Mammoet World12

How do you add value in markets where customers are faced with mounting challenges?

Find out on page 22.

Worldwide specialists

in heavy lifting and transport

Salvagepage 38

Powerpage 16

Offshorepage 24

Petrochemicalpage 6

Mining & Metalspage 12

Civil page 32

New Generation PTC at work for QUIP in Brazil

QUIP is currently building two large FPSOs for Petrobras, Brazil’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.

2 3

Corporate Marketing & Communication

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: info@mammoet.com

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.

www.mammoet.com © 2013

“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.

Expertise and Imagination

Introduction from The Board

Moving a Caterpillar front-end loader in South Africa

Mammoet moved a Caterpillar

994H front-end loader from

Middelburg SA to a mine, a 30-

kilometer route.

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

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

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.

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.

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.

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.

Jan Kleijn

President and CEO

Erik Rave

CFO

Herman Smit

COO

Just In ’t Velt

Head of Human

Capital

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 off-

shore structure. The PTC installed

13 of these spar sections. Other

lifts for this project ranged from 800

to 2,800 tons.

Segments

6 Petrochemical

12 Mining & Metals

16 Power

24 Offshore

32 Civil

38 Salvage

Contents

Close up

4 Message from the CEO

14 Meeting the client

22 Mammoet Solutions

30 SHE-Q

“Lifting with power and versatility:

the New Generation Cranes.”

“The combined weight of a spar section and

rigging was almost 1,200 tons.”

4 5

“ Mammoet moves me”

Message from the CEO

At the forefront“I joined Mammoet in 1997 as an engi-

neer. 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 large-

scale 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 ser-

vices in an expanding and industrializing

society, and he set the tone for a compa-

ny 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.”

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 his-

tory: salvaging the Kursk. This Russian

submarine, powered by two nuclear reac-

tors, had sunk in the Barents Sea on

August 12th, 2000, following an explo-

sion. 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 pro-

ject 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 hap-

pened on the Kursk project is typical of

the Mammoet approach to work. We

always find solutions, no matter the situa-

tion. 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 tal-

ented professionals – both with my col-

leagues at Mammoet and with our clients

worldwide.”

Expertise and imaginationKleijn shares this passion with many long-

term 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 min-

imize downtime, optimize costs of owner-

ship and guarantee safety. They must,

therefore, rely more on technology and

innovation. Our equipment base, the larg-

est 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.”

Global presence based on local strengthThis 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 man-

agement. 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 manage-

ment, 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 opera-

tor 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 teamMammoet 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 under-

standing our clients’ processes and

challenges in order to provide the

best possible solutions. These solu-

tions require a great deal of innova-

tion in equipment and processes.

We’ve therefore combined our

expertise, knowledge and creativity

to form a global Solutions team.

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.”

“Our focus is on

thoroughly

understanding

our clients’ processes

and challenges

in order to provide

the best possible

solutions.”

“ 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 con-

struction 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 cost-

efficient 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 moun-

tain 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.”

LOCATION: USA AND CANADA

JOB: MODULE TRANSPORT

CHALLENGE: NUMBER OF LOADS

6 7

Petrochemical

North American long haul

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.

“ Modular construction was well suited for this remote location.”

LOCATION: KROTZ SPRINGS,

LOUISIANA, USA

JOB: INSTALLING VESSELS

CHALLENGE: WORKING IN A LIVE

PLANT

LOCATION: WILLEMSTAD, CURAÇAO

JOB: CAT CRACKER HEAD

REPLACEMENT

CHALLENGE: LIMITED SPACE

Petrochemical

Hurricane Isaac interrupts work

Crane in the Caribbean

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.

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 Factory-

to-Foundation service.

“Handling the

unexpected is just

part of the job.”

“The cracker head had to be installed in a

very confined workspace.”

LOCATION: RUSSIAN FEDERATION

JOB: VESSEL INSTALLATION

CHALLENGE: SCHEDULE CHANGES

8 9

Petrochemical

Time challenges in Russia

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.

“Despite a variable

schedule, the work

was completed

early.”

LOCATION: JUBAIL, SAUDI ARABIA

JOB: TRANSPORT AND INSTALLATION

CHALLENGE: HOT WEATHER,

CROWDED SITE

LOCATION: JUBAIL, SAUDI ARABIA

JOB: HEAVY VESSEL INSTALLATION

CHALLENGE: TIGHT TOLERANCE

LOCATION: SAUDI ARABIA

JOB: TRANSPORTING COLUMNS

CHALLENGE: TIGHT TURN ON A ROAD

Petrochemical

For this petrochemical plant in Saudi Arabia, Mammoet used conventional trailers and prime

movers to transport two columns from the port to the site. 

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.

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.

“ The extensive advance

planning was invaluable.”

“ SPMTs provided

the best solution.”

“Using conventional

trailers and prime

movers.”

Transportation from port to site

Desert project in Saudi Arabia

Step-by-step

LOCATION: CHAYVO, SAKHALIN

ISLAND, RUSSIAN FEDERATION

JOB: INSTALLATION OF LARGE

MODULES

CHALLENGE: WEATHER CONDITIONS

10 11

Petrochemical

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.

Modular components for Russian facility

“The most efficient approach.”

LOCATION: WHITING, INDIANA, USA

JOB: TOWER INSTALLATION

CHALLENGE: CONGESTED SITE

LOCATION: MARINA DI CARRARA, ITALY

JOB: MODULE TRANSPORT

CHALLENGE: WEIGHT AND SIZE

Petrochemical

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.

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.

Sour water stripper in the American Midwest

The journey begins in Italy

“ This congested

site provided some

challenges.”

“ The largest transport on

Italy’s public roads.”

LOCATION: TIMMINS, ONTARIO,

CANADA

JOB: RELOCATION OF A MINING

SHOVEL

CHALLENGE: ICE AND STEEP SLOPES

LOCATION: PORT HEDLAND,

AUSTRALIA

JOB: ASSEMBLING A RECLAIMER

CHALLENGE: INNOVATIVE APPROACH

1312

Mining &

Metals

Saving months in Ontario

Australian ore reclaimer

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.

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.

“ Mammoet moved

the shovel in two

weeks without

disassembling.”

“A time-saving new

approach increased

safety while

reducing

installation costs.”

LOCATION: MA’ADEN, SAUDI ARABIA

JOB: ROOF INSTALLATION

CHALLENGE: CONGESTED SITE,

SPECIAL RIGGING

LOCATION: LONG HARBOUR, NEWFOUNDLAND,

CANADA

JOB: MODULE TRANSPORT AND INSTALLATION

CHALLENGE: SCALE OF THE PROJECT

Saudi roof placement

Long haul in Long Harbour

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.

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.

“We used special rigging to lift

and place the silo roofs.”

“ On average, we

maintain a crew

of 55 at this large

scale project site.”

Mining & Metals

14 15

We visited Matthijssen at Heerema

Fabrication Group’s offices in Zwijndrecht.

The adjacent yard displays impressive

fabrication halls. A large number of plat-

forms 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 construc-

tion 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 bounda-

ries 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 sepa-

rate 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 pric-

es. By cooperating, we gain access to

specialist expertise that we don’t have in-

house. 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 solu-

tions 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 plat-

form back on schedule, despite a delay

during the design stage. Together we con-

sider 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 solu-

tions. 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 work-

ing 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 mainte-

nance 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 proce-

dures, 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 cli-

ent’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 signifi-

cantly reducing the overall project cost

and, ultimately, the total cost of owner-

ship. 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 dif-

ferently. 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 opera-

tions and standard load-outs our-

selves. 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 com-

ing up with new developments and

designs, so we must always con-

front 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 rou-

tine jobs. As a partner you can opti-

mize the work-flow, because you

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.

“A partnership based on inspiration and challenge”

Meeting the client: Heerema Fabrication Group

Sander Splinter

are familiar with the rules and pro-

cedures on a site. We also share

the same safety standards.

Agreement in this area of coopera-

tion is essential, as different

approaches simply don’t work

when it comes to safety.”

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 coopera-

tion. It’s crucial we keep challeng-

ing 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

worthwhile expertise. The relationship has

to provide us with more than just another

supplier, otherwise it has no point.”

You mentioned shifting boundaries. Could

you give some key developments in the

market?

Matthijssen: “One example is that plat-

forms are getting bigger, especially in the

wind power industry. In fact, they’re get-

ting 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.”

Splinter: “Of course we are always devel-

oping 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 float-

ed over, and we lowered the deck. That

was another step forward.”

Returning to entrepreneurship and innova-

tion, 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 princi-

ple I cherish deeply: deliver what

you promise. By sticking to this, we

have been able to build relation-

ships with our clients based on

trust and mutual respect. By form-

ing a team with our customers, we

reach new frontiers together.

Wim Matthijssen

“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.”

LOCATION: CHOOZ, FRANCE

JOB: SPECIALIST HEAVY LIFTING

CHALLENGE: CONFINED, RADIOACTIVE

ENVIRONMENT

16 17

Power

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.

Tailor-made solutions in a French cavern

“ We designed a custom

tilt unit with four

hydraulic cylinders.”

LOCATION: JÜLICH, GERMANY

JOB: NUCLEAR REACTOR LIFT

CHALLENGE: STRICT REGULATIONS,

LIMITED SPACE

Power

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.

Seven-year relationship

“Our involvement in

this decommissioning

project began in

2007.”

LOCATION: THYBORN, DENMARK

JOB: WIND TURBINE TRANSPORT AND

INSTALLATION

CHALLENGE: NEW TURBINE DESIGN

LOCATION: ST-RÉMI, QUÉBEC, CANADA

JOB: WIND TURBINE INSTALLATION

CHALLENGE: STRONG WINDS

LOCATION: MACARTHUR, VICTORIA,

AUSTRALIA

JOB: INSTALLING 140 TURBINES

CHALLENGE: SCALE OF THE PROJECT

18 19

Power

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.

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.

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.

“Specifically

designed for

wind turbine

projects.”

“ Saving time in

the Southern

Hemisphere.”

“Close cooperation

between Mammoet

and the client’s

engineers helped

us devise the best

lifting solution.”

Innovative two-blade turbine in Denmark

Forty-four Canadian turbines

Southern Hemisphere’s largest wind farm

LOCATION: RIGA, LATVIA

JOB: TRANSPORT, LIFTING AND

INSTALLATION

CHALLENGE: LACK OF PORT

FACILITIES, BRIDGE CLEARANCES

Power

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.

“ Offering comprehensive solutions.”

LOCATION: CALGARY, ALBERTA,

CANADA

JOB: POWER TRAIN TRANSPORT AND

INSTALLATION

CHALLENGE: COMPLEXITY OF THE

PROJECT

LOCATION: IQALUIT, NUNAVUT, CANADA

JOB: TRANSPORTING ENGINES

CHALLENGE: ICEBERGS, NO PORT

20 21

Power

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.

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.

North American power plant

Power in the far north

“A dedicated team

of Mammoet

professionals from

Canada and the

USA worked

together.”

“ Harsh weather,

icebergs and the

lack of a port made

this Arctic job quite

challenging.”

LOCATION: SELLAFIELD, UK

JOB: MODULAR CONSTRUCTION

CHALLENGE: SPECIAL SITE

CONSTRAINTS, SMALL CLEARANCES

Power

For reasons of time efficiency, Evaporator D at the

Sellafield site in the UK is being built using modu-

lar construction. The main contractor pours most

of the concrete structure for the entire building,

Mammoet inserts the modules, and then the con-

tractor pours the last wall. Most of the ten mod-

ules 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 build-

ing 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.

Sellafield Evaporator D project

“ Mammoet undertook a feasibility study for an alternative to conventional cranes.”

22 23

That’s the purpose of Mammoet

Solutions. This new business unit oper-

ates 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 back-

ground in strategy and business develop-

ment.

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.”

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?

Sharing innovation

Nowadays, power stations and similar

plants are more and more often built at

remote locations. However, bringing

heavy components such as large diesel

Innovation in action: T

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 com-

ponents 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 solu-

tions wherever they are needed.

This approach also helps us identify

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 equip-

ment.

“Smart solutions

can help clients

achieve signifi cant

improvements.”

The case of the crane

trends across industries and define

our long term innovation agenda.”

Sharing expertise worldwide Mammoet Solutions has numerous

specialists in disciplines including

mechanical and electrical engineer-

ing, 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

Solut ions and Sales and

Operations, we have set up regional

Solutions think-tank meetings

where representatives can regularly

exchange information with their col-

leagues. The meetings foster a cul-

ture of connectivity, enabling us to

share expertise and best practices

throughout the company and make

smart, innovative solutions readily

available to our clients.

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 care-

fully 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 trans-

port 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 abil-

ity 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 con-

tainers, 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-

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 innova-

tive solutions. Having great hardware is

just part of the Mammoet story. Working

for the best interests of our clients is what

really moves us.

“Sometimes innovation means lots of dialogue…

and then going back 2000 years.”

Maurits Croon Pieter Jacobs

LOCATION: RIO GRANDE, BRAZIL

JOB: DECK LIFT

CHALLENGE: SIZE AND WEIGHT OF

THE LOAD

24 25

OffshoreOffshore

Seventeen thousand tons in Brazil

The P-55 is Brazil’s largest semi-submersi-

ble 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 jack-

ing operations.

“To lift and install the massive offshore platform

deck box, we built a special lifting system.”

LOCATION: HAMRIYAH FREE ZONE, UAE

JOB: VESSEL LOAD-OUT

CHALLENGE: COMPLEX LOAD

INTERACTION

Offshore

Dynamic loads

“The client built an 8,500-ton jack-up vessel and

contracted Mammoet to load it onto the barge.”

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: VUNG TAU, VIETNAM

JOB: PLATFORM PUSH-UP AND

LOAD-OUT

CHALLENGE: LATE DESIGN CHANGES,

ASYMMETRIC CENTRE OF GRAVITY

26 27

OffshoreOffshore

Offshore in VietnamFor 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.

Offshore

“ Constructing two units in parallel.”

LOCATION: LAEM CHABANG, THAILAND

AND HAUGESUND, NORWAY

JOB: OFFSHORE MODULE HANDLING

CHALLENGE: HEAVY RAIN, SIZE OF THE

LOAD, SITE LAYOUT

28 29

OffshoreOffshore

Offshore platform module construction in two countries

“Serving the client

through dedicated

collaboration.”

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.

LOCATION: MARAGOGIPE, BRAZIL

JOB: LOAD-OUT, LEG INSTALLATION

CHALLENGE: SIZE AND WEIGHT OF THE

LOADS

LOCATION: NEWFOUNDLAND AND

LABRADOR, CANADA

JOB: HEAVY PIPE REEL HANDLING

CHALLENGE: SIX WEEKS TO RELOCATE

AND BUILD A PTC

Offshore

Brazilian big rigs

Saving time on Canadian FPSO

“Two jacks on each

bundle increased

the pulling speed

and reliability of the

system.”

“ The client wanted an

approach to improve

safety while saving time.”

This Mammoet Brazil project

required the loading out of two

jack-up platforms and their canti-

levers. Each rig weighed approxi-

mately 7,000 tons, and the canti-

levers 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 config-

ured with a 96-meter main boom

and 72-meter jib.

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.

WE CARE!

LOOK OUT!

KEEP THINKING!

30 31

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 respon-

sibility 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 world-

wide. We want our people to grow, espe-

cially our operational personnel, becom-

ing 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, decen-

tralized 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 structureThe new SHE-Q structure was developed

in central and regional management meet-

ings 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 embed-

ded even more firmly within all of our

global processes. Mammoet has an ambi-

tious 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 business-

es will quickly follow suit. We are continu-

ously 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 manage-

ment 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 develop-

ing 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 coordi-

nator in Singapore acting as the global

head for T&DP. We want to give each

region greater autonomy, while still ensur-

ing global coordination.”

Working with clients and other contractorsMammoet 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 impor-

tant 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 envi-

ronments and approaches to SHE-Q that

they will encounter on the job.”

STOP

RISKS?

Take the Mammoet Minute, daily!

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.

Optimizing safety performanceKoos van Tol, Corporate SHE-Q Director

“ We aim at

continuous

personal

growth.”

1 2 3 4 5 6

STOP BEFORE YOU START YOUR TASK.

THINK CAREFULLY ABOUT THE TASK AND THE RISKS.

LOOK AROUND, ARE THERE ANY HAZARDS?

ASSESS THE RISKS.

TAKE ACTION: ISOLATE AND CONTROL THE RISKS

SAFELY START YOUR TASK!

LOCATION: ST PAUL, MINNESOTA, USA

JOB: INSTALLING BRIDGE SPANS

CHALLENGE: SLOPE, TIGHT

TOLERANCES

32 33

Civil

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.

Minimizing closure time on a US bridge replacement

“ The operation was

completed within

12 hours.”

LOCATION: LONDON, UK

JOB: TBM TRANSPORT

CHALLENGE: SIZE, HEIGHT

CONSTRAINTS

LOCATION: ALBERTA, CANADA

JOB: RELOCATING A TRAIN STATION

CHALLENGE: SIZE OF THE LOAD

CivilCivil

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.

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 spokes-

person from the museum comment-

ed, “I just can’t say enough good

things about the crew and their pro-

fessionalism; they were well pre-

pared and executed the entire move

seemingly without a worry.”

Crossrail TBMs for a major railway expansion

A train station goes for a scenic drive

“ Working with

1,000 tons and just

20-millimeters

clearance.”

“ Finding a new home for a

100-year old train station.”

LOCATION: SCHIEDAM,

THE NETHERLANDS

JOB: OFFLOADING BARGE HULLS

CHALLENGE: SPECIAL RIGGING

34 35

Civil

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.

Mammoet’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.

Barge hulls in the Netherlands

Civil

“ Comprehensive project management.”

LOCATION: AMSTERDAM, THE

NETHERLANDS

JOB: INSTALLING TUNNEL SECTIONS

CHALLENGE: ACCURATELY PLACING

EXTREMELY LARGE UNITS

36 37

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.

Amsterdam metro tunnel installation

“Adjusting with two

sheerlegs.”

Civil

LOCATION: ZUTPHEN,

THE NETHERLANDS

JOB: INSTALLING A BRIDGE

CHALLENGE: WEAK QUAY, SHALLOW

WATER

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.

“Working with ten

centimeters

between the barge

and the bottom.”

Shallow water bridge installation

Civil

38 39

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 equip-

ment, 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 experi-

ence 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

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.

Thinking outside the box

Fokko Ringersma, Managing Director Mammoet Salvage:

Salvage

24/7 Emergency response

Salvage

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

operat ions, Mammoet has

es tab l i shed a ded icated

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 salvageThe 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

network, which enables the company to

provide rapid response support in

emergencies and to minimize further dam-

age 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 solut ions that are our

company’s defining strength.

+31 (0)10 204 24 45

“This global presence

allows us to take

on both emergency

response salvage and

major wreck removal

projects.”

“ Smart solutions,

united experience.”

www.mammoet.com

Please visit our website for Mammoet job opportunities and for more information

and addresses all over the world.

Mammoet

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.

Worldwide specialists

in heavy lifting and transport

Mammoet helps clients improve construction effi ciency 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.

Offshore

Mammoet’s activities in the

offshore industry include

the accurate and safe

implementation of transport

solutions by land and by

water, load-ins and load-

outs, and the assembly of

extremely large and heavy

items. Mammoet Decom

specialises in the decom-

missioning and removal of

offshore structures such as

platforms, pipelines and

subsea templates.

Civil

Mammoet’s experiences

with multimodal transport

by road, rail and water,

along with its knowledge of

the equipment used for lift-

ing, skidding and jacking

heavy loads, ensure

Mammoet’s position as a

full-service provider in the

market for civil projects and

infrastructure works.

Salvage

Mammoet Salvage provides

worldwide salvage, emer-

gency response and wreck

removal services, at sea, in

ports and on inland water-

ways.

Mining & Metals

Mammoet’s services to the

opencast and deep mining

industry include transport-

ing and installing large

modular plants at remote

mine sites, general lifting

services and supporting

maintenance operations.

Petrochemical

Mammoet’s operations in

the petrochemical and

chemical industries largely

relate to maintenance work,

the replacement of plant

modules, complete over-

hauls and the expansion or

construction of production

sites.

Power

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 World Missing?

You can order available back issues by

sending an e-mail to

corporate.communication@mammoet.com,

stating which issue you wish to receive,

together with your name and the address to

which the Mammoet World(s) should be sent.

Mammoet World

A long drive in South Africa. Read more about it on page 7.

As the world market for heavy lifting and heavy transport continues to grow, the loads to

be lifted are getting heavier and heavier. To meet this growth opportunity, we have

developed a New Generation of PTC Super Heavy Lift cranes, with a combination of high

lifting capacity and flexibility to set it apart from the rest of the market.

Worldwide specialists

in heavy lifting and transport

A

b

d

li11

Marinepage 40

Powerpage 14

Offshorepage 24

Petrochemicalpage 6

Miningpage 12

Civil page 32