7 Pushing up to the limit!
1
Mammoet World 2007
Mammoet General.................................................. 2-9 Petrochemical projects ...................................10-13 Civil projects ...........................................................14-17 Offshore projects .................................................18-23 Power projects ......................................................23-25 Salvage projects ........................................................ 26 BTS projects ................................................................. 27
Worldwide specialists in heavy lifting and transport
www.mammoet.com
Mammoet World
The Challenges Bigger, better and recognizable In the last few years Mammoet has grown strongly in all respects. We are working with more people and more equipment than ever before on more projects spread out all over the entire world. We are exceptionally pleased and also very proud of this accomplishment. Personally, I feel our greatest achievement, besides our greatly increased activities, our OSHA rate in 2006 was good. Now, October 2007, it looks as though the OSHA rate for this year will even improve. Mammoet has the wind behind it. The economy and the big demand for raw materials provide a major impulse and, naturally, we profit from this trend. But the fact that we have increased our lead as world market leader in heavy lifting and transport solutions is a direct result of our own qualities: the quality of our employees, the equipment, the leaders and the course that we have set. Our growth is founded on a solid base. A base that we have laid in previous years with well thought-out investments, continuous attention to safety, the company-wide implementation of the SAP computerization package, and the setting up and utilization of our worldwide training and development program (T&DP).
Patrick van Seumeren (Vice-President and COO), Roderik van Seumeren (President and CEO), Jan van Seumeren Jr. (CTO) and Siem Kranenburg (CFO)
We have welcomed around 600 new colleagues just in the
The challenges
last twelve months
On the threshold of the year 2008, Mammoet is in a better state than ever before. After years of building a concrete base, the company is strong enough to take new steps. The management team, consisting of Roderik van Seumeren (President and CEO), Patrick van Seumeren (Vice-President and COO), Jan van Seumeren Jr. (CTO) and Siem Kranenburg (CFO), see plenty of opportunities for further growth. “This fine Mammoet can still become bigger. The opportunities are there, and the organization is ready for it.”
2
The Mammoet Management Team all agree that they are proud of what has been achieved in the past years and are setting very ambitious goals for the future, but are also realistic. “For the last seven years following the Mammoet and Van Seumeren merger, we concentrated on strengthening the base of the company. We have succeeded in this objective, although it will always require our attention”, states Patrick van Seumeren, referring to the effort that was put into extending the worldwide network, taking on new cooperative relationships with customers, the investments in sophisticated equipment, the training of employees and bringing service, quality and safety to the same high level the world over. “We are ready for the next phase, in which we will clearly focus our attention onward”, he continues. “The organization, as it now exists, has been established so that we can take even larger steps forward. And we have growth capital. This gives us an ideal basis for continuous growth.”
Momentum for further expansion Mammoet owes its increased financial scope to the excellent results of the last years. “The market has grown since the second half of 2005”, says Siem Kranenburg. “This has led to better use of equipment and better conditions. As well as this, we have worked more efficiently, aided by the implementation of SAP in all parts of the company worldwide. This year we have again initialized some new segments to our system, so that virtually the whole company now utilizes the system. This has all led to a better ratio of results.” The investments that were made before the commencement of the major boom have proven to be very profitable. “Our present success is not only attributable to hitching a ride on outside events. We saw this growth coming and anticipated it by investing in the top segment of the market at the right time.” One measure that has given Mammoet extra power is the change in the shareholder structure that took place at the end of 2006. With the Van Seumeren family reducing its holding to 25%, this allowed one other major shareholder to invest resulting in the availability of extra capital to finance the expansion. “This has opened the road for us to accelerate, setting our growth plans in process”, continues the CFO, who outlines two possible paths. “We will strive to increase our market share by investing in people and equipment. We are also very actively engaged in acquisitions.”
Professional, safe and complete Roderik van Seumeren names continued professionalism as the most important achievement of the previous year. “During the past year, our professionalism has stood out in the way we approach our customers, follow our investment policy, and roll out our activities world-wide. We have created closer cooperative links with a larger group of customers. In addition, we have made specific investments in having people and equipment present in all regions of the world. We are also busy entering areas where we are not yet represented. We have made plans and these have already been fulfilled in some areas.” The BoM is very pleased with the yet again improved safety figures. The systematic attention that Mammoet pays to safe and responsible working is clearly paying dividends. “We always pay great attention to safety. We set up special safety campaigns and also put safety high on the agenda in our discussions with customers.” Safety, just as quality, is an important aspect of the professionalism that the market increasingly demands. This is not just about providing equipment, but also putting forward solutions. “You notice, particularly in the middle market segment, that it is increasingly about offering a total logistics service to the customer. Working with joint ventures is being replaced by selected subcontractors who move with the trend for quality and safety, who think with you, develop ideas, have engineers on site and are able to offer the customer total solutions through engineered packages.” “Thanks to its knowledge, experience and versatility, Mammoet is a partner that is able to offer such solutions,” states Patrick van Seumeren. Mammoet has launched a new service to complete this logistics service: Mammoet Shipping. This logistics service provider does not own any ships, but does provide an important link in the entire transport chain. As a result of the increasing modular construction and transfer of production to low-wage countries, transport by water forms an increasingly vital element in total solutions, such as in the factory-to-foundation services that Mammoet offers.
Our objective is to create a company culture - One Mammoet - one way of thinking. I see this as a culture that flourishes everywhere, which adapts to the local conditions, and anywhere in the world stands for professionalism, quality, power of innovation, superb customer service and a safe manner of working. My ultimate aim is for every nation to think, feel, speak and work in the same professional manner. We are already a considerable way along this road, but we still have some way to go before this ideal is fully realized. Guiding our growth in the right direction naturally demands a great deal of attention and energy. The coming years will also be marked by constant growth. This is a fine prospect but I am realistic, because growth also brings new challenges with it. We must ensure that we retain our good people and recruit a large number of new skilled workers in order to carry out the work. Many extra employees - we have welcomed around 600 new colleagues just in the last twelve months - also means extra care for their assimilation, their training and development, the maintenance of our culture and guaranteeing our quality and safety. As well, we remain on the lookout for successful companies who are willing to combine their forces with the worldwide trendsetter in heavy lifting and transportation solutions; companies where our branch of sport, just as with us, is literally in the genes, and where the blood flows faster at the prospect of being able to work on one of the world’s most prestigious projects. In order to underscore this claim, in this year’s edition of Mammoet World we present you with a selection of notable projects that we have carried out all over the world and in all important markets. You will also be able to read how Mammoet continually works to improve its service. Cooperation, both internally and externally, with customers and suppliers, forms the core of the total solutions which enables Mammoet to be successful in the petrochemical, offshore, power, civil, marine and rental sectors. As service provider and problem-solver, Mammoet is increasingly positioned higher up the logistics ladder. We serve more and more respected customers with innovative, intelligent solutions-our other major strength. Our versatile performances form the evidence of this statement. I want to thank all our clients to have the trust in us and I personally guarantee that we will do everything to serve you to the highest standard of our profession.
Innovation and deployability Quality and innovative power are of paramount importance as far as the hardware is concerned, emphasizes Jan van Seumeren Jr. “Our power to innovate is an asset with which we absolutely Continued on page 3
Roderik van Seumeren (President and CEO)
Mammoet World
SHE-Q Continued from page 2
distinguish ourselves from the competition. Our strength is that we have everything under one roof, from development, construction, testing, operating, to working with it. This is unique.” When developing new equipment, the Equipment Management Dept. (EMD) gratefully utilizes the Engineering department and works closely with customers and suppliers. During the last year this resulted in various state-of-the-art products. These tailor-made developments, including powerful push-up systems and remote controlled underwater excavators, allow Mammoet to serve customers with ingenious and efficient solutions–solutions in
yn rgy between the he ma which the synergy many specialouse e flo ou ly. y isms that Mam Mammoet houses flourishes optimally. p pl Mammoett promotes the deployability of its wa an n equipment in all sorts of ways, continues Jan s to van Seumeren Jr. “In the fi first place, thanks ma o m our large capacity, we can easily take on major quip p projects. As well as this, we spread our eq equipment around the world, so it is not necessary to drag it over great distances. In order to save time and costs of transport, we construct new equipment as much as possible in container form. We have established a stock of all possible spare parts at Schiedam so that we are not bothered by long delivery times and
can solve problems immediately. Finally, we standardize our equipment as much as possible so that we can operate more efficiently and also increase the deployability, quality, and safety of people and equipment. In all instances our customers profit either directly or indirectly.”
Taking up challenges Despite the fact that Mammoet now has a solid base and good perspectives, the world market leader in heavy lifting and transport diligently continues to improve its own performances by investing in people, equipment, training, dissemination of knowledge, quality and safety. This has always been the case and this will
always remain so. “This is very important particularly at a time when our business is prospering”, concludes Roderik van Seumeren. “Rapid growth also brings its own challenges. We must be able to recruit sufficient qualified people and keep them with us if we are to keep up with this growth. We will also continue to work hard to be able to guarantee our one way of working and high level of quality anywhere in the world. Above all, we want to remain a forerunner as far as safety is concerned. We operate in an environment full of risks, so remaining alert is a necessity. Mammoet, as ‘One Mammoet’, is up for the challenge!”
Striving for safety: we see it all filter through Mammoet has made safety priority number one, and has continually been busy with this initiative on all fronts for many years now. So the fact that this consistent policy is bearing fruit is definitely a cause for celebration. After a steady drop in the number of incidents over the years, the statistics indicate that incidents have also reduced by half over the last year, despite Mammoet’s rapid growth. Even more reason to continue with the campaigns, training courses, management systems, staff meetings, safety pocket books, and anything else to improve safety even further.
Bryan Cronie Corporate SHE-Q Director
“Last year’s fifty percent drop in the statistics was fantastic”, says Mammoet’s Corporate Safety Director Bryan Cronie, but he refuses to accept compliments for himself for this feat. “It’s a big thank you to everyone outside. We, the safety people at the office, mastermind what we want to do, but we can’t get results unless the people out there do it. We just make the rules. We obviously monitor to see that it happens, but the bottom line is what the people out there do; they are the ambassadors of the company. They are the people who make it happen, supported by the management to help them do it.”
Consistent and proactive policy Mammoet works with a consistent and proactive safety policy that has been intensified enormously in recent years. The interaction with the department of Training & Development has led to an increasingly broader range of courses and better training facilities world-wide. As well as this, the number of safety officers has increased as Mammoet has grown. There are now 30 safety professionals working for Mammoet around the world, of which 22 are in full time service. Eight others have been appointed full time on a project basis. These people do nothing else than concern themselves with safety. “Their job is to ensure that the one Mammoet standard and our health and safety policy are implemented on a worldwide basis. They go out and visit the projects within their region, carry out audits and ensure compliance with the requirements of our safety management system.”
Safety is the responsibility of everyone Safety at Mammoet is not exclusively the responsibility of safety people; it is the responsibility of everyone. Every worker is briefed about this, is trained, and safety is brought to their attention, not only by the colleagues on the work floor, but also by supervisors and (senior) managers. “We have concentrated specifically on the supervisors this year”, explains Bryan Cronie. “They are the key to what happens outside. They form the link between the management and the people carrying out the work. So I have talked to them a great deal and meetings were
arranged at various places around the world.” The higher levels do not avoid training and awareness sessions either. All senior managers have followed a safety course this year and it has been decided that as of next year they will undertake at least one day of training each year. The range of courses offered in the field of safety as part of the Training and Development Program is also continuously being extended, because the benefit of training is crystal clear. “The reason the figures have come down is because of that training element, people with a better understanding and following the rules as they should be followed. It is the result of what we started four years ago. We see it all filter through. We see that they are not just listening, but doing, so the message is clearly getting through to the right people. The key for success at Mammoet is training, training, and training. So, looking ahead, I say: more of the same.”
Keeping the system workable Mammoet uses all experiences and insights, also from outside, to continuously update its safety management system. A system that with all its accompanying instructions and instruments is one of the best in our industry. “I doubt if anyone in our industry comes close to what we do”, states Cronie. Mammoet tries to do all that is possible to make the Mammoet safety system as workable and user-friendly as possible, because clarity and simplicity benefit safety. Unfortunately, Bryan Cronie sees the amount of paperwork increasing exponentially. “I think there’s far too much paperwork involved in safety. We need paperwork, but we need to keep it short, sharp, and sweet so that people can understand without complications.” He therefore hopes that customers will have sufficient faith in the proven quality and safety of Mammoet’s safety management system. “We have a system that is tried, tested, well documented, people know and understand it, it’s straightforward, and we get the message over in a minimum of time. The benefits for the customer are a smooth operation without misunderstandings, fewer accidents, incidents and with less loss of time.”
The key for success at Mammoet is training, training, and training
3
Mammoet World
Mammoet General HRM: people are the most important asset People are the most important asset of Mammoet. They are what make Mammoet, and it is their actions, their individual qualities, involvement and meticulous behavior that is the strength of Mammoet. Therefore, Mammoet continually invests in their development and further improvement of their skills. Training and education are important instruments for permeating Mammoet’s one way of working, that must guarantee customers all over the world the same standard of safety and quality. This is all encompassed in the Mammoet-wide Training and Development Program (T&DP), that was again extended last year. A multi-media recruiting campaign worldwide for new personnel has also been started under the name ‘Make it your world’. “Our field of work is so specific that we have developed and are still developing our own courses”, says HRM manager Natasja Sesink about the growing number of internal courses, that all consist of a theoretical and a practical part. Mammoet uses modern e-learning techniques for the theoretical part, whereby employees can often choose from six different languages. “The advantage of this is that this teaching program can be followed at any time and anywhere in the world. We have several training centers for the practical part, with the largest of these located in Malaysia. Cranes and other equipment that we work with on a daily basis are always stationed there so that students can gain practical experience. We also organize courses on the job. Safety and quality are foremost in all courses.”
Investing in people Learning begins right from the start. Every new employee, from management to entry level, must follow the compulsory introduction course. Mammoet devotes a very great deal of time to their training and development in the first two to three years of working for the company. This is very much appreciated, particularly in Asia, where people are not used to being able to follow such courses. Mammoet continues to pay attention to career development and to increasing everyone’s knowledge and skills after this
period also. Each employee has a Safety guide in his possession that documents all registered courses followed and certificates achieved. Customers may inspect these to satisfy themselves of the professional skill and safety knowledge of the people who are working on a project.
Broad and up-to-date range of courses The worldwide T&DP program is constantly being developed. Mammoet adapts existing courses to the newest technical developments, and new courses are always being prepared. These include office courses for various functions, and many field courses to offer the possibility of growth in various fields such as those of SPMT Operator or Crane Driver, for example. This has now brought the total number of internal Mammoet courses to almost 15. This is unique to our industry and an important distinguishing feature for both an increasing number of customers and those applying for a job. Our own employees also follow courses outside Mammoet, from forklift training to administrative and management courses, and Bachelor and Master courses in their branch. For instance, university-educated employees from India have been brought to the Netherlands for an internal course lasting half a year. After that they are deployed worldwide in order to gain practical experience.
Working at Mammoet Mammoet is growing steadily and is therefore constantly looking for qualified personnel, both highly-educated engineers and skilled craftsmen. As is the case for so many top technical companies, it is not easy to find suitable personnel. Therefore, Mammoet is making itself known in schools and colleges, in trade journals and on the Internet with the worldwide slogan ‘Make it your world’. The website has been changed in order to further emphasize the attractiveness as employer, with a great deal more attention being paid to working at Mammoet, vacancies and possibilities for training. Last year Mammoet was able to recruit around 600 new employees worldwide. See also www.makeityourworld.com. Mammoet makes high demands on its people, but as employer also offers a great deal in return. Naturally, its great reputation and the many projects that appeal to the imagination, but also a comradely, hands-on working atmosphere, good salary scales, the possibility of promotion, chances of an international career, a great deal of responsibility and all the space required for further training and development.
Engineering: brains with practical knowledge 4
Mammoet would not be Mammoet without engineers, because almost no projects take place without some necessary engineering beforehand. Engineering can therefore be viewed as the brains of Mammoet, as the think-tank that solves the most exceptional and complex technical problems, but always from the basis of practicality. This combination makes Mammoet the all-round specialist in heavy lifting and transportation solutions. Mammoet employs over 100 engineers, 50 of which are stationed in the Netherlands. They are sent out all over the world. That is also what is fine about being an engineer at Mammoet; they do not just sit at their desks, but also play an important role in carrying out projects as project engineer or project manager. This means that cross-fertilization between theory and practice is at a maximum, which contributes significantly to the quality of the solutions and the utilization of the technical possibilities and the available equipment. This method of engineering work at Mammoet distinguishes itself from that of a consulting engineering office which does not have strong links with actual practice. Having this as their basis also means that Mammoet’s engineers are familiar with all the different aspects of the market. They are not only clever and skilled in their own expertise, but can also work well together in a team, are flexible and can bear responsibility, in fitting with the short lines and hands-on
mentality that characterizes a flat organization like Mammoet.
Unique new construction projects The uniqueness of the work of Mammoet and that of the department of Engineering, in particular, is that no order is ever the same. In fact, there is only one thing that is standard, and that is that a unique solution for a unique problem always has to be created. An attractive field of work for the Engineering department is building unique new constructions. A recent example is the order from the navy of a foreign country for the construction of a ship specially designed for salvaging sunken submarines. This came as a consequence of another engineered project that established the reputation of Mammoet worldwide: the salvaging of the Kursk. There are numerous other projects that could be named where Mammoet’s engineers have developed ingenious solutions, whether it be a colossus of 15 million kilograms that has to be lifted, or an enormous object that has to be maneuvered in a tight situation between something on the other side of the world.
From heavy transport to nuclear reactors Engineering at Mammoet is divided into a number of specialisms, including the horizontal work (transport), the vertical work (lifting), software, nuclear/power, salvage, and the design and calculation department. There is very in-depth know-how in-house within these specialisms. Mammoet has developed quickly into a specialist in the transport and construction of reactor modules, very demanding work that must be carried out very quickly and at the same time
exceptionally safely and carefully. Mammoet engineers have designed and tested a lifting construction especially for this - the containerized winch system - that drastically shortens the assembly and dismantling times of nuclear reactors. Customers increasingly call on Mammoet to think together on how to make
Engineers are also in
Wessel Helmens Manager Engineering
contact with the customers new construction designs best suited for assembly and maintenance requirements, which save a great deal of time and costs later on. Another trend is the modular construction of complete production installations and power plants. Here Mammoet helps the customer to design the modules so that they can be transported worldwide, whereby the dimensions, the weight, and the necessary modification of the construction are all considered. After this Mammoet transports, places and assembles the modules, with the whole process involving engineers from A to Z.
From thinking to selling Naturally the various specialisms work closely together and also maintain contact with external knowledge institutes. Depending on their preference and specific branch knowledge, young engineers are appointed to one of the groups under the leadership of an experienced team leader. They gain a great deal of experience here, especially since they are also deployed to
assist in carrying out the practical project after carrying out the thinking work, where they have to utilize their own solutions in cooperation with the Operations department. Engineers are also in contact with the customers. In particular, during an initial discussion, even before the order has been received, an expert at the meeting can make a huge difference.
Safety first What applies to Mammoet as a whole certainly also applies to Engineering: safety first. Customers want everything to be fully calculated beforehand and laid out in manuals, and often also ask that an extensive risk analysis be carried out. Mammoet checks all engineering, both in theory and for practical feasibility and there is also an external check made by renowned companies for new construction projects. These safety efforts have gained Mammoet the reputation with customers of being a responsible partner that does all that is possible to allow projects to take place safely.
Mammoet World
Mammoet General
Sander Splinter Director Cranes Benelux
Mammoet rental concepts conquer the world Thinking together, providing advice and performing well: optimum collaboration with the customer is achieved by knowing the rental market and by making safety, quality and the environment our important aims. Director Cranes Benelux, Sander Splinter, explains why the Mammoet rental concept is increasingly in demand all over the world. The rental activities form one of the important pillars on which Mammoet rests. Naturally, supplying equipment that is geared to the situation is essential to this market, but the quality and safety of the services offered is also of major importance. The further optimization of the service towards the customer and the market, based on the successful Mammoet concept, were the key points for rental last year. The individual customer is the central figure in this concept, which by supplying as complete a package of services as possible ensures maximum economy with minimum worries. Mammoet is providing customers with this unique concept in an increasing number of countries. An increasing number of customers are also contracting out the work for all their international branches to Mammoet, thus guaranteeing them the same quality all over the world.
Reacting to the wishes of customers The so called Mammoet Concept exists of the use of on-site Mammoet branches on or in the proximity of the customers’ premises. In 2007 Mammoet managed to expand and further optimize our Mammoet Concept in the Benelux but also in other parts over the world. Mammoet can respond immediately on the customers request with on-site equipment and personnel. “After a certain time we become well acquainted with the various premises belonging to the customer, the procedures and the safety regulations”, according to Sander Splinter. “We never have
to search anymore. We know what permits are necessary and can offer a good, efficient service for daily maintenance and during shutdowns and turnarounds. Mammoet participates in multidisciplinary teams in order to prepare jobs accurate in close cooperation with our principal and other contractors. This early supplier involvement principle enables us together with our principal to make the most economic and efficient planning for the specific job or project. By having this kind of expertise in an early stage, we can help our principal in saving money, and thus lower the Total Cost of Ownership for our principal.” After the Netherlands, Belgium, Germany, the United Kingdom, Canada, and South Africa, the on-site concept is conquering an increasing number of countries. The tendency is for customers to purchase as many services as possible from one supplier. The possibilities that Mammoet offers for long-term partnerships and flexible contract agreements are clearly appealing. There is one contact point for everything, also for the most important point of attention: safety. “Customers take out a contract with us. We agree in the contract with the customer that we are responsible for safe working, and guarantee that safety protocols and procedures will be complied with. These are matters that customers value highly.” Mammoet works on guaranteeing the quality of its people through the rigger pool. The rigger pool is a nursery in which new Mammoet employees are trained as Rigging Operator. If they are successful in this environment, Mammoet offers the opportunity to these people to be transferred within the company after one
Energetic start for Mammoet Energy Support Stricter environmental requirements and new standards to limit the emission of harmful gases will force many energy producers to modify existing power stations in the coming years. Heavy, difficult, and precise work which must as well be carried out very efficiently to keep a stoppage as short as possible. This requires a reliable partner who is specialized in the horizontal and vertical transporting of parts within existing complexes. A task that is ideally suited for Mammoet, which has bundled its extensive knowledge and experience in this field into a new service under the name of Mammoet Energy Support. Thanks to its long presence in the energy sector, Mammoet has gained a wealth of knowledge and experience in the construction of new power stations. Know-how that is also exceedingly useful when modifying existing power stations. In combination with the unlimited transportation and lifting facilities, Mammoet Energy Support is capable of arranging complete engineered
solutions. A concept that is finding favor, as shown by the many orders that have been carried out successfully in recent years in various power stations in the Netherlands and Belgium.
year. The pool provides the customer with certainty, because he gets the personnel support that he has asked for. “Lifting is dangerous work if you do not know exactly what you are doing. Therefore, the customer asks us to take care of the complicated rigging and lifting jobs.
Modern and reliable equipment There is plenty of growth in the rental branch. This is shown by the turnover figures, but also by the increasing need for training and the extension of the equipment. Last year Mammoet invested in both the extension of its rental fleet, particularly in the top segment of heavier cranes, as well as in replacing existing equipment. The average age of Mammoet’s cranes is five years, whereas an average economic depreciation of eight years is usual. Splinter says: “This short depreciation term has to do with our vision about equipment. We want to keep up to date as much as possible with technical developments and possibilities. As well as this we try to prevent breakdowns. Therefore, we work with modern and reliable equipment, which is also to the advantage of the customer.” Finally, an example of foresight was the takeover by Mammoet last year of the lifting and transport activities of Koekkoek and KTC Noord. This takeover means that the coverage in the Benelux has been improved significantly and brings the strongly growing industrial area in the north of the Netherlands within reach. “That is where the future lies”, concludes Sander Splinter. “We simply cannot and will not be absent from there.”
5
Mammoet World
Mammoet General
Jan van Seumeren Jr. CTO
EMD: Strength in innovation is what distinguishes Mammoet The range and versatility of the equipment are part of Mammoet’s strength. Having the world’s largest fleet of heavy lifting and transportation equipment means that it can offer every imaginable solution and rapidly deploy large amounts of equipment–a fleet that is continually being extended and renewed in order to be able to respond even better to the latest trends and specific requests from customers.
6
The Equipment Management Department (EMD) is responsible for the management and maintenance of the immense quantity of equipment that Mammoet has available, including the world’s largest land cranes and other sophisticated equipment. The special challenges that Mammoet faces as world market leader in heavy lifting and transportation means that the role of EMD goes much further than simply purchasing, maintaining and replacing equipment. Unique requests often require unique solutions. These solutions are found in close collaboration with the departments of Equipment Management (EMD), Operations, and Engineering, and also with external suppliers. “Our innovation strength is what distinguishes Mammoet from others. That we design, construct, test, operate, and work with our equipment ourselves is unique. You do not see all this under one roof very often”, says CTO Jan van Seumeren Jr.
Mammoet innovations EMD already has various innovations to its credit. These concern both new equipment as well as modifications to existing equipment. EMD has again produced a very wide range of new products this year. One of the literal high spots was the delivery, after an extensive series of tests, of the PTC IV, the fourth offspring of the successful PTC family. The eighth ring crane in Mammoet’s fleet has a maximum configuration of 134 meter main boom and 99 meter jib. With the production of its second push-up system Mammoet is responding to the rapidly increasing demand for more capacity for jacking up complete oil platforms and large constructions. Push-up system II consists of eight units each with a capacity of 2,400 tonnes and 112 jacking columns. It is fitted with a control system capable of controlling a total of 16 units centrally, so that the system
Deep Water Recovery System (DWRS)
Chain puller
generates a maximum push-up capacity of 38,400 tonnes. Due to the increasing activities in the field of push-ups and loadouts, Mammoet has manufactured a second ballast system for adding and removing ballast in pontoons and barges. The system provides the enormous pumping capacity that the greater load-outs demand. A puller system has been developed specially for Mammoet Salvage, consisting of eight chain pullers that can each pull 300 tonnes. The system has been designed to pull ship’s wrecks ashore and was used in salvaging the Safmarine Agulhas. Mammoet has designed the containerized winch system (CWS) in order to respond to the demand for a compact, safe, and quick lifting method for working in existing nuclear power stations. The CWS system provides 650 tonnes lifting capacity through a mobile portal system that can be configured in various heights and widths. Last, but not least, the deep water recovery system (DWRS) was developed by Mammoet Salvage together with the Engineering Department to recover the load of aluminum from the Runner 4. This system, consisting of remote-controlled underwater cranes on the seabed and underwater robots, represents a breakthrough in the salvage world. It provides much more efficiency and certainty in comparison with the traditional salvage methods using divers.
power sector, the petrochemical industry and the offshore sector. Transporting, lifting, and assembling large parts, also such as those for windmills, require increasingly heavier equipment, a demand that we are responding to with our latest acquisitions.” Seeing the present market situation regarding the purchase and delivery of equipment, Mammoet out of necessity has been forced to make investments for the coming years already. Three LTM 11200s, the largest mobile telescope cranes in the world with a capacity of 1,200 tonnes, form part of the most recent acquisitions that have been purchased this year and will be available for rent in 2008 including in the Netherlands and Germany. Besides we ordered 392 axle lines of SPMT this year. Finally, Mammoet is continuing with more standardization and container construction for its equipment, two trends that are further improving the speed, flexibility, safety, and quality of Mammoet.
Larger and heavier Naturally not all of Mammoet’s work is tied to a project. The daily rental of cranes and other mobile equipment is another important service. The rental equipment has again been extended and renewed during last year. “Companies make increasing use of prefab, thus reducing the construction time on site”, according to Jan van Seumeren Jr. “This trend is visible in the civil sector, the
Containerized Winch System (CWS)
Mammoet World
Mammoet General
Terminal Westdorpe
Terminal Schiedam
7
Mammoet heavy lift terminals: at the center of the total logistics formula The Heavy Lift Terminal in Schiedam and the Multi Purpose Terminal in Westdorpe, both in the Netherlands, provide a unique total formula for the storage and transshipment of goods for third parties. A wide range of supplementary services like engineering and auxiliary equipment that only Mammoet can supply can be found here as well as the heavy lifting facilities.
Pieter Modderman Terminal Manager
The Heavy Lift Terminal in Schiedam, in the heart of the Rotterdam harbor area, forms the central hub for Mammoet logistics. Thanks to the ideal situation and the unique facilities that Mammoet’s home base provides, including the strongest harbor crane (250 tonnes lifting capacity) in Europoort and a RoRo quay, third parties are increasingly discovering the way here. The terminal in Westdorpe, strategically situated relative to the harbor and industrial areas of Antwerp, Ghent, Flushing and Terneuzen, also has by far the strongest harbor cranes in the surrounding area, now that a second 100-tonne harbor crane has been placed there this year. But this is not the only thing that counts, according to Pieter Modderman, Terminal Manager for Mammoet. “These cranes are a link in a chain of services. The Heavy Lift Terminal increasingly provides more value-added logistics, from complete factory-to-foundation concepts to supplementary services.”
to floating sheerlegs, can be deployed at the terminals. Apart from this, Mammoet can arrange for engineered lifting with the help of its own department of Engineering, and naturally both terminals are manned by professionals who deal with goods in a skilful, efficient, and safe manner. If desired, they are trained specifically for carrying out maintenance on, or the assembly of, your products. Thanks to these unequalled facilities Mammoet now provides the total logistics package, also on a factory-to-foundation basis, for numerous renowned customers. For instance, Mammoet provides turnkey delivery and installation for suppliers of transformers, harbor cranes, heavy vats, construction equipment for civil engineering works and complete factory modules, as well as the stock management and supply to the customers of an aluminum producer.
Steady extension Logistics solutions More and more customers are discovering the added value that Mammoet provides around its terminals. The storage and transshipment of goods forms the stepping stone to a whole range of logistics services that allows customers to concentrate on their core activities. Thus Mammoet provides logistics solutions in the form of stock management, maintenance, assembly, dismantling, transport over land and water, positioning and on site installation of heavy goods. What also distinguishes Mammoet from other logistics service companies is that all imaginable cranes and transport modalities, from special rigging equipment, SPMTs,
In order to be able to cope with their own increased activities and the growing demand from third parties, the terminals have already been considerably enlarged in recent years. There are also various extensions planned at Schiedam again for next year, reports Pieter Modderman. “With, among other things, lengthening the quay by 200 meters, increasing the storage area by 10,000 m2, and the construction of a hall that will provide an additional 1,000 m2 covered storage, we will shortly be in an even better position to be able to respond to the needs of our customers.”
Mammoet World
Sponsoring Mammoet Runs… Society expects that companies take their responsibility where social questions such as climate change, energy scarcity, poverty, and health are concerned. Mammoet counts itself among the companies that can and want to play a role in this; and by supporting and sponsoring a wide range of causes Mammoet shows its involvement with the wider world.
‘Mammoet Runs’ against hunger: Mammoet MT generates 120,000 Euros Under the title ‘Mammoet Runs… the extra mile against hunger’ the four members of the Mammoet management team plucked up their courage and put on their running shoes. They appeared at the start of the Fortis Marathon Rotterdam 2007 on a hot Sunday in April. The aim: to complete the marathon in relay form in order to collect a large amount for The Hunger Project. They managed it, at the cost of a great deal of sweat. Roderik van Seumeren, Patrick van Seumeren, Siem Kranenburg, and Jan van Seumeren Jr. decided to run against hunger. They were fully committed to their aim. Creativity, result-orientated, enterprising and stamina: a handful of important characteristics that we need so much in the challenging world in which Mammoet operates. The same characteristics are evident in the approach to The Hunger Project. “What so appeals to us in The Hunger Project”, explains Roderik van Seumeren, “is their faith in human power and creativity. The Hunger Project does not dig wells, but invests in the knowledge and capabilities of people.” The four MT members began to train in November 2006. During the preparation Patrick van Seumeren was replaced by Erik Rave, Director Finance & Organization, because of a persistent injury.
Completely overwhelmed As well as running kilometers during training, the good cause also had to be promoted.
Thanks to the ready sponsoring by employees and relatives of Mammoet the count quickly reached 60,000 Euros. It had been agreed that Mammoet would double this amount if the management team managed to complete the 42.2 kilometers within three hours and fifty minutes, in the form of a relay whereby three people would run 10 km and one 12 km. Despite the weather, which was really too hot, the aim was achieved in a good time of 3 hours and 50 minutes. “I am completely overwhelmed”, said Elisabeth Roelvink, Corporate Fundraiser of The Hunger Project in the Netherlands, when she was handed a check for 120,000 Euros. “I had never expected such an enormous amount, fantastic!”
No classical emergency help 20,000 people die from chronic undernourishment every day. Three-quarters of all deaths from hunger are children less than five years old. These are the cold facts, but perhaps the most harrowing fact of all is that we produce enough food worldwide to be able to end this hunger permanently straightaway. The Hunger Project strives to help the people that do not just accept poverty as a way of life. The Hunger Project is not a classical emergency help program in which sacks of food are distributed, but helps by investing in the development of people. See www.thp.org for more information about the vision, principles, and the special approach of this organization.
Taking education and childcare seriously 8
Mammoet Canada Western is supporting a project in Fort McMurray, Canada, where there is an urgent need for outside school hours care for the children of the employees of the plants. In Fort McMurray outside school hours care for children is more of a problem than elsewhere. This is because many parents are employed in the factories, where they work shifts that do not coincide with the childcare timetables. The problem is that the
children of these families are often left to fend for themselves and they arrive at school without having had any breakfast, which does not really help their learning. A similar problem occurs in the afternoon. Children come home to an empty house, may have to look after a younger brother or sister, and they have no supervision, so that homework and eating healthy meals easily gets left undone.
Longer opening hours
children eat their meals and do their homework under supervision. In order to combat excessive TV viewing and other undesirable activities, the time will be filled with sports and handicrafts. Although the community at Fort McMurray and the surrounding areas urgently needs this provision one obstacle still has to be overcome - finding suitable premises or a piece of ground. “With time, patience and support this will also be achieved and the whole town can profit from this project”.
The outside school hours program that Mammoet is supporting has longer opening hours and leaders that will make sure the
Crossing Alaska for KiKa Icy cold, dangerous animals and darkness predominating. Four Dutchmen are preparing themselves for a trip full of hardships right across Alaska. The exceptional expedition bears the name ‘Crossing Alaska for KiKa’, because the four adventurers have the extra aim of wanting to mean something for KiKa (Kinderen Kankervrij or Children Free of Cancer).
Mammoet also warmly supports the battle against cancer in children and has recently agreed to support the expedition. Mammoet knows as no other that exceptional conditions require exceptional solutions. Alaska is known as the country of icy cold and extensive tundra, mountain chains and thick forests. A land that is ninety percent uninhabited and where darkness rules in winter at temperatures down to -60oC. A domain for moose, and rare animals such as the musk ox, wolves, and bears. It is just this country that has been chosen by John den Outer, Johan Vaes, Maarten Harteveld, and Joost van Megen for an ultimate challenge. The team intends to cross Alaska during eleven weeks in the winter of 2008 covering a total of two thousand kilometers. The biggest risks are frostbite, polar bears and crossing rivers and lakes. “The conditions that we are going to face cannot, however, be compared to the battle that children with cancer have to fight”, say the four. “We can prepare ourselves well and use the best equipment. They have to fight an enormous, unequal battle, that they lose all too often. Our aim is to reach the end, and an important extra motivation is to mean something for KiKa in doing so financially, but also as an example and inspiration for others by showing how a team can break through the boundaries. See www.crossingalaskaforkika.nl for more information.
12
www.mammoetworkwear.com
1
HORN S3 EDGE S3 TRIBE S3 1 4 CLAW S3 SPIKE S3 ARROW S1-P BOW S1-P SPEAR S1-P FLINT S1-P MEGA S1-P HORN S3 EDGE S3 2 3 5 7 TRIBE S3 CLAW S3 SPIKE S3 ARROW S1-P BOW S1-P SPEAR S1-P FLINT S1-P MEGA S1-P HORN S3
2
1 2 3 4 5 6 7 8 9 10 11 12 13 14
4500
3
4
5
6
7
8
9
10
11
12
13
6
8
14
HORN S3 EDGE S3 TRIBE S3 FLINT S1-P MEGA S1-P ARROW S1-P BOW S1-P SPEAR S1-P CLAW S3 SPIKE S3 YAKUT ANIVA JASTREB EVENK
9
YAKUT ANIVA EVENK STREB 13AKUT 11 ANIVA EVENK JASTREB YAKUT ANIVA EVENK JASTREB YAKUT ANIVA EVENK A JASTREB YAKUT ANIVA T EVENK JASTREB
10
[ STORE ]
4000
3500
3000
2500
[PTC MODEL] Heig He iig ght: htt: 1,92 92 2 met e er L ng Le ngth tth h: 0,50 50 0 met ete er er Ro R ota tati t on ti on:: 360º 36 0º Part Pa Part rttss: s: 3 34 Building tim ime: e:: tw t o days ys
[SPE PEC CIA IALL FEATUR RES] S ale 1::50 Sc 0 √ Limi mite ted ed ted e ition √ DVD √ Manual √ Mammoett Pa ackag ge √ Ce Cert rtifi rt ifi fica cate te
[GO TO WWW.PTCMODEL.COM, FOR THE FIRST IMAGES OF THE PTC MODEL]
[ WWW.MAMMOETSTORE.COM ]
14
9
Mammoet World
Petrochemical proj projects j cts 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.
Americas Location Port Arthur, Texas, USA Job Transporting and installing plant modules Challenge Saving time by using SPMTs instead of cranes
Smart solution This project started with the transport and installation of a 950-tonne reactor, around 40 meters long and with a diameter of five meters. It was delivered by ship to Port Arthur in Texas. Mammoet used SPMTs and Goldhofer units to transport the reactor through the city, to the refinery. At the site, the reactor was uprighted and installed using the Mammoet Strand Jack Tower system. The rest of the project comprised the transport of 21 plant modules from the fabrication shop in South Carolina to the site, followed by their installation. First, Mammoet transferred the modules from the yard onto seagoing barges. Some of the modules were stacked on the barges to use the space more effectively. After arrival, the modules were transported to the site where they were installed using SPMTs. The advantages of using these hydraulic transporters for the installation were that they saved time and that disruption of the work on site by cranes or the need to build crane foundations was avoided.
Location San Francisco Bay area, USA Job Handling five pressure vessels Challenge Operating in an environmentally-sensitive area
RoRo Day at the Bay
10
Mammoet USA was commissioned to unload five coke drums (pressure vessels) with a weight of 400 tonnes each and transport them to a refinery in North California. Because the creek near the refinery was shallow, only 1.8 meters at high tide, the pressure vessels were transferred from the ships onto a barge. The major challenge was avoiding any damage to the tule plants on the banks of the creek. These plants grow up to three meters high and are important buffers against the water and wind and provide food and a habitat to a range of animal species. Tules are protected by the State of California and in order to perform the roll-off operation, Mammoet had to prove that the operation could be performed without removing, flattening, crushing or even touching these plants in a destructive way. The solution was to design and to build five 80’ (24.4 meter) ro-ro ramps between a pad onshore and the barge. The pad was built to ensure that the ramp was well clear of the tule bank. The barge collected the pressure vessels from the ships in the bay. Back at the ramp, two sets of 12-line double-width SPMTs transported the vessels two kilometers from the barge to the refinery. The whole operation went smoothly and was completed ahead of schedule. Mammoet has several more projects lined up in the beautiful San Francisco Bay area over the next two years.
Location Fray Bentos, Uruguay Job Construction of a pulp and paper mill
Tandem lifts in Uruguay
Challenge Working in rough terrain
Mammoet Europe, with the support of Mammoet Venezuela, won the contract for the heavy lifting operations for the construction of one of South America's largest pulp and paper mills, at Fray Bentos in Uruguay. Until Mammoet's arrival, the largest crane in the country was a 70-tonne model. The seven telescopic cranes and crawler cranes provided for this project had capacities from 55 tonnes to 600 tonnes. Two crawler cranes, a CC 2800 and LR 1350, were used for a number of critical tandem lifts, with a maximum load of 320 tonnes. The flexible configuration options of these units were particularly valuable. For example, the 84 meter main boom of the CC 2800 was fitted with a 48 meter jib for a total of 120 meters to assist with the internal inspection of a concrete chimney. The five smaller telescopic cranes worked practically around-the-clock. Their excellent handling on rough terrain enabled Mammoet to keep up with the busy schedule set by the client.
Mammoet World
Middle East Location Rabigh, Saudi Arabia Job Heavy lifts Challenge Demanding environment, busy sites
Crane forest Mammoet is currently very busy in the Middle East and working on a number of large projects in Saudi Arabia, Qatar, the United Arab Emirates, Kuwait and Oman. At the Rabigh site, Mammoet started a major heavy lifting project by installing an 880-tonne regenerator on a 15 meter high foundation, using the MSG II. On the same site, the PTC I lifted a VDU column weighing 825 tonnes onto a 26 meter high pedestal. Nearby, a 36-axle line SPMT and an RG 912 were working on another project. At the same time, an LR 1800, CC 2500, CC 2800 and CC 2200 were busy building a petrochemical plant, right around the ring cranes. Mammoet was also awarded a contract for an ethylene glycol plant elsewhere in Saudi Arabia, which required the MSG I, a CC 4800 and several smaller cranes. Finally, Mammoet used the MSG with an 87 meter main boom and 43 meter jib, operating at a radius of 93 meters, to install a 350-tonne regenerator. The MSG was assisted by a Manitowoc M999 used for tailing.
11
Location Jubail, Saudi Arabia Job Four gantry lifts of columns Challenge Several moves and the size of the columns to be lifted
Long hauls at Jubail Mammoet deployed its gantry lift at four places and in different configurations during the construction of various petrochemical complexes in Jubail on the Persian Gulf. The first gantry lift was the positioning of a 106 meter long splitter. The column weighing 880 tonnes was stood upright using a 112 meter high gantry fitted with 2900-tonne units, and a CC 2500 tailing crane from another company. Mammoet’s LR 1750 with 134 meter boom was used to build the gantry. The gantry had to be built up again five kilometers further on for the second lift. Six weeks later Mammoet positioned a 92 meter long and 1,600-tonne wash tower at this site. Another six weeks later a third gantry lift was used to lift a 750-tonne water quench tower onto a 15-meter high concrete base. The 63-meter long monster was first stood upright using a 93-meter high gantry with two 900-tonne strandjacks and a CC 8800 tailing crane, and lifted up 17 meters. The column was then sledged over two skid tracks using two 65-tonne push-pull units until it was above the base. A month later Mammoet rounded off the gantry work in Jubail with the positioning of a 102-meter long column weighing 684 tonnes. A 107-meter high gantry was used, fitted with two strandjacks each with a capacity of 900 tonnes.
Mammoet World
Petrochemical projects Europe Location Middlesbrough, UK Job Installing three compressors and two e-motors Challenge Small clearances, wide range of equipment needed
The whole bag of tricks! Mammoet transported a selection of plant items weighing up to 165 tonnes for the construction of an LDPE plant. The job required the full range of Mammoet equipment: 12 axle lines of SPMT, a skidding system, 50-tonne jacks and climbing jacks, load spreaders, etc. and was a perfect demonstration of the versatility of our resources and personnel. Apart from straightforward lifts, some plant items had to be skidded up to 20 meters onto their foundations. Mammoet used a range of supports and load spreaders to spread the load onto
a bridge, fill gaps in the foundation across which plant items had to be skidded, etc. Due to space restrictions some of the plant items could not be installed using cranes. Instead the lifts were made with the SPMTs and jacks. On one occasion, the clearance was only ten millimeters when installing an 84-tonne rotor inside a stator of approximately the same weight to assemble a compressor drive motor. Here it was essential to prevent the two parts of the motor from impacting each other as this would lead to serious damage. Even so, this particular lift actually took less than an hour to perform.
12 Location Gelsenkirchen, Germany Job Moving 21 furnaces Challenge Tight schedule
Furnaces old and new A major chemical plant was revamped. Mammoet removed 16 old furnaces using cranes and SPMTs, moved five new furnaces into place, and then transported the old furnaces to the demolition site. Mammoet started by removing the chimneys of the old furnaces using one crane with a man-riding basket for the operatives cutting the chimneys into sections, one crane to lower the chimney
sections down, and one to load them onto a low-loader. Supporting steel was then installed under the furnaces and they were jacked up with six 250-tonne jacks. Two 14-axle lines of SPMT then transported the furnaces to intermediate storage. This part of the project took only 13 days, five days less than estimated. The first new furnace (17
meters wide, 30 meters long and 45 meters high) was then weighed. At 2,206 tonnes it was 380-tonne lighter than expected. The furnaces were carried to their destinations using 2 x 48 axle lines of SPMT. Finally, Mammoet moved the old furnaces from the temporary lay-down area to the demolition site. The whole project was completed in only 35 days.
Mammoet World
Asia
Location Dampier, Australia Job Transporting and installing an LNG train Challenge Slope: five kilometers, eight percent
Mammoet was contracted to transport and install the modules, consisting of more than 200 items, of an LNG train five kilometers from the quayside to the construction site onto foundations. Parts of the modules were constructed as pre-assembled modules in Batam, Indonesia. Mammoet carried out the site moves and load-out by delivering them alongside heavy lift vessels. In Australia, the modules, arriving from Batam and other parts of the world, had to be transported five kilometers from the wharf to the site where they could be placed onto their foundations.
Location Inner Mongolia, China Job Installing two 2,050-tonne reactors Challenge Remote site, heavy load
Installing more than 200 items of an LNG train The fractionation module (1,850 tonnes) was the heaviest unit and required four SPMTs with 4 x 24 axle lines of SPMT each to negotiate the slope which was as much as eight percent in places. After arrival, the module was off-loaded temporarily so the SPMTs could be reduced to 4 x 22 axle lines to fit on the site. They then moved the module another 500 meters and installed it on the foundations. Its position was accurate to within a few millimeters. Other modules were installed using a Demag CC 4800, CC 2800 or CC 1800.
Coal to liquids project Mammoet used the MSG crane to lift a 2,050-tonne high-pressure reactor in place at a site in Inner Mongolia, China. This was the first of two reactors for a plant to produce oil from coal. Mammoet's contract covered 45 plant items. Firstly, there was a logistics challenge: 140 containers of equipment such as SPMTs, conventional trailers, cranes, etc. had to be transported 1,200 kilometers from the port to the job site. The MSG was delivered to Shanghai, 2,500 kilometers away. Mammoet engineers designed a special lifting lug on a flange that was bolted on top of the flange of the reactor. The two lifting trunnions lowered the lifting point in order to reduce the stresses on the neck of the reactor to an acceptable level. The MSG was fitted with an 84.1 meter main boom
and 2,500 tonnes of ballast. Meanwhile, the first reactor was transported three kilometers to the site using 52 axle lines of SPMT and 12 Goldhofer lines. Part of the area was excavated to align the reactor, crane and foundations to make the lift easier, safer and quicker and to avoid jacking. After a ceremony with fireworks, the reactor was installed. The lift took 12 hours and all went to plan. As there was a month's wait before the installation of the next reactor, all equipment was then protected against the unpredictable weather in this area and the crew enjoyed a well-deserved break. This was a challenging project in a remote area, completed safely and on time.
13
Mammoet World
Civil projects 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.
Europe Location Heuersdorf and Borna, Germany Job Moving a 13th century church 12 kilometers Challenge Difficult route
750 year old Church on the road
Built in 1258, Mammoet moved the 750 year old church-the oldest church in Saxon southeast Germany from Heuersdorf to Borna over a distance of 12 kilometers. The church had a weight of 833 tonnes, a length of 14.5 meters and a height of 19.6 meters. It was first jacked up 1.2 meters and then placed on 40 axle lines of SPMT. The unique control features of the transporter ensured the stability of the historic building while negotiating a challenging route at an average speed of two kilometers per hour. The difficulties included a number of
14
Location Amerongen, the Netherlands Job Moving the body of a mill Challenge The historic character of the object
New spot for historic mill Because houses are to be built at the present location in Amerongen, the body of a belt mill (mill on raised ground) from 1830 had to be moved in order to save the historic building.
up 1.3 meters. After that 2 x 10 axle lines of SPMT were maneuvered under the body and taken over the load from the jacking points by their hydraulic lifting system.
In order to make the movement possible the association giving the order first had the body of the mill excavated, and a new tensioned concrete foundation poured in the space that had been created. Using jacking points that had been included in the foundation, the body of the mill weighing 450 tonnes was jacked
The mill was then moved 27 meters under great interest from the public and jacked down onto its new position. There, the mill will be restored to its former glory to serve as the center of attraction in the new neighborhood.
Beverwijk, the Netherlands Job Lifting a 230-tonne container crane Challenge Working in a small area so as not to get in
the way of transshipment of containers
Mammoet lifted a 230-tonne container crane in the harbor of Beverwijk. This large crane is intended to give the local container terminal, where more than 20,000 containers are loaded each year, a major boost. Mammoet used no less than nine cranes to carry out the job: two 500-tonne, two 160-tonne, and four 80-tonne cranes and one 100-tonne crane with man bucket. The work required good organization of the
Nine cranes in a small space working area in order to keep the space taken up as small as possible, because the transshipment of the containers just carried on as normal. The operation went without a hitch, although the weather first threatened to put a spanner in the works; but on the day of the lift the weather gods fortunately favored Mammoet. After a day’s work the Beverwijk skyline had gained a new landmark.
narrow points (sometimes with clearances of only a few centimeters), gradients, bridges, two level railway crossings and several power lines. Four bridges across two rivers required strengthening for this move. Furthermore, a number of overhead power lines and pylons had to be switched off and removed temporarily. As far as Mammoet is aware, this was the first time an historic building of this age was relocated. A great challenge to man and technology.
Mammoet World
Europe Location Rugeley, United Kingdom Job Placing two engineered constructions Challenge Acting quickly to cause as little disturbance
to the rail traffic as possible
Creating a bypass at express speed Mammoet positioned two large engineered constructions at Rugeley for the three kilometer long bypass that is to relieve this small English town of traffic jams. The project was to place two tunnels underneath two existing railway lines. The first tunnel under the line to the nearby power station was placed while overhaul work was being carried out on the power station. Mammoet had two weeks during this stop to sledge the concrete bridge weighing 3,200 tonnes into position. Three months after this successful operation the second engineered construction which consisted of three parts was put into place: two concrete abutments each weighing 2,600 tonnes and a steel bridge deck
Location Amsterdam “Coentunnel”, The Netherlands Job Jacking a viaduct and transporting
seven concrete wall sections Challenge Jacking a viaduct while traffic will not be disturbed
The “Coentunnel” underneath the “Noordzee kanaal” in the ring-road around Amsterdam is a major bottle neck for the thousands of cars that use it ever day. For unknown reasons the northern tunnel entrance was shifting up for almost 15 centimeters the past years. To prevent that the tunnel entrance would raise more in the future, the authorities decided to place a wall of 2,715 tonnes in the middle of the tunnel entrance. To do this they calculated that the highway would need to be closed for 13 weekends. To minimise the disturbance of the traffic Mammoet performed the works in just one weekend. To achieve this, a concrete hollow wall was prefabricated in seven pieces of 18 meters long, seven meters high and weighing 160 tonnes about one kilometer away from the tunnel entrance. During this weekend Mammoet transported the seven sections
weighing 600 tonnes. Because this line forms part of the national railway network, the construction had to be placed in express time to restrict the disturbance to the rail traffic to a minimum. Mammoet constructed and tested the equipment, which consisted of four skid tracks each 132.5 meters long, 12 push-pull units of 64 tonnes and 28 skid shoes of 600 tonnes with a low support construction between them, during a prior preparation period of ten days. The rail traffic was then stopped and within 36 hours Mammoet had finished constructing the skid track, moved all parts 89 meters, and removed all the equipment, so that the rail traffic could resume the normal service over the new viaduct.
Building a wall between the traffic from the fabrication area to the tunnel entrance and position them in a straight line in the middle of the tunnel entrance. There was only one extra challenge: a viaduct over the highway with headroom of 4,5 meters blocked the transport route. Before the transport operation could start, the viaduct of 1,000 tonnes had to be raised 3,5 meters. This was done during a normal working day while the traffic drove underneath it. After all safety precautions were taken the deck was lifted by using six x 500-tonne climbing jacks. Once all preparations were finished, finally the wall sections could be transported. On each side of a wall section six axle lines of SPMT were positioned with a special lifting frame on top. Both lifting frames were connected to each other straight through the wall. The wall section was lifted from the ground and transported underneath the raised viaduct to its
final location. Once the seven hollow wall sections were installed, they had to be filled with a total of 590 tonnes steel bars. Monday morning 05.00PM the highway was free for traffic as if nothing happened.
15
Americas Location Yerba Buena Island, San Francisco, California, USA Job Skidding a 6,500-tonne bridge section into place Challenge Uneven loadings, extremely accurate positioning,
traffic could only be interrupted for a limited time
Connecting two cities To incorporate seismic safety features and update the look and style of the Bay Bridge in San Francisco, California, the state is building a new bridge one section at a time. A new concrete bridge section (106 x 28 meters) weighing 6,500 tonnes was built next to the existing bridge. The idea was to close the bridge for around three days, demolish the old section and move the new section into place. Mammoet proposed using the MSG heavy skid system to slide the bridge into position. The setup included sixteen 600-tonne capacity
jacks and skid shoes placed under the main longitudinal girders of the bridge. The bridge had to be installed on five meter tall columns. This meant that heavy steel mats and pipe supports had to be placed on top of the skid shoes to provide the required height. Mammoet took only a little over two hours to skid the bridge into place, completing the work ahead of schedule. This meant that the bridge could be reopened to traffic 11 hours earlier than expected, allowing traffic to flow freely between the cities of San Francisco and Oakland once again.
Location Vicksburg, Massachusetts, USA Job Transporting a retired tugboat into the city Challenge Steep slope
Mississippi tugboat turned into a museum The tugboat MV Mississippi IV (66 meters long, 1600 short tonnes) was retired 15 years ago. It will form the centerpiece of a museum in Vicksburg about the work of the US Army Corps of Engineers on the Mississippi River related to flood control and improving navigation. Mammoet's role in the project was to lift the tugboat out of the water, transport it to Vicksburg and set it onto the foundation.
The vessel was dry-docked and then picked up by 4 x 16 axle lines of SPMT with a total of 64 lines which had to traverse a 9% slope to set it down on temporary supports for painting. A few months later, 2 x 32 axle lines of SPMT transported the tugboat to Vicksburg. The MV Mississippi IV is now resting on temporary supports while the foundations are being built around it. Mammoet will return later to place the vessel in its final position.
Mammoet World
Civil projects Americas Location Ottawa, Canada Job Replacing a complete freeway bridge Challenge Relocating four bridge spans in 10 hours
A new freeway overpass... overnight! In Canada's capital city of Ottawa, Mammoet was contracted by a local construction company to provide SPMTs and hydraulic jacking systems to replace a complete highway overpass. As this bridge is typically used by over 150,000 vehicles every day, it was important to replace the bridge quickly to minimize the disruption to traffic. After the client built the two new bridge spans beside the freeway, Mammoet lifted both of the old spans
Location Providence, Rhode Island, USA Job Transporting and installing a bridge Challenge Site conditions, availability of barges
Challenges, big challenges
16
Mammoet was awarded the job of transporting a large arch bridge (2,500 tonnes) from a fabrication yard in Providence, Rhode Island, and installing it. The bridge was 125 meters long and 50 meters wide. There were a number of challenges to overcome during the three years over which the project was prepared. The initial transport was difficult due to the limited availability of large barges, a high dock at the fabrication yard and shallow water at the congested installation site. Mammoet’s solution was to tie two barges together with crane booms to create a catamaran. The bridge was transferred with self-propelled transporters. Because of the conditions at the yard and the installation site, nine meters of cribbing had to be provided between the trailers and the bridge. This was done with equipment from three Mammoet bases. Once delivered to the site, the three-arch bridge had to be lifted into position using six towers and 900-tonne strandjacks. This job also required a dredger, four tugboats, winches, pumps, the tide and planning, lots of planning. Mammoet personnel from Cambridge, Houston and Schiedam worked together closely over five weeks. The project went smoothly and received the Transport Job of the Year 2007 award by ESTA.
Location Surfside Beach, Texas USA Job Relocate seven beachfront houses
away from severely eroded beach Challenge Keeping the SPMTs from becoming stuck in the sand
Two major hurricanes struck the Gulf coast in 2005, causing widespread devastation. Surfside Beach had eroded so severely that dozens of beachfront homes were literally on top of the water during high tide. Underground utilities now lay beneath the waves and the homes themselves became unlivable as the sand surrounding the piers the homes sat on, was being further eroded away. In order for a beach rehabilitation effort, all homes on the beach needed to be demolished or moved elsewhere. Mammoet USA was brought in to move seven houses to other locations in the community. Since they were placed on piers, SPMTs could be used to drive up under the houses and lift them off their piers. 2 x 6 axle lines of SPMT were used, each equipped with a powerpack unit. Recycling dumpsters were used as spacers on top of the trailers in order to reach the undersides of the houses. Atop these dumpsters, 40’ steel mats were placed to create a solid deck to lift them. Sand was the ever present enemy. Plenty of steel plate was necessary to help prevent the trailers from digging themselves into the beach and to maintain traction when climbing from the beach to the roadway. Some of the houses required additional structural support to prevent total collapse during transport. After four long days all seven homes rested on their new piers, ready for their second life.
Second life for storm struck beach houses
off their abutments, transported them approximately 200 0 meters, and set them down onto falsework where they were later demolished. The SPMTs were then used to lift the new bridge spans and transport them to their final position. The two old spans were removed and the new ones installed in ten hours. The client quickly paved the two spans and traffic was flowing over the new bridges only two hours later!
Mammoet World
Americas It was necessary to find an alternative solution. Given the limited availability of heavy equipment on the East coast, it was decided to move the tug onto a barge. The barge would then be towed to a graving dock where the tug could be floated. The limited water depth at the shipyard made the operations with the barge quite a challenge. Cradles were designed to jack the tug boat up and to support the tug when she was on top of the 56 axle lines of SPMT. The whole project was governed by the tide which meant a very early start one morning for the Mammoet personnel. The trailers moved the tug onto the barge and held it in position while the seafastenings were installed. The barge was then towed from North Kingstown to a graving dock in New York City. Once there, the seafastenings and cradles were removed and the tugboat finally floated free.
Location East coast shipyard, Baltimore, USA Job Moving a tugboat onto a barge Challenge Shallow water
Boat on wheels Last year, Mammoet relocated a number of barge modules from Rhode Island to a graving dock in Baltimore. More recently, the same customer had a 1,650-tonne, 45 meter tugboat to be launched. The original plan of the shipyard, to load out the tug onto the floating dry dock, didn’t work. The structural integrity of the floating dry dock was not sufficient to handle the load.
Location Tamuín, San Luis Potosí, Mexico Job Kiln replacement Challenge Accurate positioning, lifting plant with a small footprint
Cement plant revamp Mammoet replaced a 1,600-tonne cement kiln in 14 sections with a maximum weight of 400 tonnes. The kiln sections were 17 to 22 meters above ground level. The old furnace sections were removed, after which new and refurbished sections were installed. Thirty truckloads of equipment were brought in from Houston, 900 kilometers away.
Asia Location Beijing, China Job Lifting in steel roof construction for the stadium Challenge Lifting the heaviest sections for the construction
of the Olympic stadium
Olympic stadium decorates the Beijing skyline Mammoet lifted the heaviest sections for the construction of the Olympic stadium in China’s capital city Beijing. The steel construction of the stadium that is being built for the 2008 Olympic Games in Beijing has been given the nickname “the Bird's nest”. During the Games, all eyes will often be focused on the Bird’s nest which will also be the site for the opening and closing ceremonies. The design is by the pair of Swiss architects, Herzog and Meuron. The total construction costs are 543 million dollars. The stadium is 330 meters long, 220 meters wide and will accommodate 100,000 spectators during the Games. A total of 36 kilometers of steel was used for the roof, with a total weight of 45,000 tonnes. Mammoet used a CC 4800 to lift in the steel frames weighing 350 tonnes and the roofing sections weighing 165 tonnes. A CC 2800 moved the 115 tonnes roofing sections, and a CC 1800 provided additional lifting support in the stadium.
Mammoet was awarded this project because its lift system had a smaller footprint and more accurate control than the crawler crane a competitor proposed to use. The system included two bases with double towers, two transverse Troll beams, cantilever beams and 180-tonne strandjacks. To move the system along two axes each tower base was fitted with four bottle jacks on skid shoes. The shoes traveled on four 67-meter runways along the furnace. The transverse movement was provided by the Troll beams. Each furnace section was lifted with the jacks and moved onto a 12-line Goldhofer trailer. The project amounted to more than 10,000 man-hours over 45 days, with an excellent safety record. This was the first time the client had used a lifting rig like this, which attracted the attention of the managers of some of their other sites around the world.
17
Mammoet World
Offshore projectss 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 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.
Asia Location Baku on the Caspian Sea, Azerbaijan Job Pushing up two platforms Challenge Five push-up operations in one year
Pushing up to the limit! Mammoet performed two 12.5 meter push-up operations in Baku. The first platform had a topside weight of 15,500 tonnes. Once it had reached the required height, the load-out frame was installed and the topside was lowered down on the load-out frame. The next platform had a topside weight of approximately 13,500 tonnes. The push-up operations were followed by load-outs using the 1,000 cubic meter ballasting system and strandjacks. Mammoet has now undertaken six push-up operations for this project which started in 2004. In 2007, in total, five push-up operations were performed by Mammoet. Apart from the project in Baku, Mammoet has worked on similar jobs in Singapore, Indonesia and Malaysia, with platforms weighing 9,000 to 17,000 tonnes and a maximum jacking height of 16 meters. All projects were completed using the dedicated push-up system developed by Mammoet.
18
Location Batam, Indonesia Job Push-up of a 16,800-tonne processing platform Challenge Use 12 x 2,400-tonne push-up towers for the operation
The Arthit Field Development Project is an important new venture for the offshore oil extraction in the Gulf of Thailand. The first phase of this project has almost been completed and many parts have already been positioned. The last step is the installation of the central processing platform, that is being constructed in a yard of a renowned company in the offshore industry in Batam, Indonesia. Mammoet was contracted to jack up this platform weighing 16,800 tonnes and position a deck support frame underneath. Mammoet used its own developed computer controlled push-up system, which had already been used successfully in Baku, Azerbaijan and Singapore, for this project. Mammoet deployed 12 x 2,400-tonne push-up towers, 44 axle lines of SPMT and 8 x 150-tonne climbing jacks for the push-up, as well as two separate teams for jacking up and installing the deck support frame. The whole operation took five days. During this period, including 265 tonnes of temporary supports, more than 17,000 tonnes was jacked up over 12 meters. A fine push-up record for Mammoet, however, seeing the trend to increasingly larger modules, will undoubtedly be beaten very soon.
Impressive push-up performance
Mammoet World
Location Pasir Gudang, Malaysia Job Transferring a spar and topsides to barges Challenge The weight during the load-out
Spar and topsides load-outs Mammoet used the Smart Skidding System to load a 13,000-tonne spar with a length of 144 meters onto a barge. This took two days, using 30 skid shoes. One of the challenges was that the weight had to be taken off the shoes as they crossed the ramp onto the barge. A month later, Mammoet loaded out the topside (4,100 tonnes, 44 meters long, 44 meters high, 50 meters wide) at the same yard, using four 900-tonne strandjacks, each equipped with 16 wires. As the module was situated approximately 50 meters away from the quayside, the 130-meter pulling operation was divided into two phases. During the first phase, the topside was pulled to quayside and during the second phase, the module was loaded onto the barge. The ballasting sequence of the barge was carefully calculated and required 56 ballast pumps with capacities ranging from 160 to 300 tonnes of water per hour. Mammoet provided a system with significant equipment redundancy to avoid delays during this critical operation. Before the load-out, heavy ramps had been placed on the barge deck to distribute the load. An inaccurate tide prediction might have caused problems, but Mammoet personnel had been monitoring the tidal movements for several days and anticipated this scenario.
Location Gove, Australia Job Transport and install all types of PAM’s Challenge Extensive project
Major project in Australia Mammoet worked on a major project at a new alumina refinery in Gove, Australia. This new plant produces a capacity ranging from 2 to 3,8 million tonnes of alumina per annum, enabling to meet the increasing worldwide demand for alumina. Mammoet was contracted to: • Load vessels in Thailand, Malaysia and Indonesia • Design grillages for PAM’s on vessels • Discharge vessels in Gove/ Nhulunbuy with SPMTs • Transport PAM’s with SPMTs to various area’s and lay down area’s • Install PAM’s/ SuperPAM’s with SPMTs and alignment • Install tanks/ transformer bays with climbing jacks and alignment • Skidding Turbine/Generators sets and alignment A total weight of 150,000 tonnes of different types of PAM’s is shipped from various locations to Gove. In Gove all types of PAM’s like washer tanks, thickener tanks, precipitation tanks, agglomeration tanks and various process modules, pipe racks, conveyors, stacks, sucstations, transformer bays, jacketed pipe units were successfully installed. Last but not least Mammoet installed the SuperPAM’s up to 28 meters wide, 50 meters long, 46 meters high weighing 3,500 tonnes. Mammoet has also raised the record for the heaviest transported object in Australia from 1,500 tonnes to 4,000 tonnes.
19
Mammoet World
Offshore projects Asia Location Map Ta Phut, Thailand and Haugesund, Norway Job Weighing and load-out of offshore module Challenge Two modules simultaneously on the same trailer
Weighed weight on wheels Mammoet was awarded the order for the load-out of offshore modules in Map Ta Phut in Thailand by a Thai manufacturer. The modules had to be transported to Norway, where they will be finished before being deployed in the Norwegian part of the North Sea for the extraction of oil and gas. The modules were weighed by using Mammoet’s high-capacity weighing system before the load-out to determine their exact weight and their centre of gravity in order to decide how best to distribute the load over the trailers and for the ballasting of the ship. A special circumstance was that the 80-meter long module consisted of two parts that were connected to each other with hinges. This meant that care had to be taken when both weighing the two parts and when moving the load to prevent the parts from touching each other. Weighing, using 600-tonne jacks and load cells, showed that the combination weighed 3,300 tonnes. This meant that the Thailand load-out record of 1,000 tonnes, that was already held by Mammoet, was broken. The module was then ridden from the construction site to the ship using 118 axle lines of SPMT without a problem, followed by the load-out of a 500-tonne module and a 70-tonne skid drum. With Mammoet also being responsible, the whole operation was carried out in the reverse order at the offloading in Haugesund, Norway. During this transfer, the large cargo vessel was continually ballasted so that its deck remained relatively level with the quay according to the transfer of weight and tidal variation. Mammoet also used their SPMTs. A big advantage here was that Mammoet knew exactly what it was taking on because of its earlier experiences with the load-out.
20
Location Kerteh, Malaysia Job Reactor load-in Challenge Continuous ballast adjustment
A reactor for a process plant was transported by barge from India to Malaysia where Mammoet unloaded it and transported it to the site. The reactor and its transport frame had a combined weight of 1,355 tonnes. Mammoet was responsible for the ballasting and mooring calculations for the barge (91.5 x 27.5 x 5.5 meters).
Beach landing The barge was beached and ballasted and the reactor was unloaded across its stern, across a linkspan bridge, onto the road. During this operation the ballast of the barge was continuously adjusted to offset the changes in load and tidal movement. The reactor was then picked up with 3 x 18 axle lines of SPMT and transported to the lay-down area.
Mammoet World
Europe Location Lerwick, Shetland Islands, UK Job Load-in of a 8,738-tonne support frame Challenge Difficult environment, tidal range, weight
Mooring and ballasting a barge during ofoading An 8,728-tonne module support frame had to be transferred from a barge to a decommissioning slab. Mammoet was responsible for the mooring and ballasting of the barge during the offloading and for providing the trailers. A project of this scale in a harsh environment, with an extremely heavy load, and 1.5 meter tide demanded the best in planning, safety measures, equipment and crew. A total of 358 axle lines of SPMT, 36 submersible ballast pumps, six mooring winches and over 450 tonnes of support equipment and ramps were used for this project. After ten days of preparations, the trailers were assembled, the supports put into place, the mooring winches rigged, the ballast pumps assembled and tested and the offloading ramp put into place. The offloading started after a test lift. The frame first had to be moved on the barge, and then from the barge onto concrete supports on the quay. This took five hours, one hour less than expected.
Kaliningrad, Russia Job Load-out of 10,200-tonne Fixed Offshore Off-loading Terminal Challenge Loading taken by the quay and the harbor bed, mobilizing large number of axle lines
Mammoet took on the order for the load-out of a prefabricated Fixed Offshore Ice-Resistant Off-loading Terminal (FOIROT) for a large Russian oil company. This large terminal of 53 x 53 x 45 meters, the first of its kind in the world, will be sited in the Barents Sea, where tankers will load oil 22 kilometers off the coast. Mammoet was involved in the project at an early stage, and carried out the engineering to strengthen the quay and the harbor bed so that these would be able to cope with the enormous loading. A challenge also was getting the no less than 432 axle lines of SPMT together that were necessary for the load-out. They were brought to Schiedam from all corners of the world, and from there all the equipment was shipped to Kaliningrad. The customer provided the pontoons.
21
Using 432 axle lines of SPMT! The first load-out was the terminal superstructure weighing 10,200 tonnes. Mammoet had positioned a pontoon with mooring winches in the correct position for the load-out earlier and ballasted this very precisely on the harbor bed on the specially constructed grounding pad. The terminal was placed on the pontoon in one day using the SPMTs following a very thorough lifting and transport plan, a job that required the utmost from the collaborating SPMT operators, the Mammoet load-out operators, and the ballasting operators of the pontoon. The load-out of the loading platform, weighing 1400 tonnes, on a second pontoon followed a few days later. This operation was carried out using 54 axle lines of SPMT and went without a hitch with the help of Mammoet’s computer controlled ballasting system.
Mammoet World
Offshore projects Americas Location Houston, Texas, USA Job Transferring a 1,450-tonne compression module Challenge Negotiating a steep slope
Compression module load-out The client had built a 1,450-tonne compression module in their fabrication yard on the Houston Ship Channel. This was the heaviest module they have built to date. Transferring the module from the yard to a barge would have been relatively straightforward, had it not been for a fairly steep earthen ramp between two parts of the site. Mammoet engineers determined the most economical and safest solution to strengthen the ramp for this load-out. On the first day of the project, the module was picked up by 2 x 24 axle lines of SPMT and taken down the ramp to the quay. The size of the barge posed some challenges and actually required the Channel to be closed for four hours during the loadout. The next day the transporters moved the module onto the barge, a job they finished well before lunch, thereby ensuring that the Channel was not closed longer than necessary. The teamwork between the client's and Mammoet's personnel ensured that the whole project progressed smoothly and safely.
Location Puerto Ordaz, Venezuela Job Lifting the main deck of a production platform Challenge Portal span
Platform lift using wide portals Mammoet was awarded the contract for lifting the main deck of a large production platform so that it could be combined with the production deck. The width of the production deck, 55 meters, required a new solution for positioning the strandjacks as beams of the required length were not available. Hence a special portal was designed to lift the main deck (76 by 34 meters, weight 950 tonnes) using six strandjacks. New components for the lifting rig were built in the USA and the Netherlands and it took just over three weeks to assemble the portals on site. The main deck was first weighed to determine the center of gravity. It was then lifted 10 meters and placed onto temporary supports so that the client could install a skid track. The deck was then lifted another six meters and the production deck was skidded underneath it after which time the two decks were connected to each other. The whole project went smoothly and involved Mammoet Engineering in the Netherlands, Mammoet USA, Mammoet Venezuela and Mammoet Trinidad.
22
Location Sao Roque, Paraguacu, Brazil Job Topsides load-out Challenge Large tidal range
Topsides over the side This project involved the load-out of two topsides modules (weight: 7,203 and 5,724 tonnes) of an oil production platform. The modules were skidded onto a barge, across its side. As the tidal range was almost two meters, this was an ideal opportunity to use the Mammoet 1,000 m3 computer-controlled ballasting system. This system automatically compensates for the tides to keep the barge deck at a constant level relative to the quay. The great benefit of this is that the loading operations are independent of the tide. It took only four days to install the ballasting system with 25 ballast pumps (each with a capacity of 1,000 cubic metres per hour) and its controls on the barge. The linkspan bridges, skid beams, strandjacks and strandwires were installed at the same time. After a final safety meeting, the first module (7,203 tonnes) was loaded out in 4.5 hours. After that, it took a few days to reposition nine ballast pumps and the other equipment for the next load-out. The transfer of the second module (5,724 tonnes) went even more quickly: 3.5 hours.
Mammoet World
Offshore project Middle East Location Caspian Sea, Kazakhstan Job Driving some 70 piles Challenge Handling large piles
Pile driving with a CC 12600 Mammoet installed around 70 piles (length 88 meters, diameter 2.6 meters, weight 328 tonnes) for an oil production project in the Caspian Sea. A CC 12600 crane was fitted with a 114 meter main boom and installed on a special designed construction barge. Once on site, the crane first had to unload the piles from a supply barge and then upright them and place them in a guide frame. This required the installation of five auxiliary winches to keep the piles under control while uprighting them. The piles were driven in two stages. A diesel hammer was used for the first 20 meters and then replaced by a hydraulic pile-driving hammer until the pipe was approximately 19 meters above sea level. Once the piles were installed, the crane fitted Mammoet’s strandjack units to their tops which will later be used to lift barge modules. For the second stage of this project, Mammoet will also be involved in placing barges by using strandjacks which are built into containers for protection and winterization during the time the barges will be hanging onto piles.
Power project 23 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 solution, 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.
Europe Location Cuxhaven on the North Sea coast, Germany Job Installing two prototype wind turbines Challenge Placing a 325-tonne load at a height of 120 meters
Mammoet used a brand new LR 11350 crane to assemble two prototype offshore wind turbines at a test yard near Cuxhaven. Normally, the nacelle (generator housing) is installed on the mast in three sections. However, this crane made it possible to install the unit in one lift of 325 tonnes. Just after Mammoet's new crane had been assembled on the job site, a heavy storm struck. Once the weather improved it was loaded with over 500 tonnes of ballast. The 114 meter boom was fitted with a 12 meter heavy-duty jib.
The mast was installed first, which included a section weighing 168 tonnes. The wind turbine machine housing weight was 316 tonnes, resulting in a total lift of 325 tonnes, once fitted with the rigging and cross beam. It took the LR 11350 less than an hour to lift the unit onto the 120-meter mast for installation. After that, the crane, with a total weight of 1,150 tonnes, travelled 300 meters, fully rigged and with all the counterweights, to the site where the second turbine was installed. This project clearly demonstrated the time savings which can be made with Mammoet's new crane.
LR 11350 places huge wind turbine nacelle in a single lift
Mammoet World
Power projects Europe Location Fljotsdalur, Iceland Job Weak and narrow bridges, icy roads, narrow tunnels Challenge Portal span
Europe's largest hydroelectric powerstation is currently being built in Iceland. Mammoet was commissioned to transport the transformers 80 kilometers from the quayside into tunnels in a mountain. This involved crossing two narrow bridges with a limited load capacity. In one case, the clearance was only 2.5 centimeters. The equipment was specially selected to limit both the load on each axle and the total load. The transformers were transported at night as the road had to be closed. Other challenges on the way included icy roads, hair-pin bends and inclines. Once on site, the equipment was modified for use in the tunnels. It took two right-angle turns to reach the transformer bays where the transformers were finally positioned using skids and jacks. Obviously, the Mammoet team had carefully surveyed the tunnels and drawn up detailed plans in advance. All the units were transported and installed in just one week.
24
Location Castejon, Spain Job Installation of a generator and transformer Challenge Limited headroom
Powerstation in Spain Mammoet was commissioned to install a 351-tonne generator inside the turbine hall and a 274-tonne transformer outside of a powerstation. This job required nine truckloads of equipment from the base in the Netherlands, which included two gantry beams with a length of 24 meters. First, the generator was brought into the turbine hall and placed on a set of temporary supports. The client then undertook some work on the transformer. Once the overhead crane had been moved out of the way, there was just enough space to assemble all the Mammoet equipment. The transformer was then lifted up, skidded into position and placed onto the foundation with millimeter accuracy. The next job, outdoors, was to rotate the transformer 90 degrees with a turntable, place it on temporary supports, install the wheels and then lower it onto the transformer track and pull it into position. This part of the project, from unloading the Mammoet equipment on site to loading it again, only took two and a half days. A similar generator has since been installed at another site in Spain for the same client.
Transporting transformers for a hydroelectricity project
Mammoet World
Americas Location Watts Bar, Tennessee, USA Job Exchange of four steam generators Challenge Limited allowable axle loadings and space
Steam generator exchange Mammoet’s PTC crane was supplied for the exchange of four steam generators, a job that was awarded to Mammoet USA. In the Port of Savannah the containers of the PTC were arrived. Due to the limited allowable axle loadings on American highways, about half of the containers had to be unpacked and re-loaded onto other trucks in the Port of Savannah. It took three weeks, 121 trucks, and three railcars to get all the material on site. Because no storage room was available inside the plant itself, all containers were off-loaded in a storage area outside the security zone of the plant. Here the containers were further dismantled in various smaller sections that had to be transported inside in the correct sequence. It took less than three weeks to erect the crane with 75-meter main boom and 39-meter jib. The positioning of the assist cranes also required careful planning because of the limited space. In a period of three weeks, PTC lifted part of the concrete dome of the reactor, removed the steel liner, exchanged the four steam generators, and replaced the liner and concrete dome. Each steam generator weighed 435 tonnes and the maximum reach was 52.2 meters.
Location Jensen Beach, Florida, USA Job Replacing reactor head and steam generators Challenge First project for CWS; designing and building two gantries
using CWS in confined space; transport with minimal clearances
Brand new Containerized Winch System 25
Mammoet USA was contracted to replace one 110-tonne reactor head and two 500-tonne steam generators in a plant in Jensen Beach, Florida. The items had to be removed from the reactor building and transported to designated storage areas. The plant was originally not designed for changing all this major equipment. Mammoet designed a temporary crane inside the building, an elevated skid system through an opening cut in the wall, and an overhead lifting gantry outside in order to be able to perform the work. Both the temporary crane and outside gantry were fitted with the new 650-tonne Containerized Winch System (CWS). The CWS was specially designed for this type of work and provided a fast operational solution. Another major challenge was the transportation of the steam generators. The only transportation route was located between two buildings, and was only a few centimeters wider than the vessels. Besides this, we negotiated a turn between the buildings and underneath a large overhead crane. The client and plant owners were very pleased with this solution, which meant the overhead crane did not have to be dismantled, saving time and costs. More information about the CWS on page 6
Mammoet World
Salvage projects Mammoet Salvage is a division within Mammoet. The salvage division is manned by salvage experts with proven records of success across the world. With the synergy of know-how, insight, daring and self-confidence, Mammoet Salvage is in a unique position to develop and implement smart solutions by using innovative solutions and taking the responsibility for major salvage projects. This knowledge and expertise is linked to the virtually unlimited heavy-lifting and transport capabilities of Mammoet, its staff and equipment. That is the power of united experience and of Mammoet Salvage. When it comes to salvage at sea, the goal is to be the best maritime service provider. Whatever the job. Wherever it takes us. We will succeed.
Having the ideal mix; smart solutions, united experience Mammoet Salvage was born in the spring of 2006. One and a half years later the young salvage company has already carried out a number of orders and is now a full-fledged market player that surprises both friends and foes with solutions that have never been seen before. Yet again proof of the united experience by which Mammoet manages to distinguish itself in so many areas. “Mammoet Salvage got off to a flying start last year with orders from all corners of the world”, says Managing Director Fokko Ringersma, with a really big order coming at the end of the year: the salvaging of the Safmarine Agulhas in South Africa. “We have already fulfilled the global ambition that we had envisaged for Mammoet Salvage right from the start. Our aim in the first year was to put our name on the map and become known to the insurers in London so that we could compete for tenders. Fortunately, we were not only allowed to tender, but we also received the order. We have now successfully completed the salvage in South Africa, within the agreed time and budget, and to the full satisfaction of the customer.”
Fokko Ringersma Managing Director Mammoet Salvage
Ideal mix The secret of the success lies in Mammoet’s special approach. “We arrive at completely surprising new ideas and techniques because we possess the ideal mix: the united experience of specialists that think in terms of onshore, in terms of lifting, together with the salvage specialists of Mammoet Salvage, who often have a maritime background and also think from that tradition. This means that we arrive at clever solutions making optimum use of each other’s knowledge and techniquestechniques that are already available, but that nobody in the established world of salvaging applies because they are used to thinking, among other things, in terms of diving. Diving is always the weak link in such an operation. The human factor gets involved and you are vulnerable to such factors as wind, currents, temperature and visibility. We eliminate these risk factors by looking for technical solutions that are usually quicker and cheaper. Apart from this we already have a lot of equipment in-house, while salvage companies have to rent equipment. All this, together with our worldwide network of local representatives, gives us an advantage over others.”
Own developments Fine examples of innovative solutions that Mammoet has developed specially for salvage orders are the chain pullers for the salvage of the Safmarine Agulhas, and the Deep Water
Recovery System (DWRS), remote controlled underwater cranes, that were deployed for salvaging the cargo of aluminum on board the sunken Runner 4. While developing these solutions it was apparent how fruitful the interaction is between the wide range of specialisms and specialists at Mammoet. “We thought up a completely different solution for salvaging the cargo from the aluminum ship with our remote controlled system, which did not involve any divers, than would have been proposed by the established salvage industry. That illustrates the different way of thinking at Mammoet, which is possible due to the innovative strength and the capacities in the fields of engineering and equipment.” Thanks to the successful approach, Mammoet Salvage is on course. It is now working hard to strengthen and improve its position, including forming collaborative associations with tug owners. The framework to be able to act immediately is already in place at various strategic places around the world. “If there is an emergency, we can sail out straightaway, without first having to negotiate.” Ringersma would like to negotiate more such agreements. “We do not have the ambition to maintain a whole fleet of tugs ourselves.”
26 Location Gulf of Finland Job Salvaging a load of aluminum Challenge Great depth, deployment of new technology,
weather conditions
Mammoet Salvage carried out a successful and unique salvage operation in the Gulf of Finland, halfway between Finland and Estonia. The insurers had placed an order for salvaging a valuable cargo of alumina ingots from a depth of 90 meters from the wreck of the Runner 4, a cargo boat that had sunk after a collision. Making use of its many disciplines, Mammoet developed an ingenious in-house Deep Water Recovery System (DWRS) specially designed for this salvage operation. The core of this system consists of remote operated underwater excavators, using parts from standard excavators. The excavating arm is mounted on a 12-meter high foot with legs that rest on the seabed. The arm is fitted with a camera, special suckers, and long cables connected to the cabin located
A new dimension to salvage at the surface. Two of these systems were deployed from a specially equipped pontoon for the salvage operation. As well as the cabins, the pontoon also had two control room containers for controlling the underwater cranes, some forklift trucks, and two MPC cranes used to lower the DWRS and lift up the salvaged cargo. The salvage operation was carried out completely using remote operated vehicle technology, without the use of divers. After the deck cranes and the hatches of the ship had been removed, the operators operated the arms from the control rooms on the basis of sonar and camera images that were displayed on computer screens. They picked up ingot after ingot and placed these in baskets, which the MPC cranes then lifted up. In this way the crew of 30 men, working
in shifts around the clock, was able to salvage 3,200 of the 5,300 tonnes of aluminum until the weather became too bad to continue. Mammoet Salvage has added a new dimension to salvage with this innovation: unloading ships at a depth of more than eighty meters without using divers! Mammoet’s innovative DWRS will undoubtedly prove its unique value many more times in the future. More information about the DWRS on page 6
Location East London, South Africa Job Removal of a huge wreck Challenge Difficult location and environmental aspects
Mammoet Salvage won the tender put out by the insurance companies for the quick, safe, and especially environmentally-friendly salvaging of the wreck weighing 17,000 tonnes. This 184-meter long container ship had run aground off East London in South Africa and lay in two parts against the harbor pier. It was the first large order for the just set up Mammoet Salvage. The innovative solution, the presence of our own heavy mobile cranes in South Africa, and the ‘Black Empowered’ status of collaborating partner Mammoet Southern Africa were contributory reasons for the awarding of the contract. Mammoet also made use of a wellknown South African demolition company. Mammoet began by laying a track on the pier, on which three self-propelled portal cranes were installed. These cranes, with a capacity of 450 tonnes each, were used for various lifting jobs, including salvaging part of the 100 containers that were still on board.
Innovative salvage of stranded vessel The cranes also lifted the accommodation section and parts sticking out above the water ashore after these had been cut into sections using cutting torches. Prior to this, the last of the oil had been removed from the wreck with a skimmer. Mammoet had developed a totally new solution for salvaging both parts of the ship’s hull: a puller system, consisting of eight 300-tonne chain pullers that were set up on the pier. The remains of the bow section of the ship weighing 2,000 tonnes were first pulled out of the water using this puller system. After the bow section had been dismantled on shore, the smaller but much heavier stern section, containing 46 containers as well as the ship’s engines, was pulled onto the pier. This section of the ship weighing 8,000 tonnes had also been cleared up by the end of May, so that Mammoet was able to complete this order before the heavy autumn storms would have the coast in their grip.
Mammoet World
BTS projects BTS is a professional and flexible company with more than 20 years’ experience in the field of maritime service on inland and coastal waters. By ongoing investment in people and material, BTS anticipate rapidly the needs and developments in the market. This, along with close cooperation with the client, enables us to offer a solution for all your maritime lifting and transport questions.
Location Ghent, Belgium Job Salvage of sunken vessel Challenge Offer a quick solution with a coordinated effort
Unexpected help while scrapping the Seatrader Together with third parties, BTS salvaged the wreck of the RoRo ship, Seatrader, within a few weeks. The Seatrader was moored alongside the quay in Ghent to be scrapped by a Belgium demolition company. During the demolition work, the front of the ship broke off the main body and a few hours later the ship had sunk in about 12 meters of water. During the combined operation, the salvage company first used underwater metal-cutting torches to cut the bow section loose from the main body. This was then raised by the floating derrick Amsterdam and placed on the quay. The middle and stern sections were then tackled. The remains of the ship were made buoyant by pumping air into the top tanks. The middle and stern sections of the ship were transported to the slipway belonging to the demolition company with the help of a floating derrick and some tugs, after which time the ship could be scrapped as planned.
Location River Seine, Paris, France Job Lap of honor for prize-winning train Challenge Provide the necessary equipment for transporting
a TGV in a very special manner
TGV over the Seine The French TGV, type V150, that had improved the rail speed record to 574.8 kilometers per hour, made a lap of honor over the Seine in Paris in the Whitsun weekend of 2007 to celebrate this achievement. BTS supplied the pontoon Zeevang for the French Railways because there was no pontoon of this size (65 x 11.40 meters) to be found in France. BTS brought the pontoon by sea from Schiedam, the Netherlands, to Le Havre, France where a subcontractor took over the pontoon and sailed it to Gennevilliers. There, the pontoon was ballasted with 1,100 tonnes of river water to give a freeboard of 60 centimeters
Location Berlin, Germany Job Installing a 150 meter bridge Challenge Tight clearances
Building a bridge in Berlin A new bridge was built across the river Spree in the OberschĂśneweide district of Berlin. The overall bridge span was approximately 150 meters and its central pylon had a height of some 40 meters. The bridge deck was delivered in two sections, one 67 meters long and weighing 170 tonnes and one 80 meters long and weighing 190 tonnes. The Mammoet IBIS (crane pontoon) started by installing the pylon. After that it was changed over to the Superlift configuration to install the two deck sections. Installing the first deck section required moving it 15 meters through the pylon with a clearance of only 26 millimeters on each side. After this job the IBIS removed an old bridge in Saint Omer, Northern France, together with the floating derrick Phoenix. The Phoenix installed the new replacement bridge.
27 (draft 2.65 meters) in order to be able to pass all the bridges over the Seine. After loading the locomotive (110 tonnes) and the car (60 tonnes), the pontoon was ready to begin the lap of honor over the Seine and in front of the head office of the SNCF. The pontoon was moored right in front of the Eiffel tower, where a second tug assisted in approaching the shore head on. The pontoon was then raised back to a height of 2.15 meters to allow all those interested in admiring the super train from close by, to come on board safely during the next 10 days.
Watch it! New website Mammoet will have a new website starting early 2008. A more transparent website has been created to offer better services to visitors from different regions. The new site offers specific and dedicated information of a region or country and offers a visitor the possibility to contact the local Mammoet specialists directly. Furthermore the new site has more interactive features.
Mammoet in action In recent years Mammoet documented numerous projects on film. Those projects offer a perfect and impressive view of the World of Mammoet. The films have been collected in a special DVD-box which will be available via www.mammoetstore.com in the first quarter 2008.
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 B.V. Phone +31 10 204 2424 Fax +31 10 204 2442
Mammoet Salvage B.V. Phone +31 10 204 2445 Fax +31 10 204 2447
Mammoet Merchandise B.V. Phone +31 10 204 2611 Fax +31 10 204 2442
Mammoet Workwear Phone +31 10 204 2599 Fax +31 10 204 2442
Mammoet Energy Support Phone +31 10 204 2661 Fax +31 10 204 2455
• 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 • 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 • Branch Assen Phone +31 592 341 456 Fax +31 592 347 698 • Branch Zuidbroek Phone +31 598 615 814 Fax +31 598 441 187
Phone +31 10 204 2427 Fax +31 10 204 2442
BTS B.V. Phone +31 10 204 2483 Fax +31 10 204 2442
Europe
Mammoet Roadcargo B.V. Phone +31 165 319 650 Fax +31 165 315 535
Mammoet Shipping
The Netherlands Mammoet Europe B.V. Phone +31 10 204 2614 Fax +31 10 204 2455
France
Asia
Mammoet Fostrans sa Phone +33 495 061 474 Fax +33 495 061 475
Sakhalin
Germany Mammoet Deutschland G.m.b.H. Phone +49 3461 432 681 Fax +49 3461 432 688
• Branch Geleen Phone +31 46 477 1802 Fax +31 46 476 8405
China
Australia
Venezuela
Mammoet Australia PTY Ltd. Phone +61 7 3390 7369 Fax +61 7 3390 6352
Mammoet Venezuela C.A. Phone +58 281 2744 866 Fax +58 281 2750 539
Spain
Japan
Azerbaijan
Mammoet Transport Espana S.L. Phone +34 91 3768 700 Fax +34 91 3869 965
Mammoet Europe Holding B.V. Branch Tokyo Phone +81 3 3280 6671 Fax +81 3 6408 0722
Mammoet Caspian B.V. • Branch Azerbaijan Phone +971 4 333 1252 Fax +971 4 333 1366
Malaysia
Kazachstan
• 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
Mammoet Caspian B.V. • Branch Kazakhstan Phone +971 4 333 1252 Fax +971 4 333 1366
Norway
United Kingdom Mammoet UK Ltd. Phone +44 191 2639 222 Fax +44 191 2639 333
Turkey Mammoet Europe B.V. Branch Istanbul Phone +90 212 2743 687 Fax +90 212 2743 688
Singapore Mammoet (S) Pte Ltd. Phone +65 6861 1638 Fax +65 6861 2718
Russia Mammoet Russia LLC Phone +7 495 956 0838 Fax +7 495 956 0735
• Branch Gent Phone +32 9 3459 891 Fax +32 9 3455 376 • Branch Antwerp Phone +32 3 5401 284 Fax +32 3 5401 283
Mammoet Irga do Brasil ltda Phone +55 11 3942 8189 Fax +55 11 3942 8130
Mammoet Norge A/S Phone +47 35 505 950 Fax +47 35 505 960
Mammoet Italy S.r.l. Phone +39 02 5770 1938 Fax +39 02 5751 5100
MVS Betonbouw Phone +31 182 589 898 Fax +31 182 589 899
Brasil
PT Mammoet Indonesia Phone +65 6861 1638 Fax +65 6861 2718
• Shenyang Mammoet Heavy Transport & lifting Co. Ltd. branch Shengyang Phone +86 24 2341 3996 Fax +86 24 2341 4996 • Shenyang Mammoet Heavy Transport & lifting Co. Ltd. branch Shanghai Phone +86 21 5306 8787 Fax +86 21 5382 2995
Italy
Thailand
Belgium Mammoet Nederland B.V. Phone +31 10 204 2440 Fax +31 10 204 2433
Mammoet Sakhalin LLC Phone +7 4242 425 241/235 Fax +7 4242 425 237
Indonesia
Southern Africa • Mammoet Southern Africa Pty Ltd. Phone +27 11 882 4499 Fax +27 11 882 4422
Mammoet (Thailand) Ltd Phone +66 38 882 556-60 Fax +66 38 603 800
Laos Mammoet Lao Co Ltd Phone +66 38 882 556-60 Fax +66 38 603 800
Colophon
Photography
Design & Layout
Copyright
Mammoet Employees and others
Graphic Invention B.V.
Texts and photos can only be reproduced after permission from the editor
Editor Mammoet Holding B.V., Corporate
Text Mammoet Holding B.V.,
Printing
Communications
Corporate Communications
Badoux B.V.
Mexico
Middle East United Arab Emirates CMK Mammoth Gulf B.V. • Branch Dubai Phone +971 4 333 1252 Fax +971 4 333 1366
Americas Mammoet USA Inc. Rosharon Phone +1 281 369 2200 Fax +1 281 369 2178 • 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 • Mammoet USA Inc. Greens Bayou Phone +1 713 422 8850 Fax +1 422 8880
Mammoet de Mexico S.A. de C.V. Phone +52 81 8378 2079 Fax +52 81 8378 2170
Canada Mammoet Canada Eastern Ltd. • Cambridge ON Phone +1 519 740 0550 Fax +1 519 740 3531 • Montreal QC Phone +1 450 923 9706 Fax +1 450 923 1815 • Halifax NS Phone +1 902 450 0550 Fax +1 902 450 0545 Mammoet Canada Western Ltd. • Edmonton AB Phone +1 780 4490 552 Fax +1 780 4179 623 • Calgary AB Phone +1 403 252 0551 Fax +1 403 258 3846 • Ft. McMurray AB Phone +1 780 791 5049 Fax +1 780 791 5053
www.mammoet.com