New Generation PTC at work for QUIP in Brazil QUIP is currently building two large FPSOs for Petrobras, Brazilâ€™s leading oil and gas company. The PTC is being used to install components weighing as much as 1,700 tons on the FPSO hulls. Because of its flexibility and efficiency, the new generation PTC is the perfect crane for this sort of project.
Petrochemical page 6
Mining & Metals page 12
Power page 16
Offshore page 24
Civil page 32
Salvage page 38
Worldwide specialists in heavy lifting and transport
How do you add value in markets where customers are faced with mounting challenges? Find out on page 22.
Introduction from The Board
Expertise and Imagination “Building collaborative relationships with clients.”
Last year, Mammoet professionals traveled the world, sailed several oceans, and worked in far-flung locations. Meanwhile, closer to home, we created new collaborative structures to ensure that our clients always receive optimal solutions. In this edition of the World, we’d like to share our vision.
We begin with a simple belief: The added value of Mammoet is actually realized in the work of its professionals. As CEO Jan Kleijn observes: “Our equipment base is exceptional, but it is the expertise and imagination of my colleagues that really makes us extraordinary.” In the “Mammoet moves me” article, Jan Kleijn discusses the role of the new Solutions team in a global market. Sometimes, great clients make great partners. In “Meeting the client”, Heerema Fabrication Group COO Wim Matthijssen explains why his company has recently signed an exclusive long-term agreement with Mammoet. We also interview Matthijsen’s counterpart at Mammoet Europe, Sander Splinter, who echoes the idea of building collaborative relationships with clients, saying, “by forming a team with our customers, we reach new frontiers together.” In the “Sharing Innovation” interview, Directors Maurits Croon and Pieter Jacobs shed some light on the start of Mammoet Solutions in 2012. This global team of engineers and sales professionals is responsible for delivering innovative solutions and sharing expertise with our clients worldwide. In the “Case of the crane”, we learn how a Solutions dialogue resulted in the development of our new
Jan Kleijn President and CEO
MTC 15 crane. Based on a modern interpretation of an ancient design, this innovation allows for more time & cost efficient logistics solutions in ports with limited facilities.
Erik Rave CFO
In the article “Optimizing safety performance”, Corporate Safety Director Koos van Tol discusses the importance of regional and cultural awareness and the new SHE-Q structures that were developed over the last year. Continuous development, decentralization and refinement of the organizational structure are key elements of the Mammoet plan.
Herman Smit COO
Mammoet Salvage is known for “United experience, smart solutions.” In “Thinking outside the box”, Managing Director Fokko Ringersma discusses the value of engineering capacity, asset base and “outside the box thinking” for delivering optimal solutions for salvage and oil industry projects.
Just In ’t Velt Head of Human Capital
In this issue of the World, we’ll take you inside our “sharing innovation think-tank meetings” and across the globe to far-flung locations. Along the way, you will encounter flying roofs, traveling railway stations, underwater tunnels, cold boxes in hot places and some big jobs in very cold places. We hope you enjoy the journey.
Moving a Caterpillar front-end loader in South Africa
Corporate Marketing & Communication
Mammoet moved a Caterpillar 994H front-end loader from Middelburg SA to a mine, a 30kilometer route.
This magazine is a publication of Mammoet Holding B.V., Corporate Marketing & Communication Department, P.O. Box 10000, 3505 AA Utrecht, The Netherlands. E-mail: email@example.com
Conversion factors 1 meter = 3.28 feet 1 metric ton = 0.984 long tons (UK ton) 1 metric ton = 1.102 short tons (US ton) 1 metric ton = 2205 pounds 1 foot = 0.305 meters 1 long ton = 1.016 metric tons = 2240 pounds 1 short ton = 0.907 metric tons = 2000 pounds
Text & photography: Mammoet Employees, Clients, Andrew Walkinshaw, Chris Hoefsmit, Ads&Strats, TechTrans, The English Center Layout & printing: Badoux BV, Houten - The Netherlands Copyright: Text and photos may only be reproduced with permission from the Corporate Marketing & Communication Department of Mammoet Holding B.V.
“Lifting with power and versatility: the New Generation Cranes.” LOCATION: INGLESIDE, TEXAS, USA JOB: HEAVY LIFTING CHALLENGE: WEIGHT OF THE LOADS
First PTC lift in the USA You may have read about our New Generation PTC (Platform, Twin Ring, Containerized) Cranes in the previous issue of Mammoet World. The first New Generation lift in the USA took place when our crane lifted a large spar section for an offshore structure. The PTC installed 13 of these spar sections. Other lifts for this project ranged from 800 to 2,800 tons.
6 12 16 24 32 38
4 14 22 30
Petrochemical Mining & Metals Power Offshore
Message from the CEO Meeting the client Mammoet Solutions SHE-Q
“The combined weight of a spar section and rigging was almost 1,200 tons.”
Message from the CEO “Our focus is on thoroughly understanding our clients’ processes and challenges in order to provide the best possible solutions.”
“Mammoet moves me” Jan Kleijn was appointed CEO of Mammoet in July 2011. Like most senior managers, he’s been with the company for a long time and is passionate about Mammoet’s clients, professionals and equipment. In this interview, he shares with us his passion and strategic vision: “Our equipment base is exceptional, but it is the expertise and imagination of my colleagues that really makes us extraordinary.”
At the forefront
Expertise and imagination
“I joined Mammoet in 1997 as an engineer. What most attracted me was the Mammoet mentality, that virtually anything is possible.” This mentality stems from the company’s roots, established in 1807. At this time Jan Goedkoop was one of the first entrepreneurs to begin offering largescale transportation services, in the form of a 140-ton sailing barge. Ever since then, visionary entrepreneurs like Goedkoop have led the companies from which present-day Mammoet has emerged. Kleijn: “Goedkoop foresaw the ever-growing need for transportation services in an expanding and industrializing society, and he set the tone for a company that’s always been at the forefront of market developments. The motto of one of Mammoet’s former owners was: ‘Challenges, be welcome.’ This has become ingrained in our DNA.”
Kleijn shares this passion with many longterm members of the Mammoet team. But the direction in which this passion drives Mammoet is changing. “For our clients, the exploration of energy resources and raw materials is more difficult than ever. In the construction and process industries, projects are now being completed on ever larger scales and are constantly growing in complexity. To solve these challenges, our clients need smart solutions that minimize downtime, optimize costs of ownership and guarantee safety. They must, therefore, rely more on technology and innovation. Our equipment base, the largest and most advanced available, enables us to realize such solutions. But it is the expertise and imagination of the Mammoet people that makes it possible for us to find these solutions.”
Soon after Kleijn was hired, he would encounter this mentality first-hand while working on one of the most challenging and renowned projects in Mammoet history: salvaging the Kursk. This Russian submarine, powered by two nuclear reactors, had sunk in the Barents Sea on August 12th, 2000, following an explosion. Mammoet took on the job, which required innovation along with meticulous planning and execution, all in difficult and unpredictable conditions. Kleijn: “What really struck me throughout the entire project was how everyone on the Mammoet team was absolutely convinced that we would succeed. In spite of the risks and unforeseen obstacles, that common belief was always present. Since then I’ve worked on many projects throughout the world, and I’ve learned that what happened on the Kursk project is typical of the Mammoet approach to work. We always find solutions, no matter the situation. The combination of imagination and expertise always gets us there, without making any concessions for safety. It’s a great privilege to work with so many talented professionals – both with my colleagues at Mammoet and with our clients worldwide.”
Global presence based on local strength This change in focus has led to changes in Mammoet’s corporate structure. For example, Europe now functions as a separate region with its own local management. This enables it to respond more quickly to the needs of its European clients, emphasizing Mammoet’s position as a global operator with its head office in the Netherlands. This local presence gives greater responsibility to regional management, allowing them to respond to local conditions. At the same time, they benefit from Mammoet’s global fleet, which can be deployed anywhere at any moment. Kleijn: “If you compare our business now with what it was ten years ago, you’ll notice how much stronger we’ve become in many regions. From a strong head office managing projects worldwide, we have now developed into a global operator with strong hubs in the U.S., Canada, Europe, Singapore, Australia and the Middle East, and a growing presence in developing regions including Africa and South America. Mammoet is unique in this approach, and we are grateful that our clients recognize this fact and continue to entrust us with more work every year.”
Solutions team Mammoet has a long tradition of industry-leading technology with its strong equipment base. Kleijn: “We recognize that our equipment alone, though unique in its scale and capabilities, is no longer the most important thing to our clients. It’s how we use it that truly matters. Our focus is on thoroughly understanding our clients’ processes and challenges in order to provide the best possible solutions. These solutions require a great deal of innovation in equipment and processes. We’ve therefore combined our expertise, knowledge and creativity to form a global Solutions team.
“It’s a great privilege to work with so many talented professionals – both with my colleagues at Mammoet and with our clients worldwide.” This team is now responsible for devising and implementing new, smart solutions. We are increasingly focused on adding value through time savings, improved safety and cost efficiency. Large modular construction projects, in mining, oil & gas and power industries, provide excellent examples. We work with our clients from the very start to
help them design and build modules which can be transported around the globe and installed in the most costefficient way, without the need for a large workforce at the installation site. One example is the gantry system we provided to a yard in Brazil, allowing them to install the huge deck box of a semi-submersible platform on its hull. This solution allowed the client to build the two halves at the
same time and avoid the need for special barges, saving both time and money.” At the conclusion of the interview, Kleijn reiterated how he feels about his work: “Like all of my 5,000 colleagues, I am at the service of Mammoet. But Mammoet feels like our business, like an extension of our lives. When I go out on my mountain bike, I put on a Mammoet T-shirt.
When I do jobs around the house, I wear Mammoet safety gear. It’s a characteristic that many of my Mammoet colleagues share: we eat, drink and sleep Mammoet, a demonstration of the pride and passion that makes this a wonderful company to work for. Few people realize just how essential this is to our brand.”
North American long haul
â€œModular construction was well suited for this remote location.â€? LOCATION: USA AND CANADA JOB: MODULE TRANSPORT CHALLENGE: NUMBER OF LOADS
In remote locations, modular construction is often an ideal solution offering both time and cost efficiency. In this case, our client was building a large oil facility in a remote location in Canada and had therefore selected a modular construction method. Starting in the US port of Lewiston, Idaho, Mammoet transported more than 300 modular units overland to Fort McMurray in Alberta - a journey of about 2,000 kilometers. Although poor weather and rough terrain presented some difficulties, the project was completed safely and efficiently.
Hurricane Isaac interrupts work Mammoet was asked to install several units – including a 154-ton reformate splitter – at a refinery in Louisiana. The crane lifted the top of the splitter while the bottom was supported using an SPMT and tailing frame. Unfortunately, after placing the first unit - the splitter - the work had to be interrupted due to serious weather conditions. The team had no choice but to lower the crane boom to the ground and leave the site because of the approaching hurricane. After Hurricane Isaac passed, the work was completed.
“Handling the unexpected is just part of the job.” LOCATION: KROTZ SPRINGS, LOUISIANA, USA JOB: INSTALLING VESSELS CHALLENGE: WORKING IN A LIVE PLANT
Crane in the Caribbean
LOCATION: WILLEMSTAD, CURAÇAO JOB: CAT CRACKER HEAD REPLACEMENT CHALLENGE: LIMITED SPACE
In 2011, Mammoet headed to the Caribbean to deliver a cat cracker head for a petrochemical refinery in Curaçao. In 2012 the team returned for the head installation. Usually this is quite a straightforward job but in this case the workspace was very limited. Nonetheless, Mammoet provided the right equipment and the head replacement was executed on schedule. Two and a half days later, the rigging was removed and within another four days, all remaining items were reinstalled and the crane was ready. This project is a good example of our Factoryto-Foundation service.
“The cracker head had to be installed in a very confined workspace.”
Time challenges in Russia LOCATION: RUSSIAN FEDERATION JOB: VESSEL INSTALLATION CHALLENGE: SCHEDULE CHANGES
â€œDespite a variable schedule, the work was completed early.â€?
On this project in the Russian Federation, professionals from Mammoet Russia and Mammoet Europe worked together to install 38 vessels at a petrochemical facility. The variable vessel delivery schedule presented a complex challenge, which was compounded by an accelerated deadline request from the client. The team efficiently managed all aspects and completed the work one month ahead of schedule. The tasks included, among others, the installation of a 70-meter column weighing 354 tons, which was installed on a 27-meter high pedestal. Also, Mammoet found a solution for eleven heat exchangers, which lacked suitable lifting points and required the fabrication of special lifting beams and saddles.
Transportation from port to site “Using conventional trailers and prime movers.”
For this petrochemical plant in Saudi Arabia, Mammoet used conventional trailers and prime movers to transport two columns from the port to the site.
LOCATION: SAUDI ARABIA JOB: TRANSPORTING COLUMNS CHALLENGE: TIGHT TURN ON A ROAD
Desert project in Saudi Arabia The requirements for this air separation plant included a cold box plus 20 other units. The largest unit weighed 571 tons and measured 72 x 8 x 8 meters. The work site was crowded and afforded little space for the positioning of equipment, making detailed advance planning an important part of the process.
“The extensive advance planning was invaluable.”
LOCATION: JUBAIL, SAUDI ARABIA JOB: TRANSPORT AND INSTALLATION CHALLENGE: HOT WEATHER, CROWDED SITE
Step-by-step In Jubail, Saudi Arabia, Mammoet installed a 950-ton emergency surge bullet for a gas plant. It was the first heavy item installation at the site. Using SPMTs provided the most efficient solution – as compared to heavy jacking equipment - to lift the vessel up step-by-step while simultaneously increasing the thickness of the jacking timbers on the temporary supports and on the SPMTs. This approach proved to be the most economical option. Finally, SPMTs were used to place the vessel on the 5.8-meter high pedestal. Notably, the position of the anchor bolts meant that the clearance allowed just six millimeter tolerance.
“SPMTs provided the best solution.” LOCATION: JUBAIL, SAUDI ARABIA JOB: HEAVY VESSEL INSTALLATION CHALLENGE: TIGHT TOLERANCE
Modular components for Russian facility â€œThe most efficient approach.â€?
LOCATION: CHAYVO, SAKHALIN ISLAND, RUSSIAN FEDERATION JOB: INSTALLATION OF LARGE MODULES CHALLENGE: WEATHER CONDITIONS
This project required the extension of an oil processing facility in the Russian Federation. For the most efficient approach, Mammoet had designed a solution that enabled modular construction. Mammoet handled the load-out, transport and installation of 12 oversize plant modules, and used a ballasting system for the barges. The remote location and difficult weather conditions were the key challenges on this job. The range of modules and road conditions required several SPMT configurations and our utmost concentration, particularly for the crossing of a kilometer-long bridge. This was our second project on this site, we also helped build the original facility, in 2005 - 2006.
Sour water stripper in the American Midwest One of Mammoet’s stateside jobs in 2012 required the installation of a sour water stripper at a facility in Indiana. Despite the size and weight of this sort of sour water stripper tower, the job would normally have been quite straightforward. However, the working area was very congested and the team had to work around tight corners and obstructions. Mammoet professionals used SPMTs to bring the tower onto the site and fitted both rigging to the top and a tailing unit to the bottom. A crawler crane then lifted the tower into vertical position, after which the tailing unit was removed and the tower was placed on its foundations.
“This congested site provided some challenges.”
LOCATION: WHITING, INDIANA, USA JOB: TOWER INSTALLATION CHALLENGE: CONGESTED SITE
The journey begins in Italy Our Italian client built a huge module weighing 2,300 tons and measuring 27 meters high, 23 meters wide and 54 meters long for a large gas plant in Australia. Mammoet transported it over the public roads to the local port where we loaded it onto a ship. The module was then shipped to Australia for installation at the gas plant. This was the largest transport ever made on Italy’s public roads. Despite the relatively short distance - only 1,500 meters - the journey required two years of planning due to necessary road alterations. Extensive communication with the local authorities resulted in a route suited to Mammoet vehicles and load. The total weight (including 144 SPMT axle lines) was 3,000 tons with a length of 60 meters, a width of 23 meters and a height of 30 meters. En route, we jacked-up the module by as much as three meters to clear fences and other obstructions. Once in port, the module was lowered to load it onto the heavy lift ship.
“The largest transport on Italy’s public roads.”
LOCATION: MARINA DI CARRARA, ITALY JOB: MODULE TRANSPORT CHALLENGE: WEIGHT AND SIZE
Saving months in Ontario
Mining & Metals
This client operates two open pit mines located a few kilometers apart, and wished to relocate a huge shovel from one mine to the other. Mammoet proposed a solution that would complete the job in two weeks rather than several months. In the past, the client had disassembled the shovel, transported the components on trucks and then reassembled it. This process usually took months to complete. When asked to provide a better solution, Mammoet suggested moving the whole unit on 36 axle lines of SPMTs. The client accepted the proposal and gave us two weeks to complete the job. At each mine site, we used gravel and crane mats to create ramps so that the shovel could drive on and off the SPMTs. While the icy roads and steep slopes proved to be a challenge, our experienced crews completed the job on time.
Australian ore reclaimer LOCATION: PORT HEDLAND, AUSTRALIA JOB: ASSEMBLING A RECLAIMER CHALLENGE: INNOVATIVE APPROACH
“A time-saving new approach increased safety while reducing installation costs.”
By masterminding a new approach, Mammoet was able to realize a safer and more cost efficient installation of an ore reclaimer’s 250-ton boom at an iron ore handling port. Normally such booms are fitted in a dual lift operation with two cranes. This time, however, the client wanted to reduce the footprint of the operation and avoid dual lifts for safety reasons. Mammoet’s suggestion was to rest the bucket wheel end of the boom on SPMTs, while a crane would lift the other end. The equipment owner, equipment manufacturer and the main contractor all approved of the approach. The SPMTs were fitted with a large turntable, equipped with a specially designed wedge, in order to support the boom and to accommodate the required tilt range. At the start of the operation, we checked the weight and center of gravity of the components and made some necessary adjustments of the rigging. After checks and adjustments, the operation went smoothly as planned.
LOCATION: TIMMINS, ONTARIO, CANADA JOB: RELOCATION OF A MINING SHOVEL CHALLENGE: ICE AND STEEP SLOPES
“Mammoet moved the shovel in two weeks without disassembling.”
Mining & Metals
Saudi roof placement Mammoet used a heavy crawler crane to lift and place roofs on four silos for this client’s large aluminum facility in Saudi Arabia. The silos’ roofs, which had been assembled on the ground, each had a diameter of 42 meters and a weight of 235 tons. Because the permissible deflection of the roofs was very small, a special rigging system was designed. Other challenges included the congested site and the tight schedule.
“We used special rigging to lift and place the silo roofs.”
LOCATION: MA’ADEN, SAUDI ARABIA JOB: ROOF INSTALLATION CHALLENGE: CONGESTED SITE, SPECIAL RIGGING
Long haul in Long Harbour Our client is building a large nickel processing plant, and Mammoet has been involved in the project for over two years. One of our key responsibilities is the unloading of large plant modules from barges and transporting them to the site on SPMTs. With a route of three kilometers and slopes as high as 6%, we have now handled over 200 modules, tanks and other pieces of equipment, sometimes using over 300 axle lines of SPMTs. Other Mammoet equipment on site includes cranes, conventional trailers, jacks, and weighing equipment. On average, we maintain a crew of 55 at this site.
“On average, we maintain a crew of 55 at this large scale project site.”
LOCATION: LONG HARBOUR, NEWFOUNDLAND, CANADA JOB: MODULE TRANSPORT AND INSTALLATION CHALLENGE: SCALE OF THE PROJECT
Meeting the client: Heerema Fabrication Group
“A partnership based on inspiration and challenge” Heerema Fabrication Group specializes in the engineering and fabrication of large and complex structures, mainly for offshore oil & gas and energy related industries. Heerema has been working with Mammoet for decades, delivering lifting and transport operations at their yards in Zwijndrecht and Vlissingen (NL) and in Hartlepool (UK). Previously every project went out to tender, but today the company prefers to work on the basis of an exclusive Long-Term Agreement (LTA). Wim Matthijssen, Heerema’s COO, told us more about this cooperative way of doing business in a dual interview with his professional counterpart, Managing Director Europe, Sander Splinter.
We visited Matthijssen at Heerema Fabrication Group’s offices in Zwijndrecht. The adjacent yard displays impressive fabrication halls. A large number of platforms have been built here, in addition to specialized structures such as bridges (e.g. Erasmus Bridge Rotterdam) and steel structures for buildings (like the head offices of Mammoet Europe, ‘De Bolder’). Heerema provided a sheltered construction area in Zwijndrecht where De Bolder was constructed concurrently with its foundations in Schiedam. Mammoet transported the whole building to Schiedam with a large pontoon, installing it in a spectacular operation. The two businesses have much in common: they are both internationally acclaimed in their respective fields, and they are both known for daring projects that shift the boundaries of what is considered possible. Heerema doesn’t want to do everything in-house, therefore it works with partners. Why are you working with Mammoet on the basis of an LTA rather than on a separate contract for each project? Matthijssen: “The advantage to working on the basis of an LTA is that you don’t always have to focus on the commercial aspects of a project. First and foremost, it’s our job to focus on the best solution for any given project. We draw up a “shopping list” of all the equipment we will need and how much it will cost, so we don’t have to waste time negotiating prices. By cooperating, we gain access to specialist expertise that we don’t have inhouse. When bidding for a new project, we work with Mammoet during the tender stage to see how we can best do the job. But not all of our joint efforts are related to projects. Currently we are studying solutions for lifting platforms, which continue to grow larger and can weigh upwards of 15,000 tons. We also recently discussed how we could get the fabrication of a platform back on schedule, despite a delay during the design stage. Together we consider the options, based on each party’s expertise. We can always find a solution.
Splinter: “I call this making the impossible possible. By bringing the best people together, you can develop the best solutions. And that’s one of Mammoet’s key objectives. We want to provide our clients with smart solutions in order to give them a competitive advantage. The best way to achieve this is by working closely with the client and by contributing expertise and skills early on, while the client is still working on their tender. A solution can have a major influence on the price of a project. For example, we once jointly developed a solution for installing lock gates in the Panama Canal, reducing installation time by six months.” Are other clients also working with LTAs? Splinter: “Yes, particularly with maintenance projects for some of the world’s largest companies, where the barrier to entry is high. These clients appreciate that we’re familiar with their sites and procedures, and that our people know exactly what to do on their sites. Companies that place importance on these factors won’t put every project out to tender. Mammoet aims to excel in these areas, so we always become intimately familiar with our client’s culture, providing good service over a long period of time. It’s a well-known fact that a client who opts for the lowest hourly rate won’t necessarily get the best deal overall. The total cost of the project also depends on how long the work takes, and to what extent you can optimize the client’s processes. This is where our smart solutions have a real impact on significantly reducing the overall project cost and, ultimately, the total cost of ownership. That’s how Mammoet provides added value.” Matthijssen: “That’s right. It’s not just about the price, it’s about the package. We want Mammoet to work with us to develop optimal solutions, to consider savings in certain key areas, and to achieve better results by doing things differently. We are constantly thinking about how we can deliver the highest added value to our clients, and we expect our
partners to do the same. This form of cooperation also eliminates a certain amount of work for us. In the past we handled routine operations and standard load-outs ourselves. We organized everything from A to Z. We now have a regular partner for that. We keep an eye on the work, but we no longer design and manage everything in-house. Instead we leave that to Mammoet. We know each other well by now, and we trust each other’s expertise. Our coordination is ongoing and ever-evolving; we are always coming up with new developments and designs, so we must always confront the newest challenges. We discuss these challenges and we find the best possible solution.” Splinter: “Yes, we always find a solution. As Matthijssen mentioned, we don’t only work together on high-end projects, but also on routine jobs. As a partner you can optimize the work-flow, because you
“We want Mammoet to work with us to develop optimal solutions, to consider savings in certain key areas, and to achieve better results by doing things differently.”
are familiar with the rules and procedures on a site. We also share the same safety standards. Agreement in this area of cooperation is essential, as different approaches simply don’t work when it comes to safety.”
worthwhile expertise. The relationship has to provide us with more than just another supplier, otherwise it has no point.”
Matthijssen: “Another key element is the exchange of know-how and complementing each other. We both have a certain knowledge and expertise, and we’re happy to share these with one another. You know more about lifting than we do, so we can learn from you. Mammoet also gains experience from their other projects, and we discuss our findings together. Both parties benefit from that kind of cooperation. It’s crucial we keep challenging and inspiring each other to stay focused on the big issues. Ultimately, the most important thing is to achieve our shared objectives. We have to complement each other and be able to offer one another
Matthijssen: “One example is that platforms are getting bigger, especially in the wind power industry. In fact, they’re getting much bigger, meaning we need to think about how we’ll build them in the future. Are we going to continue using single platforms, or divide them into sections? Will the modules become so large that you can’t install them with the available heavy lift vessels, and have to use float-overs instead? Or modules assembled at sea? There’s a whole range of potential solutions. We are currently studying them together with Mammoet.”
You mentioned shifting boundaries. Could you give some key developments in the market?
Splinter: “Of course we are always developing new methods. We have often mated platform sections onshore, and are now quite familiar with the technique. But off-
shore mating is new to us. In Brazil, we recently did a semi-offshore mating of a deck weighing 16,000 tons. We lifted the deck up in a dry dock, the base was floated over, and we lowered the deck. That was another step forward.” Returning to entrepreneurship and innovation, it seems you broadly share the same background. Splinter: “If you look back at the roots of our businesses, you can see there has been quite a lot of synergy because of our
shared experience. Here’s a principle I cherish deeply: deliver what you promise. By sticking to this, we have been able to build relationships with our clients based on trust and mutual respect. By forming a team with our customers, we reach new frontiers together.
Tailor-made solutions in a French cavern LOCATION: CHOOZ, FRANCE JOB: SPECIALIST HEAVY LIFTING CHALLENGE: CONFINED, RADIOACTIVE ENVIRONMENT
One of the reactors at this nuclear site in the north of France is being decommissioned. As it was an early prototype for this sort of facility, there was little consideration in the original design regarding eventual decommissioning. Notably, this reactor is housed in an unusual location - a cavern in a hill - and it’s also the first pressurized water reactor in France to be decommissioned. Mammoet was contracted to extract four steam generators from the plant, each weighing 120 tons. Although the loads were not particularly heavy or large by Mammoet standards, the project was a challenge, as the limited space inside the building required us to design a custom tilt unit and undertake extensive engineering. Given the nature of the job, our work was scrutinized in detail by the client’s engineers and the authorities. Our tilt unit - with four hydraulic cylinders - was suspended from the overhead crane and gave us full control of the movement of the steam generators. These were first lifted vertically, then tilted to a horizontal position, and then moved sideways. Next, they were moved to an initial decontamination area, after which we jacked them up and transported them to temporary storage on SPMTs. Our project team started working on this job three years before the actual lifts were undertaken, and greatly benefited from the nuclear industry specialists in our engineering department.
“We designed a custom tilt unit with four hydraulic cylinders.”
LOCATION: JÜLICH, GERMANY JOB: NUCLEAR REACTOR LIFT CHALLENGE: STRICT REGULATIONS, LIMITED SPACE
“Our involvement in this decommissioning project began in 2007.”
This nuclear research reactor in Germany was shut down in 2006 after 44 years of operation. Mammoet’s involvement in the decommissioning project began in 2007 and is scheduled for completion in 2014. The task includes lifting the reactor, skidding it out of the building, and transporting it to a storage facility. A complex lifting and skidding unit fitted with strand jacks was built specifically for this job. Installing the two 53-ton crane girders of this unit in the reactor building presented an interesting challenge, as there was very little operating space. The system was tested with a 138-ton mock-up of the relevant parts of the reactor, and was approved by the authorities and the client. Because of the delicate nature of the load, Mammoet is working closely with the client, authorities, other contractors and the regular inspectors for safe and efficient completion.
Innovative two-blade turbine in Denmark The client developed a wind turbine with an innovative two-blade rotor using a partial pitch system, and commissioned Mammoet to install the prototype at a test site. Mammoet engineers devised the best lifting solution for this new model turbine in close cooperation with the engineers of the client. The advantage of this two-blade system is that the load on the turbine can be reduced during a storm. The job began in the workshop, with jacking up the nacelle (220 tons, 13 x 6 x 8 meters) and then using our SPMTs to bring it to the quay for loading onto a vessel that took it to Thyborn, near the west coast of Jutland. In the meantime, Mammoet prepared for its arrival by installing a heavy foundation ring, electrical containers and the turbine tower. When the nacelle arrived in Thyborn, it was transported 300 meters to the site - again on SPMTs - and fitted with its two blades, each 63-meters long. The overall weight of the nacelle and rotor was 260 tons.
“Close cooperation between Mammoet and the client’s engineers helped us devise the best lifting solution.”
LOCATION: THYBORN, DENMARK JOB: WIND TURBINE TRANSPORT AND INSTALLATION CHALLENGE: NEW TURBINE DESIGN
Forty-four Canadian turbines This Canadian wind turbine project required 15 cranes and a crew of almost 100. Mammoet was awarded a contract for the installation of 44 large wind turbines in Saint Rémi, Quebec. One of the main challenges was using wind-restricted lifts in an area that is naturally windy. For this assignment, Mammoet delivered a turnkey solution that included post-tensioning, mechanical and electrical work. A narrow track crane was used that is specifically designed for wind turbine projects and does not demand the use of wide site roads. This led to considerable time and cost savings.
LOCATION: ST-RÉMI, QUÉBEC, CANADA JOB: WIND TURBINE INSTALLATION CHALLENGE: STRONG WINDS
“Specifically designed for wind turbine projects.”
Southern Hemisphere’s largest wind farm When the installation of all 140 wind turbines has been completed, this wind farm will be the largest in the Southern Hemisphere. Our involvement is covered by two contracts, one with the main contractor (provision of cranes and other equipment), and one with the turbine manufacturer (installation of the turbines). The advantage for the clients is that they deal with just one heavy lifting contractor for the duration of the project - leading to significant efficiency gains. The turbines, which use a new model, have a capacity of three MW each. Mammoet installed them using a heavy mobile crane and a special narrow track crawler crane. As explained in the previous case, this narrow track unit helps save time and costs in wind turbine projects as compared to the use of a conventional crawler crane.
LOCATION: MACARTHUR, VICTORIA, AUSTRALIA JOB: INSTALLING 140 TURBINES CHALLENGE: SCALE OF THE PROJECT
“Saving time in the Southern Hemisphere.”
“Offering comprehensive solutions.”
Multidisciplinary power project Our client built a gas-fired power station in Riga, Latvia and awarded Mammoet the transport, lifting and installation contract. Because Riga’s port normally handles only bulk cargo, we began by transforming one of their berths into a goods and RoRo quay. We offloaded, stored and reloaded 26 Super Over Dimensional Cargo items (SODC), 126 Over Dimensional items and over 500 general cargo items. The SODC loads had to be transported to the other side of Riga on a special barge over the Daugava River, which took over nine trips. The journey required us to sail under five bridges, sometimes with little clearance. At the destination, we built a RoRo facility to drive the loads off on SPMTs, and then transported the SODCs 12 kilometers through town. Once at the site, Mammoet installed the gas turbine, generator and rotor with a special lifting system. We also installed three condenser vessels and two transformers with our jacking and skidding system, plus a generator and two turbines with the containerized winch system. Finally, we used our heavy cranes to install 15 sizeable heat-recovery steam generator modules and several other items.
LOCATION: RIGA, LATVIA JOB: TRANSPORT, LIFTING AND INSTALLATION CHALLENGE: LACK OF PORT FACILITIES, BRIDGE CLEARANCES
North American power plant “A dedicated team of Mammoet professionals from Canada and the USA worked together.”
LOCATION: CALGARY, ALBERTA, CANADA JOB: POWER TRAIN TRANSPORT AND INSTALLATION CHALLENGE: COMPLEXITY OF THE PROJECT
The client was responsible for the construction of a large new power station in Calgary, Canada. They arranged to have two gas turbines (333 tons each) and three generators (255–298 tons) shipped to Duluth, Minnesota, in the USA. The cargo was then offloaded onto our SPMTs, moved to the rail yard and transferred onto specialized railcars for the journey to Calgary. In Calgary, we offloaded the cargo, transported it to the site and then installed it. In addition, we installed 36 heat-recovery steam generators, steam drums, a 500-ton condenser unit, and other heavy items. We used a range of gantries, strand jacks and hydraulic jacks. For this international project, a dedicated team of Mammoet professionals from Canada and the USA was utilized.
Power in the far north Nunavut is Canada’s newest, largest and least densely populated territory. This arctic region has no roads linking it to the rest of Canada and is only accessible by air and water. Mammoet Canada Eastern was contracted to deliver two diesel engines to Iqaluit (Place of Many Fish), which is the rapidly growing capital of the territory. Harsh weather, icebergs and the lack of a port made this job quite challenging. The engines were transferred from the ship onto a barge that was towed close to the shore. Once the 12-meter tide had beached the barge, there was a small window of time in which to set up our ramps and drive the engines off the barge on our SPMTs. The route to the power station was challenging, including some steep inclines. Additionally, the power company had to lift some power cables to enable us to pass underneath. As a result of the two new 5MW units, our client was able to double its capacity.
LOCATION: IQALUIT, NUNAVUT, CANADA JOB: TRANSPORTING ENGINES CHALLENGE: ICEBERGS, NO PORT
“Harsh weather, icebergs and the lack of a port made this Arctic job quite challenging.”
â€œMammoet undertook a feasibility study for an alternative to conventional cranes.â€?
Sellafield Evaporator D project LOCATION: SELLAFIELD, UK JOB: MODULAR CONSTRUCTION CHALLENGE: SPECIAL SITE CONSTRAINTS, SMALL CLEARANCES
For reasons of time efficiency, Evaporator D at the Sellafield site in the UK is being built using modular construction. The main contractor pours most of the concrete structure for the entire building, Mammoet inserts the modules, and then the contractor pours the last wall. Most of the ten modules weigh 100-480 tons and measure about 10 meters high, 7.5 meters wide and almost 10 meters long. The main contractor wanted to avoid the use of conventional cranes due to the special nature of the site and the surrounding structures. Therefore, Mammoet undertook a feasibility study for an alternative method, and our solution won the contract. Most of the modules were installed in 2012, and the project will be completed in 2013. For this project, we developed a dedicated strand jack gantry (34 meters high, 38 meters long and 18 meters wide), which moves between the building sections on skids. The modules are built at Ellesmere Port, then transported 1.5 kilometers to the quay on our SPMTs and loaded onto a pontoon. The pontoon is towed to a beach near Sellafield, where the modules are driven off on the SPMTs. We then cross the beach, a bridge specially built for this project, a railway, and a 10% incline in order to arrive at a temporary storage area. The modules are then transported to the installation site one at a time. Once positioned under the lifting gantry, each module is lifted off the SPMTs and placed on the lifting table. The table lifts the module up to the required level where it is skidded into the building shell. To complete the installation, the modules are lifted slightly, the skid tracks are removed, and the modules are lowered into their final position.
Sharing innovation Our clients are responsible for some of the world’s toughest jobs - dealing with supersized challenges in circumstances that grow more demanding every day. Factors such as remote locations, harsh climates and emphasis on environmental care raise the bar. They put pressure on productivity, safety measures and timeframes. In such situations, insightful, creative approaches to transport and installation can significantly impact the timing, safety and cost-efficiency of the overall project. But coming up with innovations is just one part of the story. How do we ensure that best practices and smart solutions are shared with clients, wherever and whenever they need them?
“Smart solutions can help clients achieve signiﬁcant improvements.”
That’s the purpose of Mammoet Solutions. This new business unit operates globally and has strong ties with all regions. Solutions supports local Mammoet sales staff by providing clients with global expertise and innovative strength. At Mammoet, we know that when we listen carefully and offer smart solutions, our clients benefit. At its best, our logistical insights and smart solutions can have a widespread positive effect, transforming all kinds of client practices and often, the bottom line. By optimizing the Mammoet-client conversation, and therefore, our performance, we can help clients achieve significant improvements that influence the big picture, well beyond the boundaries of our part in the whole. Recently, Mammoet World interviewed two people central to the new business. Here’s a look behind the scenes. Mammoet Solutions Director Pieter Jacobs studied mechanical engineering and has worked in various roles at Mammoet. Strategy Director Maurits
Croon is an economist and has a background in strategy and business development. Croon: “Essentially, we want to develop better solutions to the challenges our clients face as identified by our sales teams. They engage in dialogue with our clients to get an in-depth understanding of their projects. So, if a client asks for a crane which can lift X tons at a radius of Y meters, we want to know more about the details of the project and why they want to move the load that way. That may enable us to come up with a different approach that can bring benefits in terms of reduced overall project costs, timesaving and risk reduction. Sometimes a better solution requires the development of new equipment, but significant gains are often made by simply using a different lifting and transport method, or by using existing equipment in a different manner. Obviously, it helps if we get involved in a project at an early stage.”
Jacobs: “Mammoet has always been able to serve clients with technological developments and process innovations. Imaginative salespeople and creative engineers team up with clients and come up with new approaches. A recent project for a mining company in Canada is a good example. The client requested crane assistance and trailers for disassembling a large shovel, transporting the components and then reassembling it at another mine site. That was going to take weeks. Instead of just giving them a quote for the cranes and trailers, our salespeople discussed the project in greater detail. It turned out that transporting the shovel without disassembling it was actually a much better solution. We managed to engineer the project and bring our equipment to the site in two weeks and then only needed four days to relocate the shovel. That saved the client significant downtime and avoided the risks associated with dismantling and assembling heavy equipment. With Mammoet Solutions, we share our clients’ questions with a global team that consists of salespeople and engineers from all regions and backgrounds. This ensures access to as much technical expertise and creativity as possible, and helps us to serve our clients with smart solutions wherever they are needed. This approach also helps us identify
Innovation in action: T
Nowadays, power stations and similar plants are more and more often built at remote locations. However, bringing heavy components such as large diesel
engines and generators to these sites can be difficult and costly due to poor roads. Transport over water is potentially more attractive, but there is rarely a nearby harbor with large cranes for unloading ships. Some heavy-lift vessels do have cranes, but such vessels are costly, their availability is limited, and they cannot reach small harbors. Bringing in a crawler crane is also unattractive, as cranes with adequate capacity are themselves very large and heavy and need to be assembled using a fairly large mobile crane. In short, conventional methods involve significant costs and the use of very heavy equipment.
trends across industries and define our long term innovation agenda.”
Sharing expertise worldwide Mammoet Solutions has numerous specialists in disciplines including mechanical and electrical engineering, structural engineering, naval architecture, offshore dynamics and software development. Bringing them together in one team means that our innovative strength is now more concentrated, more focused and more accessible to all Mammoet regional operations and clients. To facilitate a good interface between regional Mammoet Solutions and Sales and Operations, we have set up regional Solutions think-tank meetings where representatives can regularly exchange information with their colleagues. The meetings foster a culture of connectivity, enabling us to share expertise and best practices throughout the company and make smart, innovative solutions readily available to our clients.
The case of the crane Question: What does the client really need? Answer: The MTC 15 To help clients operating at such remote sites, Mammoet Solutions talked to clients, and then decided to go back to square one and carefully analyze the clients’ lifting needs. In many cases, all that’s needed in a port is the ability to lift a component from a ship onto a trailer or SPMTs for further transport to the construction site. In other words, there may be no need for all the functions provided by heavy crawler cranes, such as slewing (crane rotation) or the ability to move the crane once it’s on
site. This insight led to the design of Mammoet Terminal Crane 15 (MTC 15). Essentially, it’s a derrick crane, a form of machinery that’s been known for at least 2000 years. It has a lifting capacity of 500 tons at a radius of 30 meters, comparable with a 1,200-ton crawler crane (which is much heavier, larger and costlier). The whole crane is packed into shipping containers, which can be transported to the site by ordinary trucks. The MTC 15 only needs a relatively modest mobile crane for assembly, and its ground bearing pressure is low enough to operate close to most quay edges with no need for civil works. The MTC 15 is also a good solution for projects where a crane needs to be on site for a long time, but only needs to make occasional lifts. This is quite com-
“Sometimes innovation means lots of dialogue… and then going back 2000 years.” mon in ports serving modular construction projects. The MTC 15 has been the right answer for several Mammoet clients. The development of the MTC 15 is just one example of how adding extra value for our clients demands dialogue, creative thinking, internal networking and innovative solutions. Having great hardware is just part of the Mammoet story. Working for the best interests of our clients is what really moves us.
Seventeen thousand tons in Brazil LOCATION: RIO GRANDE, BRAZIL JOB: DECK LIFT CHALLENGE: SIZE AND WEIGHT OF THE LOAD
The P-55 is Brazil’s largest semi-submersible offshore platform. It has been built in two parts: the deck box and the lower hull. For lifting and installing the huge deck box, Mammoet engineered, built and installed a special lifting system – which requires 160 containers for transportation. The P-55 deck box was constructed inside a dry dock on five meter high temporary supports. Mammoet erected the Mammoet Gantry System on two sides of the dock. The system included 12 lifting towers (MSG and PTC crane mast sections), six gantry beams (each 23 meters long and 2.5 meters high), and 24 strand jacks, each with a capacity of 900 tons. The lifting started by weighing the deck box, which set a record for our gantry system – 17,000 tons. The lifting system was then subjected to a 110% load test, after which the deck box was raised to an intermediate level, just above the dry dock. With the box at this level, the client prepared the dock blocks to receive the lower hull. The dry dock was then flooded and the doors opened. This meant that our gantry towers were partly under water. Next, the lower hull of the offshore platform was towed into the dock. Following that, it was time to lift the deck box to its top level, 47.2 meters.
The next day, the lower hull was towed underneath the deck box and positioned. After that, we slowly lowered the deck box to mate it with the lower hull, leaving the whole structure sitting on the dock blocks. Finally, the two modules were installed on top of the P-55 platform. The installation of these modules involved transport, lifting using a gantry system, skidding, and jacking operations.
“To lift and install the massive offshore platform deck box, we built a special lifting system.”
Dynamic loads In the UAE, one of our clients built an 8,500-ton jack-up vessel for wind turbine installation operations and contracted Mammoet to load it onto a barge. The client tested the new jack-up system while the unit was still on our SPMTs and trailers. The first operation was a sideways load-out with several space restrictions for the SPMTs and trailers and little allowance for weight or center-of-gravity changes. Next, the vessel’s legs were jacked down while it was still on our SPMTs and trailers and on the barge. Four sets of dynamic loads had to be considered, affecting the floating barge, our SPMTs and trailers, the vessel’s legs, and the tide. Mammoet’s engineering department assessed all the relevant forces and successfully planned the operation in detail.
LOCATION: HAMRIYAH FREE ZONE, UAE JOB: VESSEL LOAD-OUT CHALLENGE: COMPLEX LOAD INTERACTION
“The client built an 8,500-ton jack-up vessel and contracted Mammoet to load it onto the barge.”
Offshore in Vietnam LOCATION: VUNG TAU, VIETNAM JOB: PLATFORM PUSH-UP AND LOAD-OUT CHALLENGE: LATE DESIGN CHANGES, ASYMMETRIC CENTRE OF GRAVITY
For this project in Vung Tau, Mammoet undertook a major push-up operation and two load-outs. The yard decided to build the deck support frame and the deck itself (approximately 12,000 tons) separately, both at a low level, making it possible to construct the two units in parallel. Mammoet was contracted to push-up the deck platform so that the frame could be inserted underneath it. Although there were some late design changes, close cooperation between the client and Mammoet ensured that all nine units of the 2,400-ton push-up system were available on time and that the operation went smoothly. The frame was placed under the platform, which was then lowered down onto it, resulting in a structure with a total weight of 14,300 tons. The next task was to load the resulting large structure onto a barge. The combination of tidal conditions and an
asymmetrical center of gravity proved to be quite a challenge. Mammoet engineers, in close consultation with the client, decided to shift the center of gravity towards the middle of the platform by installing counterweights on one side and pumping water and fuel to the tanks on that side. We also loaded the platform jacket (length 145 meters, weight 11,500 tons) onto a barge, which required us to pull it across 250 meters using four of our 900-ton strand jacks. In addition, we provided ballasting systems (30 pumps with capacities of 500 m3/h and 1000 m3/h) for the barges, and lastly, we handled the mooring of the barges.
“Constructing two units in parallel.”
Offshore platform module construction in two countries â€œServing the client through dedicated collaboration.â€?
LOCATION: LAEM CHABANG, THAILAND AND HAUGESUND, NORWAY JOB: OFFSHORE MODULE HANDLING CHALLENGE: HEAVY RAIN, SIZE OF THE LOAD, SITE LAYOUT
The client, who operates yards in Norway and Thailand, was building offshore oil and gas platform modules in both locations. The upper module (living quarters) was being built in Thailand and the lower module was being built in Norway. Mammoet began in Thailand, weighing the living quarters module using our jacks and load cells, and then updated our plans with the verified weight and center of gravity. We then loaded the module out onto a vessel using SPMTs for transport to the yard in Norway. At the yard in Norway, we had to combine the lower platform module with the upper platform module (including the living quarters). Again, we first weighed the lower module using load cells and jacks, and we then used our SPMTs to move it out of the assembly hall and set it down on the quayside. Once the barge with the upper module arrived, we fitted it with our ballasting system and then moved the upper module onto the quay with SPMTs. The upper module was fitted with rigging so it could be lifted by our two heavy crawler cranes and placed on the lower module. The next step was to move the combined structure back into the hall, though now only part of it fit into the building. Given the site layout, this took some careful maneuvering with our SPMTs. Fortunately, our crews and those of the client benefited from particularly good
weather. Mammoet will return to the site later to load the completed platform, weighing 11,600 tons, onto a barge.
Brazilian big rigs This Mammoet Brazil project required the loading out of two jack-up platforms and their cantilevers. Each rig weighed approximately 7,000 tons, and the cantilevers weighed 1,500 tons. We used two strand bundles and four strand jacks of 900-ton capacity. Having two jacks on each bundle increased the pulling speed and reliability of the system. After the load-outs, our CC-6800 crane helped assemble the 145-meter high platform legs. It was configured with a 96-meter main boom and 72-meter jib.
“Two jacks on each bundle increased the pulling speed and reliability of the system.”
LOCATION: MARAGOGIPE, BRAZIL JOB: LOAD-OUT, LEG INSTALLATION CHALLENGE: SIZE AND WEIGHT OF THE LOADS
Saving time on Canadian FPSO LOCATION: NEWFOUNDLAND AND LABRADOR, CANADA JOB: HEAVY PIPE REEL HANDLING CHALLENGE: SIX WEEKS TO RELOCATE AND BUILD A PTC
This project required the replacement of flow lines and risers of an FPSO (Floating Production, Storage and Offloading unit). In the past, the client had used crawler cranes and transporters for such operations. This time, they wanted an approach to improve safety while saving time. Mammoet offered a solution involving our unique PTC crane, as it could perform all lifting and handling
operations required. Given its size and reach, it would not have to be relocated between lifts and eliminated the need for other handling equipment. The client accepted our proposal, but allowed us a lead time of just six weeks. In that period, Mammoet shipped a PTC from India and assembled it on the job site. In total, the job represented several kilometers of pipeline. The harsh climate in the area meant there was an ice-free window of only five months. The pipes were delivered on 42 reels with diameters of ten meters and weights of 160 to 280 tons. The scope of the project was to offload the reels from the heavy lift vessel which delivered them, store them on a quay, load them onto the pipe-laying vessels, and eventually load the empty reels back onto the heavy lift vessel. This is now the client’s preferred method for projects of this nature.
“The client wanted an approach to improve safety while saving time.”
Koos van Tol, Corporate SHE-Q Director
Optimizing safety performance Continuous development, decentralization and refining the organizational structure: these are key elements of Mammoet’s plan to optimize performance and deliver greater added value to our clients. These elements also drive our Safety, Health, Environment and Quality (SHE-Q) efforts. Corporate SHE-Q Director Koos van Tol explains: “Having worldwide operations means that we have to recognize cultural differences; you can’t work the same way everywhere. We have to delegate responsibility and promote flexibility, while still ensuring that a coordinated approach is followed worldwide. We’re developing a new corporate structure to accommodate that.”
He continues: “Just like our clients, we are well aware of the basics of SHE-Q, the hardware, the skills and procedures. We’re now focusing on our own behavior, both on an individual and on a team level. A team of consultants has assessed our professional culture worldwide, and following this assessment, each region has selected two issues to focus on. The consultants are also helping four regions foster leadership development programs for middle management, which will soon be rolled out throughout Mammoet worldwide. We want our people to grow, especially our operational personnel, becoming more aware of what they’re doing and becoming even better at assessing the diverse situations that they work in. Most of all, we want our personnel to stay sharp and think for themselves. It’s never enough to simply follow procedures. All of this ties in perfectly with our new, decentralized SHE-Q structure.” To ensure that SHE-Q is firmly embedded throughout Mammoet, everyone attends safety instruction sessions, including senior management and office personnel. Safety toolbox meetings are held at the head office every other week, just as they are on the shop floor.
New SHE-Q structure The new SHE-Q structure was developed in central and regional management meetings over the past year. We considered input from our developing business regions especially important, as these
regions will soon be gaining greater independence. Quality, safety, health and environmental protection will be embedded even more firmly within all of our global processes. Mammoet has an ambitious SHE-Q agenda; Van Tol mentions several of the many initiatives: “A number of Mammoet businesses have already been certified to ISO 9001 (quality management), ISO 14001 (environmental management) and OHSAS 18001 (safety management). Other Mammoet businesses will quickly follow suit. We are continuously improving our risk management and updating our Corporate Safety Requirements. The Safety, Health & Incident Management System (SHIMS), introduced in 2011, was updated in 2012 and provides us with invaluable management information. It also ensures effective communication between all parties involved in the case of a serious incident. Additionally, a Corporate Quality Manager has now been appointed and is developing an action plan. The Training and Development Program (T&DP) is being updated and aligned with the new SHE-Q structure. T&DP coordinators will be appointed in all regions, with the coordinator in Singapore acting as the global head for T&DP. We want to give each region greater autonomy, while still ensuring global coordination.”
Working with clients and other contractors Mammoet works with clients from many different industries and cultures, often on projects involving multiple contractors. Van Tol: “We promote effective safety practices rather than just concentrating on paperwork. This is particularly important when working in a multiparty setting. Our people and our organization have been trained to be highly flexible, and to adapt quickly to the many working environments and approaches to SHE-Q that they will encounter on the job.”
Take the Mammoet Minute, daily!
“We aim at continuous personal growth.”
STOP BEFORE YOU START YOUR TASK.
THINK CAREFULLY ABOUT THE TASK AND THE RISKS.
LOOK AROUND, ARE THERE ANY HAZARDS?
ASSESS THE RISKS.
SAFELY START TAKE ACTION: YOUR TASK! ISOLATE AND CONTROL THE RISKS
Minimizing closure time on a US bridge replacement LOCATION: ST PAUL, MINNESOTA, USA JOB: INSTALLING BRIDGE SPANS CHALLENGE: SLOPE, TIGHT TOLERANCES
The Maryland Avenue Bridge, which crosses over a major road in St. Paul, Minnesota, had to be replaced. In the past, the client had used conventional construction methods that required prolonged road closures. This time, the client decided to have the two new bridge spans (each approximately 40 x 30 meters and 1,200 tons) built on an adjacent site. Once the old bridge had been demolished, Mammoet used two sets of SPMTs (with a total of 88 axle lines) equipped with jacks to transport the new spans and position them on the site. The first part of the trip was the most difficult, as we had to negotiate a 9% incline ramp. To ensure correct alignment of the dowels of each span, the units had to be installed within tight tolerances. Once the SPMTs had positioned the spans, they were lowered onto the supports with the jacks. The operation was completed within 12 hours, as requested by the client. The local residents were pleased with the reduction in area disruption and the minimized bridge closure time.
â€œThe operation was completed within 12 hours.â€?
Crossrail TBMs for a major railway expansion
“Working with 1,000 tons and just 20-millimeters clearance.” Crossrail is a major railway expansion project that requires 21 kilometers of twin bore tunnels under central London, UK. Mammoet provided cranes for the assembly of two 1,000-ton Tunnel Boring Machines (TBM). Later, we provided SPMTs and other equipment to move them from the assembly yard to the tunnel portal. The units included a 160-meter long conveyor system which was transported with the TBMs in one piece. Mammoet also jacked a pedestrian bridge up several meters to provide clearance for the passage of the TBMs and SPMTs. Due to height constraints in the tunnel portal (in some places, as little as 20-millimeter clearance), a skidding system was used for the final 150 meters.
LOCATION: LONDON, UK JOB: TBM TRANSPORT CHALLENGE: SIZE, HEIGHT CONSTRAINTS
A train station goes for a scenic drive The Beiseker Railway Museum (near Calgary, Alberta, Canada) purchased the disused 100-year-old train station of the town of Bassano, 155 kilometers away. The station weighed around 165 tons and was 51 meters long. The project started by jacking-up the station up and placing beams underneath it. We then transported it to the museum on conventional trailers. A spokesperson from the museum commented, “I just can’t say enough good things about the crew and their professionalism; they were well prepared and executed the entire move seemingly without a worry.”
“Finding a new home for a 100-year old train station.”
LOCATION: ALBERTA, CANADA JOB: RELOCATING A TRAIN STATION CHALLENGE: SIZE OF THE LOAD
Barge hulls in the Netherlands LOCATION: SCHIEDAM, THE NETHERLANDS JOB: OFFLOADING BARGE HULLS CHALLENGE: SPECIAL RIGGING
A Dutch shipyard bought 18 large hulls in China. The hulls were stacked 4-high on two barges that were transported to Rotterdam by a semisubmersible vessel. The barges were then floated off and towed to the Mammoet Heavy Lift Terminal at Schiedam, just outside our European head office. The hulls weighed between 400 and 1,460 tons each, with lengths of 72-135 meters. Mammoetâ€™s task was to individually unload the barges in a step-by-step procedure. We first lifted a hull off the stack. Secondly, we ballasted the barge and moved it out of the way. Thirdly, we lowered the hull into the water and moved it to a mooring. Lastly, we returned the barge to the quayside to allow the cranes to lift the next hull. One crane stayed in place while the other one moved along the quay, depending on the length of the hull to be lifted. Special rigging designed to spread the loads on the hulls was used for this task.
â€œComprehensive project management.â€?
Amsterdam metro tunnel installation LOCATION: AMSTERDAM, THE NETHERLANDS JOB: INSTALLING TUNNEL SECTIONS CHALLENGE: ACCURATELY PLACING EXTREMELY LARGE UNITS
“Adjusting with two sheerlegs.”
Mammoet Maritime installed three tunnel sections for the new north-south metro route in Amsterdam. The concrete tunnel elements were initially constructed at dock nearby, which was then flooded in order to move the floating sections to temporary storage. Finally, the tunnel sections were transported by four tugs and one pusher tug to the location where they were to be installed. Each section was approximately 140 meters long, 12 meters wide and 8 meters high. The installation of each tunnel section began by placing foundation blocks on the riverbed with our sheerlegs. Next, each floating tunnel section was positioned using tugs, a pusher tug, and in one case, wire ropes and winches. The ballast tanks were then flooded with water to submerse the tunnel section. Finally, the section’s position was carefully adjusted with two sheerlegs to ensure that it connected flawlessly with the previously placed tunnel section.
Shallow water bridge installation
“Working with ten centimeters between the barge and the bottom.”
This bridge, with a length of 117 meters, a height of 15 meters and a weight of about 1,000 tons, was built in a yard located three kilometers away from the installation site. The bridge would provide multiple improvements, such as better access to an industrial estate near Zutphen, and reduced traffic through the town. However, the asymmetrical design of the bridge (with a bicycle path on one side), the weak quay and the shallow waterways posed some interesting challenges. The weak quay at the construction yard meant that Mammoet’s heavy equipment was required to stay 11 meters from the water’s edge. Hence, a creative solution had to be developed in order to move the bridge from the yard onto the barges. We decided to use SPMTs to move the bridge so that one end extended over the canal, which was then supported by an auxiliary
barge. Next, the SPMTs and auxiliary barge moved the bridge further across the canal so that our main barges could be positioned underneath to pick it up. We then lifted the bridge seven meters above the main barge deck, using our JS500 push-up system. On the way to the installation site, canal water depth presented another challenge. In order to reduce the draft, Mammoet distributed the load between three linked barges, clearing the canal bottom by as little as ten centimeters in some places. Close to the installation site, four winches were used to turn the bridge to span across the canal, and then pull it into position. Finally, the push-up system gently lowered the bridge onto the abutments.
LOCATION: ZUTPHEN, THE NETHERLANDS JOB: INSTALLING A BRIDGE CHALLENGE: WEAK QUAY, SHALLOW WATER
Fokko Ringersma, Managing Director Mammoet Salvage:
Thinking outside the box Mammoet Salvage has established itself as a leading international salvage company on the basis of “Smart solutions, united experience.” This means thinking outside the box and having the engineering capacity and asset base to support smart solutions. Along with wreck removal projects, this division of Mammoet undertakes emergency response salvage and decommissioning jobs.
Managing Director Fokko Ringersma is proud of his division’s success and looks forward to its continued development. Ringersma: “Our company is thriving, with a growing team of dedicated professionals. In addition to Mammoet’s long standing network of depots, we now have dedicated Salvage depots in Houston, Singapore and Schiedam, and sales offices in London and Korea. We have a wide range of emergency response equipment in a custom-bonded area at Amsterdam Airport Schiphol, ready for global dispatch at any time. A network of subcontractors all around the world helps support our operations. This global presence allows us to take on both emergency response salvage and major wreck removal projects.”
Salvage projects Mammoet Salvage recently began work on a wide range of projects. The largest is the wreck removal of the B. Oceania, a bulk carrier transporting 67,000 tons of iron ore that sank in the busy Straits of Malacca after a collision in 2011. Ringersma: “The position of the ship in the channel leading to Singapore was a critical factor in the bid for work. The major challenge is that other ships often pass extremely close by. Safe navigation requirements are therefore particularly demanding. In addition to our working
pontoon, we have an observation post with radar and communications equipment, along with two additional ships patrolling the area in order to warn approaching vessels. In 2012, we made good progress on this wreck removal project. We recovered the cargo, the engine room section, and the bow and accommodation block. Now we are clearing the double bottom sections between the engine room and the bow. The project is well on schedule, and we hope to have it completed by spring 2013. Environmental protection is an important component of this project - we carefully dispose of all recovered cargo and scrap while also offsetting our carbon emissions.” Salvage has also invested in a customized directional drilling system, designed by Mammoet Solutions. This is used to place cutting and lifting chains under the Oceania wreck. The Mauritania ships’ graveyard project was completed in fall 2012 with the removal of the 74th shipwreck from Nouadhibou Bay. Ringersma: “We completed this project well before the deadline. The wrecks were removed and dismantled safely. Environmental protection was an especially important consideration, as we were dealing with hazardous materials, including asbestos. Mammoet runs its business with great
care for the local environment and community. While working on the project, we made generous donations to the Nouadhibou Bay community, among others to Enfant du Monde, and we sponsored the Nouadhibou Marathon two years in a row. It’s all part of our Corporate Social Responsibility Program. Additionally, we improved the local infrastructure and set up an education program for Nouadhibou residents. By hiring personnel locally, we provided not only employment, but also practical, on-the-job training. This project will have long-term environmental benefits, as we have prevented future toxic emissions from harmful materials.”
Oil industry projects Projects involving offshore oil and gas platforms are another important market for Mammoet, given our petrochemical and offshore experience and our salvage expertise. We demonstrated our strength in this market during our work on the Pico lift boat, which was positioned in near proximity to a platform in the Gulf of Mexico. The lift boat toppled over, and the topside of the boat and the top end of the legs broke
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“This global presence allows us to take on both emergency response salvage and major wreck removal projects.”
off, leaving the bottom leg sections with spud cans buried in the seabed. We had to remove these leg sections with immense care, as they were only meters away from a seabed operating platform containing live high-pressure oil pipelines. Because of the growing demand for these kinds of operations, Mammoet has established a dedicated Decommissioning business unit as of January 1, 2013, specialized in removing end-of-life offshore structures. Ringersma: “One of our greatest strengths is that we offer proven solutions based on united experience. This is extremely important when dealing with the oil and gas industry, where safety is the top priority.”
Emergency response salvage The quality of our workmanship was a decisive factor in Mammoet Salvage’s successful bid to refloat the Feruz ferry in Turkey. In a heavy storm, the captain had found refuge by grounding his vessel in the small harbor of an “aqua park.” Ringersma: “The Feruz is not large, but it’s an unusual ship, a RoRo ferry with railway tracks for train wagons. Therefore, the ship owner
wanted immediate action so as to limit damage to the ship. We provided emergency response support, working with a local diving contractor and a tug company in our international network in order to stabilize and inspect the vessel. At first, this looked like a routine salvage job, but due to the shallow water it was difficult to pull the Feruz from the harbor without damaging the hull. Our naval architects developed a solid and innovative refloating plan - that’s why the project was awarded to us. After refloating the vessel, we successfully towed it to a port nearby.” This project demonstrates the strength of Mammoet Salvage’s international salvage
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network, which enables the company to provide rapid response support in emergencies and to minimize further damage to vessels. The advantages of having a local presence with salvage expertise are magnified by our global scope and resource network. Emergency response salvage is often followed up by complex wreck removal operations, and Mammoet Salvage benefits from the larger Mammoet group’s equipment, know-how and engineering support, delivering the smart solutions that are our company’s defining strength.
“Smart solutions, united experience.”
Mammoet Mammoet helps clients improve construction efﬁciency and reduce downtime of plants and installations. For that purpose, we provide solutions for lifting, transporting, installing and decommissioning large and heavy structures. Our services are focused on the petrochemical and mining industries, civil engineering, power generation and offshore projects. The logistic challenges in these industries are growing daily, with factors such as remote location, harsh climate and emphasis on environmental care raising the bar. We help clients reduce the cost of ownership and optimize uptime of their plants and installations with the following services: • • • • • • •
Lifting, transportation and installation of modular constructions Factory-to-foundation projects Plant turnaround logistics Lifting and transportation services Salvage and wreck removal Decommissioning of on and offshore installations Trading in new and used equipment worldwide
Mammoet is known for the unique size and capacity of its state of the art equipment. But it is the trust of our clients that enables 5,000 Mammoet professionals to give their best every day and truly make a difference in projects all over the world.
Mammoet’s operations in the petrochemical and chemical industries largely relate to maintenance work, the replacement of plant modules, complete overhauls and the expansion or construction of production sites.
Mining & Metals
Mammoet’s services to the opencast and deep mining industry include transporting and installing large modular plants at remote mine sites, general lifting services and supporting maintenance operations.
Mammoet has established a formidable reputation for itself in all parts of the power industry, from fossil fuel and nuclear plants to facilities using renewable energy sources.
Mammoet’s activities in the offshore industry include the accurate and safe implementation of transport solutions by land and by water, load-ins and loadouts, and the assembly of extremely large and heavy items. Mammoet Decom specialises in the decommissioning and removal of offshore structures such as platforms, pipelines and subsea templates.
Mammoet’s experiences with multimodal transport by road, rail and water, along with its knowledge of the equipment used for lifting, skidding and jacking heavy loads, ensure Mammoet’s position as a full-service provider in the market for civil projects and infrastructure works.
Mammoet Salvage provides worldwide salvage, emergency response and wreck removal services, at sea, in ports and on inland waterways.
Global service, local presence Mammoet has clients and projects in all parts of the world. To keep the lines of communication short and to stay abreast of the local markets, Mammoet has operating companies throughout Europe, the Americas, Africa, the Middle East, Asia and Australia. Global or highly complex projects and global logistics are handled centrally from our home base in Utrecht, the Netherlands. As much as possible everything else is handled locally. This structure enables us to act swiftly, effectively and cost-efficiently in your local market, while offering the benefit of a central knowledge and experience center for more demanding aspects of your project.
A As the world market for heavy lifting and heavy transport continues to grow, the loads to b be lifted are getting heavier and heavier. To meet this growth opportunity, we have d developed a New Generation of PTC Super Heavy Lift cranes, with a combination of high lilifting capacity and flexibility to set it apart from the rest of the market.
Petrochemical page 6
Mining page 12
Power page 14
Offshore page 24
Civil page 32
Worldwide specialists in heavy lifting and transport
A long drive in South Africa. Read more about it on page 7.
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Worldwide specialists in heavy lifting and transport