Mammoet Germany used a LTM 1500
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was a maintenance job at the Zodel wind turbine park close to the Polish border. It involved the replacement of a 33-tonne drive unit. For this specific job, the LTM 1500 was equipped with the complete 84-meter main boom, Y guys and a rigid one-piece jib. It also had an additional 105-tonne counterweight on the upper structure. Near Magdenburg, the LTM 1500 was used to fit new blades to a Vestas V80 wind turbine alongside the A2 highway. To replace the 24-meter blades, the crane was erected with a jib and equipped with a 60-tonne counterweight.
A 650,000 kg tunnel drill Rotterdam, the Netherlands Unloading, transporting and offloading a tunnel drill Challenge Extremely wide and heavy transport in an urban setting Location Job
Car factory applies wind energy Highlight:
Sunderland, United Kingdom Job Transporting and erecting six 55-meter-high wind turbines Challenge Preparatory consultancy and execution in close association with the client Location
Highlight:
A car manufacturer in Sunderland, UK, purchased six 55-meter-high wind turbines for installation on-site to supply electricity directly to its factory. Mammoet UK was contacted to find the optimal solution for transporting the turbine parts from the storage area and erecting them at their locations. The client had allocated specific time slots for the delivery of parts and new cars. Erecting the wind turbines was not allowed to interrupt these slots and roads could not be closed during shift periods, so the Mammoet crew had to work to a very tight schedule.
A new rail connection being built in Rotterdam, the Netherlands, will run partly underground through twin 6.5-meter-diameter single-track tunnels with a length of 2.4 kilometers. This tunnel, which will be some 25 to 30 meters below ground level, is the first to be bored in an urban region. The drill used to bore the tunnel was made in Schwanau, Germany. From there, it was shipped in sections to the Mammoet Heavy Lift Terminal in Schiedam, the Netherlands, where a PHB harbor crane loaded the sections onto trailers before they were transported in twelve special road convoys to the construction site in the Rotterdam area. The transport took place during two consecutive nights, with three, four and five axle line trailers
and an additional 4-bed-6 combination and a 2-bed-4 combination on the first and second night respectively to carry the taller sections. Some street furniture along the route had to be removed temporarily to create sufficient space for the seven-meter-wide loads, and the roads were temporarily closed to other traffic. The transports were accompanied by two exceptional convoy vehicles with further assistance being provided by the police. The whole operation enjoyed a great deal of interest from the newspapers and national and regional TV stations. After an uneventful trip the sections, including the cutter head, cutter wheel, centre shield and trailing shield, arrived at the site. There, a 500-tonne crane and Mammoet’s crew were waiting to unload the trailers. It then took two months to assemble the drill.
Before starting the work, Mammoet carefully studied the locations and advised the client about what would have to be done to erect the wind turbines. The preparations, in combination with precise measurements to ensure that none of the cranes’ outriggers would be above the underground services, ensured that the entire operation went ahead smoothly. Each wind turbine consisted of four parts: the base tower (33.1 tonnes), the upper tower (15.9 tonnes), the nacelle (20.6 tonnes) and a rotor (7 tonnes). One tractor unit with an extendable trailer of up to 35 meters and capable of carrying a load of 33 tonnes provided the transport. The cranes used for the operation were one LTM 1055, two 4075 GMKs and one LTM 1500 with the 84-meter boom extended by 68.1 meters and a 45-tonne counterweight.
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Seven different clients on one site!
MAMMOET
AMERICAS Location Job Challenge
Highlight:
At the Becancour industrial park approximately one hour north east of Montreal a new 500 MW combined cycle power plant is currently under construction. Mammoet is taking care of the transport and installation of all the plant’s heavy equipment. This comprises two combustion turbines, three large generators weighing approximately 250 tonnes each, one steam turbine, sixteen heat recovery (HRSG) modules, four large HRSG stack sections, two auxiliary boilers, two steam drums, three large transformers, and a few miscellaneous items. Unusually, construction of the plant was divided into several mechanical installation contracts: one for the combustion turbines, one for the steam turbine, one for the heat recovery boilers, one for the auxiliary boilers, etc. Each contract had its own heavy equipment transportation and lifting requirements. Mammoet bid for all nine of these subcontracts, and was honored to be awarded no fewer than eight of them! Working on eight contracts for seven different clients required outstanding coordination, if only because for most of the time just one 12 axle line SPMT was used to transport most of the 33 heaviest items. Other interesting
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Becancour, Quebec, Canada Transporting and installing all a power plant’s heavy equipment Eight contracts for seven clients required outstanding coordination
equipment operated on the site included a 450-tonne Lift-n-Lock gantry system, a 500-tonne skidding system, a 400-tonne jacking tower, a Western Star prime mover and, during one peak busy period, an additional selfpropelled conventional 12 axle line Scheuerle Intercombi transporter. One of the challenges was to skid the four HRSG stacks underneath a low pipe rack that bridged the only road exiting the port facility. Mammoet relocated each stack section under the pipe rack at a rate of one per day.
Transformer transformed Location Job Challenge
Taft, Louisiana, USA Replacing a 286-tonne transformer Mississippi crossing, nuclear challenges, replacing a transformer with a new, wider one during an outage
Highlight:
Mammoet was asked to replace a transformer at a nuclear facility in Taft, Louisiana, west of New Orleans. It was an exceptional challenge because, apart from meeting the usual extremely strict requirements on safety, personnel training/instruction/admission and adherence to drawings and procedures for a nuclear plant, the job had to be done during an outage. This demanded meticulous planning and coordination. Furthermore, the new transformer was slightly wider than the old one so that the clearance when installing it was just one inch on each side. What’s more, the 286-tonne monster was delivered on the wrong side of the Mississippi! The transformer arrived at the Port of New Orleans on the East Bank of the Mississippi River and Mammoet had mobilized its Schnabel car for a direct discharge from the ship. After tie-down, the load broke all records on this rail/road bridge and gaining the clearances required to cross the river here cost the Mammoet rail crew a great deal of negotiation and hard work.
Helping the customer out Upon arrival, the transformer was skidded off the railcar onto a double 10 axle line SPMT and then offloaded onto load spreading mats placed directly on the facility’s parking lot. The actual exchange was performed a few months later. Due to very strict ground bearing limitations, a lot of steel had to be installed under the skid tracks. Since the entrance road was only wide enough for a double-wide SPMT, the Mammoet crew loaded and offloaded the transformers using their 450-tonne capacity gantry.
Between moving the old transformer and placing the new one, the Mammoet crew helped the customer and another subcontractor install cooler panels and associated steelwork. These parts are located behind the transformer and can only be reached when it is removed. It turned out that the contractor that was supposed to do the job did not have all the right paperwork and people. The customer didn’t find that out until it was just about to start work. To avoid losing time, Mammoet helped out by using the crane intended for the gantry setup and some additional rigging. This was a smaller job than those Mammoet’s crews normally carry out and very detailed in nature. All in all, it was a pretty complex job completed safely and on time.
Cold Boxes for a Cold City Location Job Challenge
Sudbury, Ontario, Canada Delivering, erecting, and installing the six largest items for cold boxes at a new oxygen plant Complex transport route by road and water, with several restrictions
Highlight:
A major nickel mine in Sudbury, Ontario, built a new oxygen plant. Oxygen plants typically require the installation of a “cold box”, a large tower that separates air into its two main gases: nitrogen and oxygen. Mammoet delivered, erected, and installed the six largest items for this project. To do so it had to overcome many logistical challenges. The first was that the items came from two different fabricator’s shops and two load-out quays. This meant they had to be carried from the two locations several hundred kilometers apart over the road from the shops to the quays. Three items were loaded onto a medium-sized barge at the first quay and three others at the second quay. Owing to the size of the barge, it was a very tight squeeze to fit all six items on it. A larger barge, however, could not be used because the offloading site in Killarney at the
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end of the 750-kilometer journey across several lakes was no more than a rocky beach with limited access. For the final stage, from Killarney to the site by road through a very rugged area, a structural consultant had to be engaged to analyze the many bridges along the route. Furthermore, the route could not accommodate more than three heavy-haul vehicles at the same time due to traffic congestion. The six items were carried over these 100 kilometers three at a time in two separate trips by three transporters. At the final destination Mammoet used a CC 2500 crane to erect and position the equipment. Fitted with 72 meters of main boom and 200 tonnes of superlift, the crane erected and positioned all six items in the course of one week. The total project took approximately one month.
There’s no such thing as routine work Wilmington, Delaware, USA Replacing a steam turbine generator Challenge No matter how often we do the work, it’s always unique and carefully designed, engineered and checked Location Job
Highlight:
The client manufactures generators and turbines and is also one of Mammoet’s global clients. The most recent contract to be won is to replace a steam turbine generator in Wilmington, Delaware. To lift and transport the 165-tonne generator, Mammoet mobilized a TITAN tower, four 100-tonne strand jacks, a skidding system, 12 axle lines of SPMT and a 450-tonne gantry system. In the short course of three and a half weeks, the equipment was assembled, the old stator removed
Smart transport solution cuts costs Location Job Challenge
Shelburne, Ontario, Canada Erecting 45 wind turbines Cost efficient crane transport solution with two self-propelled transporters
Highlight:
A large power plant constructed in Shelburne, Ontario, has adorned the rural landscape with 45 new wind turbines. These wind turbines, the first phase in the Melancthon Grey Wind project, will produce 67.5 MW of electricity to power 50,000 homes. To erect the wind turbines, Mammoet’s Cambridge office was contracted to dispatch a CC 2600 and a CC 2800. Mammoet also provided five hydraulic cranes, crane mats, and specialized rigging, most of which was custom-designed and built specifically for this project. An interesting aspect of this project is the considerable cost saving for the client, which was achieved by using two self-propelled transporters to move the cranes on the site over distances of up to three kilometers. This strategic choice meant the road needed to be only five meters wide in many areas. This saved costs that would otherwise have been incurred to widen the road to 12 meters or to dismantle and reassemble the cranes in order to move them. Mammoet has since been contracted to carry out lifting work in phase two of the Melancthon Grey Wind project. Starting in August, it will involve the erection of a further 88 wind turbines.
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and put in storage, the new stator installed, and the tower system disassembled and demobilized again. It may sound like a routine job but in the world of Mammoet each operation is designed, engineered and checked individually. On this job, the TITAN tower was the most economical solution for the client. The only other viable solution to replace the generator was to cut a hole in the roof and then lift out the old generator with a very big crane. It would take a crane such as a PTC to accomplish this.
“Learning and developing is common sense. You need it, just
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Highboy conquers the road to Kaeng Khoi
MAMMOET
ASIA
Location Job
like daily food and
Challenge
Kaeng Khoi, Thailand Transporting and installing turbines, generators, transformers and condensers for a 1,400 MW power plant Transporting a 5.4-meter-high turbine over 77 bridges and through passages with 5.5-meter clearances
drinks.” Highlight:
Mammoet handled the transport and installation of equipment for a 1,400 MW combined cycle power plant in Kaeng Khoi, Thailand. The transport consisted of four GT turbines (370 tonnes), four GT generators (325 tonnes), four GT transformers (220 tonnes), two ST generators (250 tonnes), four condensers (100 tonnes) and two ST transformers (250 tonnes). The load had to cross a distance of about 300 kilometer from port to site by a route on which some pedestrian bridges and overpasses had clearances of just 5.5 meters.
Neil Birkbeck Managing Director, Mammoet Asia
This height limitation was not a problem for the transportation of the GT transformers and the GT generators thanks to the Highboy frame that Mammoet has designed and built especially for
this kind of work. But to transport the 5.4-meterhigh GT turbine, a new solution had to be devised based on the original Highboy. It consisted of suspension beams designed especially for this purpose by an engineer at Mammoet Canada Eastern. The beams suspended the turbine by its lifting hooks and fitted inside the contours. The frame passed under the 77 bridges on the route with just millimeters of clearance, with the Highboy helping to spread the weight. The height of the condensers, ST transformers and ST generators was not a problem and these items were transported on conventional trailers. The cargo was installed using skidding and jacking systems and a hydraulic gantry system.
On the road in Bukadra Location Job Challenge
Bukadra, Dubai, UAE Unloading and transporting a transformer A number of height restrictions
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MAMMOET
MIDDLE EAST
Highlight:
For the construction of the Dewa transformer station in Bukadra, Dubai, Mammoet was awarded the contract to transport and install a total of four transformers, each weighing 280 tonnes – and all within a 12-day period. In addition, Mammoet was asked to transport two 55-tonne reactors during the same timeframe. The transformers arrived one by one in the Port of Bukadra, transferred to a Cometto 14 axle line trailer and transported to the site. Mammoet also used a prime mover to carry out this engagement. The project was complicated by a number of height restrictions due to bridge overhead gantries – with clearances of no more than two to three centimeters. In addition to their many other skills, the Mammoet crew had to demonstrate their excellent driving skills!
Turbo transport for turbine Jebel Ali, Dubai, UAE Transporting and installing three 185-tonne turbines Challenge Do an afficient operation Location Job
Highlight:
The Aweer power station in Dubai is being enlarged. As part of the job, Mammoet Middle East is transporting and erecting three 185-tonne turbines . The 66 kilometers from the Port of Jebel Ali, where the turbines arrived, to the power station was covered in some four hours using a Cometto MX 12 lines. At the site, the turbines were lifted from the platform trailer with the Lift-n-Lock gantry. Since the trailer could not be positioned above the end position owing to the height of the foundations, the suspended turbines had to be moved sideways for 36 meters before they could be placed on the supports. Operations at the site took just two hours. The safe and swift service here could well count as the fastest operation ever accomplished.
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Marine Advanced engineering capabilities, a huge range of specially developed auxiliary facilities and an equipment fleet including pontoons and floating cranes mean Mammoet can offer tailor-made solutions for heavy lifting and transport jobs on water as well. The construction of large bridges
between islands, the commissioning and decommissioning of offshore facilities and the removal of ship wreckage are just some examples of successfully completed marine jobs – as are the cases featured on this page and the next one.
Mammoet Salvage Mammoet Salvage B.V., a joint venture with various experts from the international salvage scene, is a new initiative to make more targeted use of Mammoet’s comprehensive experience and expertise. It will adopt an innovative, high-quality engineering approach that unites Mammoet’s experience in heavy lifting and transport with specific salvage expertise. Operations started in January 2006 and are managed by Fokko Ringersma. His team members came from Wijsmuller Salvage, Smit Salvage and, of course, Mammoet. Mammoet Salvage has already executed their first contract for the removal of the inland push barge “Thor” and its cargo of 340 steel plates in the Antwerp port area. The weight of the steel plates is nearly 3,000 tonnes (eight tonnes each) and with a dimension of 12 x 4,5 meters. Whilst waiting for the locks in the port, the barge “Thor” developed a crack in the hull and sank within a matter of minutes.
“Zeevang” was fitted with two Hitachi KH-300 crawler cranes. The tug “Groenland” accompanied the “Zeevang”. The steel plates were lifted with the help of steel plate grippers. Divers placed these grippers on the bottom of the harbour inside the sunken barge at a depth of 16 meters, where after the cranes lifted the plates on deck of the “Zeevang”. In a week the cargo was discharged from the barge. Afterwards the barge itself had to be lifted, which was found to be in two pieces. On both sections, the divers installed lifting chains through holes in the side of the barge. Both sections of the barge were lifted by a floating sheerleg. The sections have been placed ashore at a quay nearby.
Several months later Mammoet Salvage carried out the operation in cooperation with BTS and Mammoet Nederland. The salvage vessel “Jumbo” had been loaded with diving containers and is the working platform. For the lifting of the cargo the pontoon
Drawing on a fat ‘cigar’ Location Job Challenge
Highlight:
After watching over Germany’s territorial waters for nearly 30 years, an end has come to the working life of the U21 submarines. Following a European tendering procedure, a Dutch breaker’s yard was awarded the contract to break up each of the vessels and five decommissioned submarines were towed from Kiel, Germany, to Amsterdam, the Netherlands, where they would be cut up into sections. Before they could be broken up, of course, the submarines had to be lifted out of
Amsterdam, the Netherlands Salvaging a 450-tonne submarine Lifting a submarine in a concerted effort using three floating derricks
the water. Mammoet lifted the first U21 several years ago; now it was time for the second one. Twelve BTS salvagers and three floating derricks mounted an attack on the 450-tonne submarine. The challenge lay in lifting it in a concerted effort using the three floating derricks – which was certainly out of the ordinary and made things extra complicated. In a delicate balancing act the floating derricks’ lifting power was gradually stepped up and the submarine rose agonizingly slowly out of the water. However, the most critical part still had to come.
The three floating derricks needed to lift their load over a port railroad and place it in saddles about 13 meters from the quay. It did not look as though that was going to be easy because the saddles were a little farther from the water’s edge than had been agreed. A handy bulldozer driver helped move the saddles a little nearer and the floating derricks also maneuvered a little closer to the quayside. Eventually, the enormous “tin fish” was lowered very gradually onto the concave saddles.
Lifting jobs at sea Location Job Challenge
IJmuiden, the Netherlands Positioning two 145-tonne topsides on the Seafox 4 Crane to be erected in mid-air
Highlight:
For a Dutch contractor, a CC 2800 was installed on the Seafox (self-elevating accommodation and multi-support platform) to carry out a number of lifting jobs at sea. First the body of the CC 2800 – which weighed more than 70 tonnes – had to be lifted more than 36 meters onto the Seafox 4’s cantilever. The next job was to assemble the crawler tracks, counterweight and boom at a height of about 10 meters using an AC 500 and an AC 650. But there was no space to lay the boom down; in effect, the crane was erected in mid-air! Mammoet used the CC 2800 to position two 145-tonne topsides on the Seafox 4 and to lift some smaller equipment on board. The project that the Seafox 4 was used on was concluded with the offshore installation of a monopile and monotower by the CC 2800. The crane was also used to lift the 145-tonne topsides onto the monopile and tower.
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Bridge reconstruction helps New Orleans get back on its feet Location Job Challenge
New Orleans, Louisiana, USA Repairing a bridge on a key highway into New Orleans High tempo and far from ideal conditions in the wake of a hurricane
Highlight:
Part of the only highway connecting New Orleans with the east and the north is the ten-kilometer long Twin Span Bridge across Lake Pontchartrain. Hurricane Katrina had damaged the bridge so badly that it could not be used and New Orleans was locked in a corner. The Louisiana authorities demanded that the bridge be repaired as quickly as possible.
A crew of between 10 and 15 people worked 24/7 in three day shifts and two night shifts, using three pontoons, skidding and jacking equipment and 4x10 self-propelled Goldhofer axle line. Sometimes, they were asked to do the seemingly impossible but their professional attitude and knowledge helped them do a very good job, to the great satisfaction of the governor of Louisiana and Mammoet’s client which.
The bridge is made up of 872 prefab concrete parts, each weighing 290 tonnes. 74 of them had to be completely replaced and 380 had to be repositioned. Mammoet was contracted to lift and position all the parts.
Container vessel buckled in the middle Location Job Challenge
Highlight:
When a ship enters a dry dock, the risk of its rupturing is mitigated by supporting it over the entire length of its keel. Mammoet has designed a jacking system to support high, unexpected loads that offers maximum flexibility thanks to its built-in hydraulic compensation system. The solution as a whole is partly pre-engineered so that the systems’ capacity is known in advance and partly based on hands-on experience. The support system can be mobilized quickly and installed in any situation.
Schiedam, the Netherlands Providing a safe docking solution for a buckled container vessel Fast mobilization and installation of a support system
The system is the perfect solution when speed is vital, such as when a container ship was grounded on a sandbank off the Dutch coast near Flushing. The 260-meter ship buckled in the middle and had to be towed to the Port of Rotterdam. To repair the ship, the damaged section – about 28 meters long and weighing 2,500 tonnes – was removed. The client, which carried out the repairs, turned to Mammoet for a safe and flexible system to provide support underneath the unknown shape of the buckled section. A team of creative supervisors with experience in jacking and skidding projects and a track record
in unexpected problems took on the job. The ship was docked on a stack of keel blocks and climbing jacks placed beneath the buckled section followed the precise profile of the buckle. The keel rested on six supports, each support consisting of a steel mat placed on the floor of the dry dock. Three 600-tonne climbing jacks were placed on each of the mats and a second steel mat was positioned on top of the climbing jacks. This sandwich of mat/climbing jack/mat was constructed to provide additional support for the vessel, thereby achieving the stability and safety required to cut through the its hull.
Heavy Lift Terminal enlarged to meet growing demand Mammoet’s Heavy Lift Terminal in Schiedam, The Netherlands has recently been enlarged to accommodate the growing demand for handling, storing and loading the equipment and cargo of third parties, and there are plans to extend the quay further. Significantly more storage capacity is expected to become available in the near future. The concept has proven to be very successful. Both Mammoet and its clients use the terminal chiefly for the temporary storage of equipment and project cargo. In addition, Mammoet offers assembly services and special support for the offshore industry from the site.
Unique concept for storage, assembly... The site in the greater Rotterdam area has many facilities, including a 250-tonne PHB harbor crane with a high lift capacity. Combined with auxiliary equipment, nearby engineering capacity, a large fleet of smaller cranes and a variety of platform trailers, construction halls and storage areas, it represents a unique concept in the Port of Rotterdam and illustrates the specific added value that Mammoet’s logistics chain can generate for its clients. An example of transport handling is the storage of power generators. A German manufacturer
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of power generators ships its products to Schiedam on a river barge. Mammoet stores the equipment, along with other components that arrive at different times from different origins. Once the “set” is complete, Mammoet takes care of the load-out onto a seagoing vessel for shipment to, for instance, the US, South Africa, Indonesia or Latin America. There is a great deal of variety in the assembly work. A customer recently asked Mammoet to remove a harbor crane from a site in Düsseldorf, Germany. It was to be sold, but there was no customer yet. So Mammoet took that crane in parts to its site. Once the destination was known, the crane was assembled and, after undergoing a complete test program and certification, it was rolled onto a RoRo vessel. Mammoet literally delivered it turnkey.
... and offshore support The Schiedam terminal is also well equipped to provide offshore support in the form of, for instance, conversion programs for specialized vessels. These often comprise heavy components, such as struts and beams, or platforms that need heavy lifting and transportation as part of the dismounting and re-assembly activities. Customers know in advance exactly
when the converted vessel will be ready for its new tasks. Mammoet also loads supply ships, runs equipment testing programs, modifies pontoons and installs winch systems to keep free-floating vessels or platforms moored to buoys.
If necessary, some services can be provided instantly. The success of this concept, a logistical addition that also supports Mammoet’s core activities, has prompted us to consider rolling it out elsewhere in Europe and beyond.
MAMMOET SUMMER COLLECTION 2005
DESCRIPTION
WORKWEAR
SUPER COMFORT WORKJACKET, PLENTY OF POCKETS WITH ZIPPER AND STORM FLAP, 3M REFLECTIVE
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The introduction of Mammoet workwear in 2004 was inevitable. Mammoet’s staffs carry out their work in the most extreme conditions – ranging from freezing no-man’s land to sweltering sand plains. Consequently Mammoet knows better than anyone else how people need to protect themselves when working in the most extreme conditions.
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pany’s corporate strategies; focusing on international offshore-, petrochemical- and power industries. Therefore the collection is also characterized by its compliance with the statutory multi-norms including: Flame retardant / Anti-static / Water proof / Chemical resistant
DOORGESTIKTE 100% POLYESTER
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Safety clothing needs to fit like a second skin and move with your body. Mammoet workwear is developed based on this vision. Clothes with rounded shapes which follows the contours of your body perfectly. With extra room around the knees, elbows, underarms and lower back, rounded forms provide extra freedom when bending forward, lifting, hauling and working above head level.
The offshore-, petrochemical-, and power industry set higher safety requirements for working attire. Mammoet 2006/ 2007 collection is in compliance with the required multi-norms including: Flame retardant / Anti-static / Water proof / Chemical resistant
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Mammoet Holding B.V. Phone +31 10 204 2424 Fax +31 10 204 2442
Mammoet Global B.V. Phone +31 10 204 2424 Fax +31 10 204 2442
Mammoet Trading Phone +31 10 204 2424 Fax +31 10 204 2442
• Branch Terneuzen Phone +31 115 648 050 Fax +31 115 630 724 • Site Dordrecht Phone +31 78 630 9415 Fax +31 78 630 9669 • Site Huntsman Phone +31 181 292 680 Fax +31 181 293 977 • Site Westdorpe Phone +31 115 472 600 Fax +31 115 472 639
Germany
BTS B.V. Phone +31 10 204 2424 Fax +31 10 204 2442
Norway
Mammoet Deutschland G.m.b.H. Phone +49 3461 432 681 Fax +49 3461 432 688
Italy • Mammoet Italy S.r.l. Phone +39 02 5770 1938 Fax +39 02 5751 5100 • Mammoet Palumbo S.r.l. Phone +39 02 9571 7401 Fax +39 02 9571 7357
Mammoet Salvage B.V. Phone +31 10 204 2445 Fax +31 10 204 2447
Mammoet Norge A/S Phone +47 35 505 950 Fax +47 35 505 960
Mammoet Merchandise B.V. Phone +31 10 204 2424 Fax +31 10 204 2442
Mammoet Roadcargo B.V. Phone +31 165 319 650 Fax +31 165 315 535
Mammoet Europe B.V. Phone +31 10 204 2424 Fax +31 10 204 2442 Mammoet Nederland B.V. Phone +31 10 204 2424 Fax +31 10 204 2442 • Branch Geleen Phone +31 46 477 1802 Fax +31 46 476 8405 • Branch Pernis Phone +31 10 4720 374 Fax +31 10 4164 885 • Site Moerdijk Phone +31 168 355 811 Fax +31 168 323 125 • Branch Velsen-Noord Phone +31 251 229 341 Fax +31 251 224 488
Australia
Brasil
Sakhalin
Mammoet Australia PTY Ltd. Phone +61 732 654 600 Fax +61 732 654 644
Mammoet Irga do Brasil ltda Phone +55 11 3942 8189 Fax +55 11 3942 8130
MIDDLE EAST
Venezuela
China
United Arab Emirates
• Shengyang Mammoet Heavy Transport & lifting Co. Ltd. branch Shengyang Phone +86 24 2281 8327 Fax +86 24 2281 8325 • Shengyang Mammoet Heavy Transport & lifting Co. Ltd. branch Shanghai Phone +86 21 5306 8787 Fax +86 21 5382 2995
CMK Mammoth Gulf B.V. • Branch Dubai Phone +971 4 333 1252 Fax +971 4 333 1366
Mammoet Venezuela C.A. Phone +58 281 2744 866 Fax +58 281 2750 539
Japan
Kazachstan
Mammoet Europe Holding B.V. Branch Tokyo Phone +81 3 3280 6671 Fax +81 3 6408 0722
Mammoet Caspian B.V. • Branch Kazakhstan Phone +971 4 333 1252 Fax +971 4 333 1366
Malaysia
AMERICAS
Mammoet Sakhalin LLC Phone +7 4242 425 235 Fax +7 4242 425 237
Azerbaijan Mammoet Caspian B.V. • Branch Azerbaijan Phone +971 4 333 1252 Fax +971 4 333 1366
Spain
EUROPE The Netherlands
ASIA
Mammoet Van Oord Windmills B.V. Phone +31 183 64 2750 Fax +31 183 64 2760
Mammoet Transport Espana S.L. Phone +34 91 3768 700 Fax +34 91 3869 965
United Kingdom Mammoet UK Ltd. Phone +44 191 2639 222 Fax +44 191 2639 333
MVS Betonbouw Phone +31 182 589 898 Fax +31 182 589 899
Mammoet Russia LLC Phone +7 495 956 0838 Fax +7 495 956 0738
• Mammoet Romstar Sdn Bhd Phone +60 6799 3200 Fax +60 6799 3220 • U.E.S. Sarawak Sdn Bhd Phone +60 6799 3200 Fax +60 6799 3220
Southern Africa
Singapore
• Mammoet Southern Africa Pty Ltd. Phone +27 11 882 4499 Fax +27 11 873 8372 • Branch Germiston Phone +27 11 825 7287 Fax +27 11 873 8372
Mammoet (S) Pte Ltd. Phone +65 686 11 638 Fax +65 686 12 718
Russia Belgium • Branche Gent Phone +32 9 3459 891 Fax +32 9 3455 376 • Branche Antwerp Phone +32 3 5401 284 Fax +32 3 5401 283
France Mammoet Fostrans sa Phone +33 495 061 474 Fax +33 495 061 475
Thailand B&J Mammoet Co., Ltd. Phone +66 38 882 556 Fax +66 38 603 800
Photography
Design & Layout
Copyright
Colophon
Chris Pennarts, Ruud van Leeuwen, Mammoet Employees and others
Graphic Invention B.V., De Meern
Texts and photos can only be reproduced after permission from the editor
Editor Mammoet Holding B.V., Corporate Communications
Text Mammoet Holding B.V., Corporate Communications
Printing A-D druk B.V., Zeist
USA Mammoet USA Inc. Rosharon Phone +1 281 3692 200 Fax +1 281 3692 178 • Mammoet USA Inc. Mammoet Western Inc. Phone +1 626 442 5542 Fax +1 626 442 0841 • Mammoet USA Inc. Atlanta Phone +1 404 696 4982 Fax +1 404 696 4984 • Mammoet USA Inc. Louisiana Phone +1 337 365 3200 Fax +1 337 365 3260
Mexico Mammoet de Mexico S.A. de C.V. Phone +528 378 2079 Fax +528 378 2170
Canada Mammoet Canada Eastern Ltd. • Montreal QC Phone +1 519 7400 550 Fax +1 519 7403 531 • Cambridge ON Phone +1 902 450 0550 Fax +1 902 450 0545 • Halifax NS Phone +1 902 450 0550 Fax +1 902 450 0545 Mammoet Canada Western Ltd. • Calgary AB Phone +1 403 252 0551 Fax +1 403 258 3846 • Edmonton AB Phone +1 780 4490 552 Fax +1 780 4179 623 • Ft. McMurray AB Phone +1 780 791 5049 Fax +1 780 791 5053