This innovative, sustainable solution improves the bearing capacity of the soil for heavy lifting projects.

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This innovative, sustainable solution improves the bearing capacity of the soil for heavy lifting projects.

Heavy industry construction and turnaround projects have a common requirement – the need for a solid foundation to support equipment and structures. In many cases the access roads and construction areas for projects must be reinforced to accommodate cranes, transporters and their loads. Gravel, mats, concrete slabs and other materials are traditionally used for this purpose. But these materials are often heavy and can therefore add to the weight applied to the ground, causing settlement problems. These materials also need to be transported to and from site, resulting in additional cost and environmental impact.

Mammoet’s Enviro-Mat provides a more efficient, cost-effective and sustainable alternative. Saving time, material and money while lowering the carbon footprint of a project. Enviro-Mat can be used to provide both temporary and permanent pavement for roads, lay down areas, hard stands and crane pads.

Combining sustainability benefits with quick installation, it can be used in a wide range of situations. If offers particular advantages on sites where the ground bearing capacity of a large area needs to be increased within a short timeframe. Quickly installed and fully reusable, Enviro-Mat offers a simple and convenient method for increasing a site’s ground bearing capacity.

More efficient construction

Across all sectors, project engineers are seeking even greater efficiencies. One way to achieve this is through greater economies of scale. As a result, project components, and the equipment required to move them, are becoming bigger and heavier than ever before.

Modern construction techniques, including modular or prefabricated construction approaches, where key components are manufactured off site and then transported for installation, help to reduce costs, save time and improve safety. These more efficient construction approaches for today’s power plants, refineries, wind farms, mines and infrastructure call for specialized engineering techniques alongside heavy lifting and transport equipment on an unprecedented scale.

One result of the trend for increasing scale in construction approaches is that the ground where machinery and plant components are travelling, standing or operating needs a greater load bearing capacity than ever before.

Before the construction of a major facility can begin, stabilizing and fortifying the soil can be a civil engineering project in its own right. Preparing access roads, hard stands, laydown areas and crane pads requires planning, ground preparation, the delivery of a significant amount of materials and construction time.

The heavy lifting and transport scope of the project may then call for additional reinforcements consisting of gravel, wooden mats, concrete slabs and other materials. Permanent areas used for heavy lifting operations often require the construction of a piling mat. All of these aspects take time, and costs can be considerable.

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A complete solution

Although Mammoet is known for its ground breaking heavy lifting and transport innovations, we have also taken the initiative in making sure the ground doesn’t break underneath us. With Enviro-Mat, we have developed a solution that vastly improves the load bearing capacity of the soil while at the same time reducing material and construction requirements. Enviro-Mat is a complete solution that paves the way for greater project efficiency.

When clients engage with Mammoet early in a project’s design phase, our team assesses the scale and range of lifts and movements required. This enables us to select the most efficient approach and identify which equipment to deploy. Once we have the engineering and equipment plans in place we will calculate the load bearing requirements of access routes and operational areas during the project. We can then compare traditional methods of ground reinforcement or stabilization with Enviro-Mat to assess the efficiencies it brings in both cost and in shortening the critical path of your project.

Construction advantages

Enviro-Mat is quick and easy to apply. It is mixed with cement, additive and any local soil to create a hard surface with a load bearing capacity of up to 50 tons/m2 and beyond. Settlement is often an issue when heavy standings are laid, but by using soil from the site Enviro-Mat won’t add significant weight to the stabilization. This results in an even laydown/assembly area or hardstand, with very limited settlement.

Environmental benefits

As the name suggests, Enviro-Mat offers environmental benefits. It uses less cement than equivalent concrete installations would require. More significantly, with Enviro-Mat there is no need to excavate and export existing soil from the area, or to transport new building materials  to the site. This means a reduction in the number of truck movements needed, which in turn reduces a project’s carbon footprint and cost. Because Enviro-Mat’s binding agent locks in pollutants, it can also be used on contaminated soil opening up brownfield sites for reuse and redevelopment.

Durable and long-lasting

Once the construction of your plant is complete, the Enviro-Mat surface can be left in place as a permanent feature. It is water resistant, and is not subject to cracking when freezing or thawing. Enviro-Mat is durable in hot and cold climates, although the temperature does need to be above 5°C when it is laid, set and cured. Future versions of Enviro-Mat for installation in colder climates are under development.

If the Enviro-Mat surface is not required after project completion, it can be broken up and mixed back in with the local soil. Unlike concrete, no unbound cement will be left in the soil and disintegrated Enviro-Mat has zero environmental impact.

Offering a winning combination of cost, time and environmental benefits, Enviro-Mat improves the efficiency of a project. Direct and overall costs can be reduced by 20% or more, timelines can be reduced, and investors, regulators and the public benefit from its sustainability benefits.