Mining & metals

Heavy lifting experience

For two centuries Mammoet has worked extensively across heavy industries, with a large focus on mining and metals. Our drive to innovate and engineer better heavy lifting and transport solutions has chimed with our clients’ desire to find safer and more efficient ways of constructing and operating their mines – often at a larger scale and with increasing pressure to reduce timelines. From the introduction of our first heavy-duty barge in 1807 right up to the development of the Focus crane, Mammoet has pushed the boundaries of engineered heavy lifting and transport.

Improving profitability

Mining and metals companies are continuously looking for ways of optimizing efficiency, minimizing downtime and reducing time to market. Mammoet has a long history of successfully executing a range of mining projects. We move deadlines forward and optimize construction time by drawing on our operational expertise and utilizing a large and diverse fleet of equipment.

Modular construction

Facilitating the use of modular construction techniques is just one of the ways Mammoet helps mining companies meet these objectives. The pioneering Red Dog Mine in Alaska was a game changer for the industry. Modular construction on this scale had never been attempted before. It was built in giant units in the Philippines, where work could be carried out safely, all year round, in controlled conditions and by a skilled and plentiful labor force. Mammoet transported the units to the current site inside the Arctic Circle. To this day, Red Dog remains one of the biggest nickel producers globally.

Heavy equipment transport

The relocation of draglines and other heavy equipment is another area where mine operators and their equipment suppliers can realize efficiencies and increase uptime. Moving heavy machinery in one piece presents a huge challenge but brings enormous benefits. When moving pieces of equipment weighing 8,000 tons or more, extensive preparation, attention to safety and a detailed route plan are essential. The advantages of this approach for mine operators and owners are in production time saved by the operation. Dismantling, moving and rebuilding such machines could take them out of production for months. With Mammoet’s help this can be significantly reduced.

Driving efficiency

Mammoet can optimize construction, expansion, maintenance and equipment moves while improving efficiency and reducing timelines. On each project, our professionals combine a can-do attitude with the highest regard for safety requirements. Our engineering expertise, long standing experience in mining and metals, and our state-of-the-art equipment come together to deliver a safe, high-quality execution that meets – and beats – deadlines for our clients.

New mine construction

Mammoet offers an integrated approach to the engineered heavy lifting and transport requirements of our mining and metals clients. While we are always happy to contribute to a project as a subcontractor, by working in close partnership with Mammoet from the earliest planning stages, we are able to find ways of saving time, improving efficiency, reducing downtime and enhancing safety whenever heavy lifting and transport are on a project’s critical path.

Heavy transport logistics

When commissioned to move a single large piece of mining or metal processing equipment, Mammoet's planning expertise is vital for optimizing schedules. Road quality and inclines, power lines, interchanges at ports, transport permits, bridge reinforcement – all obstacles along the route, handovers between modes of transport and regulatory requirements are carefully assessed and planned by our experienced logistics teams. Our oversize load experts know how long it takes to put all the planning of a major move into place and can prepare everything so that the move goes like clockwork and the machinery arrives as planned, ready to be put into production as soon as possible.

Maintaining and upgrading mines

Mines and metal foundries that are already in operation require the regular renewal of equipment. Equally, turnarounds to install higher-capacity production machinery can improve the overall productivity of a facility. In either case, early involvement can help ensure downtime is kept to a minimum while old components are removed and new ones installed. With input into how the new components are designed and manufactured, and knowing the specifics of their size and weight, Mammoet can help make their transport and installation feasible and find tailored engineering solutions to facilitate this. As a result, productivity can be significantly increased in the most cost-effective way.

Whatever the nature of the project, involving Mammoet's expertise during the planning phase makes it possible to identify different ways of achieving the project’s goals. Our smart engineering, combined with a fleet of state-of-the-art equipment, unlocks operational efficiencies. The goal is to optimize the heavy lifting and heavy transport needs of every project - whether it’s a new mine, a turnaround or moving a piece of specialized equipment. We ensure the maximum utilization of heavy lifting equipment, coordinating activities with other contractors, applying the highest safety standards and getting the components installed on time and on budget. This frees up the management time of our clients so that they can focus on their business of mining and metal production.

Construction options

Project logistics are dependent on a range of factors. One of the first is the method of construction. A stick-built facility may present fewer logistical challenges and therefore the upfront cost of heavy transport and lifting requirements might be lower. However, this approach often means higher construction costs and increases exposure to factors such as the weather and labor markets. Consequently, modular construction is frequently the preferred option.

Modular construction allows the main components of a mine or foundry to be built in a controlled environment, which is safer and limits the impacts of bad weather or other environmental factors. It can also take place where the right labor and skills are available. Additionally, modules can be fabricated in parallel, shortening the construction timeline. There may be higher logistical costs because numerous large and heavy components will need to be shipped to the location of the facility, but these are usually offset by the construction efficiencies gained. This is particularly the case when using one logistic contractor for the entire logistics operation – a factory-to-foundation approach.

Another major factor affecting the logistics of mining and metals operations is the plant’s location. Whether a stick-built or modular approach is taken, transporting the materials and/or components needs to take place in a safe, timely and efficient way - whether over road, rail or water.

Planning and execution

Whatever the construction approach, location or type of plant, our professionals help you decide on the best modes of transport, equipment and routes to use. We can also make design suggestions so that all the components and equipment have the structural strength, necessary lifting and fastening points and movement support points for safe lifting and transport operations. Safety is the top priority.

For an integrated approach to a project's logistics we offer a factory-to-foundation approach, which enables our engineers to work with clients to consider various options for the entire logistics chain. This service streamlines the logistics, managing the complexities with specialist skill to optimize the critical path and reduce risks.

Once the route, modes of transport and loads have been defined, a detailed timeline can be planned. This will take into account all the external factors, including permitting, infrastructure, climate and the interfaces between modes of transport such as ports and rail yards. Efficient planning will avoid unnecessary demurrage fees, but more importantly it will include contingency plans. Mammoet’s experienced project managers will produce a complete risk analysis for the project that accounts for any variables. By asking ‘What if…?’ we can prepare by developing plan B and plan C.

Whether the project involves the construction or expansion of a mine or metals plant, or moving large and heavy equipment to aid productivity, Mammoet’s logistical expertise offers the opportunity to improve efficiency and optimize the timeline. The time to market can be reduced meaning new capacity comes online in time to capitalize on improving commodity prices. Meanwhile, downtime of major equipment can be minimized in order to maximize output, boost revenue and improve the bottom line.

Digging equipment

Haul trucks, shovels and draglines are the three main types of large-scale machinery that make open-cast mining feasible, cost-effective and profitable for mining corporations on every continent. Draglines remove overburden, exposing minerals like coal and iron ore, which can then be excavated and removed using shovels and haul trucks. Each machine represents significant capital investment, but thanks to their large capacity the cost per cubic meter excavated can be minimized.

Material handling equipment

To store and load coal and iron ore, large and expensive material handling equipment such as stackers and reclaimers are used at mine sites and portside facilities. Newly purchased stackers and reclaimers must be delivered and installed onto their rail systems. However, with the increased focus on efficiency within the industry, mining companies also aim to maximize equipment utilization by relocating such equipment. Either way, having the equipment in place and operational is crucial to productivity.

Maximizing uptime

Downtime for any equipment reduces productivity, eating into the bottom line. It can occur whenever maintenance is required, or when the time comes to relocate. For instance, when a mineral deposit has been mined out, mine operators face tough choices: To dismantle a 7,000-ton dragline and write it off as a capital loss or to walk it to a new location. The latter is an extremely slow and costly process due to its internal power requirements, not to mention the risk of damage en route. However, to dismantle it for relocation may also lead to excessive downtime, wear and tear on its parts, hydraulic and lubricant spillages, and on-site safety issues.

Solutions for mining companies

Mammoet offers a cost-effective alternative: moving the equipment whole, or in a few large pieces. Our team will explore the engineering and equipment solutions available; plan the lifting, loading and haulage in fine detail; run through logistics troubleshooting; cover all the safety precautions; work with local transport agencies for permits; and execute the move as part of a single, project-focused service. Moving a dragline or a stacker/reclaimer using traditional methods can take months. Moving it in one piece significantly reduces this time and makes the process more cost-effective.

Long term benefits

A significant advantage of moving a haul truck, shovel, dragline or stacker whole is that the machinery will be ready to contribute to productivity soon after arrival. It will not be compromised by the complex reassembly process, which often involves wear and tear on parts, replacing hydraulic fluids, resealing some of its systems, resolving mechanical issues and testing. Mines and ports receiving equipment in one piece do not have to set aside an area for assembly, which can be disruptive to the mine’s workflow and result in safety issues.

By moving the biggest types of digging and material handling equipment quickly and efficiently Mammoet creates new opportunities and greater flexibility for mining companies and their owners. Larger digging equipment can be brought to smaller mineral deposits so they can be excavated more cost-effectively. Safety at mines is not compromised by dismantling and rebuilding work, and the working life of major items like draglines and stackers is extended, reducing capital wastage. With downtime substantially reduced and improved productivity, there is a healthier bottom line.

Efficient transport

Mammoet’s global experience in the mining sector means we are able to help our clients optimize the use of their equipment in the most efficient way. This includes our ability to move loading stations and slurry prep facilities in one piece, and ore processing trains in the fewest possible separate loads. While lifting and transporting such large units is challenging, the time saved by avoiding complete dismantling and rebuilding of these structures is significant, not to mention cost-effective.

Each piece of equipment in an ore processing train will have its own specific lifting requirements. Our engineers are able to offer tailored solutions to meet the needs of each lifting or transporting operation. They will calculate the total weight, and identify the correct lifting points for each item. Considering the limitations and challenges of the load, and the planned route, they work with our clients to find the safest and most efficient lifting and transportation equipment and optimal method for the job.

Complex engineering

Moving loading stations with crusher equipment inside poses complex engineering challenges. They are tall structures, with a high center of gravity and uneven distribution of weight. The thorough preparation we undertake for any move will include detailed engineering drawings that take into account all the dynamics that will affect your equipment. Mammoet has developed our own specialized jacking solution for such lifts.

From cranes and jacking systems to trailers and self-propelled modular transporters (SPMTs), the range of high capacity options in Mammoet’s fleet means we are able to explore a variety of approaches to each move. That, and our expert understanding of the specific challenges involved in moving processing equipment allows us to avoid over- or under-dimensioning the solution. This means the direct costs will be controlled, while the safety, speed and smooth operation of the relocation won’t be compromised.

In the end, the real benefit is that we can optimize the schedule. By cutting the time it takes to relocate large and heavy processing equipment, Mammoet will help you ensure downtime is kept to a minimum. The machinery can go back into production as quickly as possible, keeping your mine running optimally, your customers supplied, and your bottom line in the black.

Modular construction

Modular construction techniques make it more efficient to construct the main components of a facility in factories and then ship them whole or in a small number of main segments for assembly and installation.

Based on the location of the proposed mine or plant and the transport logistics involved, Mammoet’s engineers can advise on the construction of its components so that they can be optimized for safe and efficient shipping. By bringing in engineered heavy lifting and transport experts early in the project planning phase, components and modules can be designed to take into account the forces that the units will endure when travelling by sea, road and rail. Working closely with the client, component design can be refined so that it includes elements needed to make lifting and transport operations as efficient as possible at each stage along the logistics chain.

Integrated lifting and transport

Beyond the planning phase, Mammoet has the operational skills and specialized equipment to provide a safe and efficient transport and installation service. Our optimized site wide construction approach for modular construction projects streamlines the building process. In many markets, it is typical for the construction contractor to split the operation into four separate areas – transport, heavy transport, installation and heavy lifting. Mammoet’s comprehensive service delivers oversight across all the haulage and crane requirements, helping mining companies reduce time to market, and optimize efficiency and safety.

With four contractors, each with a different scope, the interfaces between transport, lifting and installation activities are where time and money are lost. Mammoet’s appointment as the sole contractor covering these scopes of work will ensure the coordination of operations, protecting the timeline and managing the risks.

Safety first

Mines, metal processing plants and construction sites are all hazardous environments. Mammoet has a stringent approach to safety and a safe execution is always our number one priority. We know that mining customers and construction contractors feel the same way we do about safety.

Mammoet’s skilled teams all have up-to-date training that meets or exceeds local regulations. From the first engineering drawings right through the logistics and on to the execution of the project, our focus is on ensuring a safe and efficient operation. This aligns perfectly with the needs of mining clients who want to get their facilities into production quickly and without incident.

The right preparation

For all planned shutdown, turnaround and maintenance operations preparation is key. Addressing all the engineering issues during the planning stages of an operation helps manage out many of the risks and realize efficiencies. During scope meetings with the client’s team prior to a shutdown, Mammoet can provide all the information needed to prepare for the operation, ensuring clarity of roles and responsibilities between all contractors. We ensure all supply-chain contingencies are in place down to the smallest detail and provide engineered drawings of all critical lifts.

Reliable equipment

The heavy lifting, loading, transportation and installation services we offer are nearly always on the critical path of any maintenance program or turnaround operation. Equipment failures or mechanical problems can disrupt the critical path, leading to a negative impact on the schedule, and potential loss of production.

Mammoet operates a reliable, state-of-the-art fleet of equipment. Cranes are never more than 10 years old, and we couple that with a very strict maintenance regime. Not only do we exceed manufacturer requirements, but we have fluids analyzed for wear and tear to identify any issues to prevent future mechanical failure. And all our highly skilled operators recognize the value of uptime to our clients in the metals and mining industries.

Diverse solutions

Our fleet of equipment is highly maintained and contains the most diverse array of machinery available. Alongside hydraulic cranes we use gantry cranes, self-propelled modular transporters (SPMTs), jacking and skidding equipment, and more. Combining this range of tools with industry-leading engineering capabilities, Mammoet is usually able to find more than one way of lifting and transporting a heavy object. Thus we can explore different options to reduce the up-front cost of the shutdown, make projects safer and shorten the critical path so that any loss of production is minimized.

Continual improvement

After a maintenance or turnaround project, we carry out a post-shutdown review, analyzing our working methods and using client feedback to identify areas where we can improve. The aim is that when the next shutdown occurs, we have captured all the data and documented every task. We then have an outline to work from and are able to optimize future maintenance activities, produce the engineering drawings and eliminate any unplanned work or surprises on the critical path.

Safety is our top priority on any project, and our clients appreciate this because they can rely on Mammoet to meet and exceed safety requirements in the mining and metals industries. We have our own programs to develop the skills and training of all our professionals, ensuring they are continually improving and benefitting from the latest in safety and operational best practice.

Expanding old mines

The expansion of a mine that has been operating for a long period of time can have an impact beyond its direct physical premises. In many places, towns have grown up around a mining facility, and are dependent on it, thanks to the economic activity a mine can bring. Sometimes homes, businesses and cultural buildings have been built above valuable mineral deposits.

A specialist heavy lifting and transport company can offer solutions to enable mine expansion without requiring the demolition or undermining of local buildings and infrastructure. With careful planning, entire buildings and structures can be lifted in one piece, transported to a new location and set down again. This means that the community can continue to thrive alongside the mine, which is able to remain profitable.

Processing tailings

In other places, old mines and past mining activities continue to have an impact on local communities for other reasons. Tailings heaps surround many former mines and in some cases, newer and more efficient processing techniques now make it viable to recover good quality ore that remains in old mine dumps.

Operations by mining companies to remove these missed deposits not only add to their bottom line, but can help revitalize the landscape for local communities if the dumps are removed in the process. A heavy lifting and haulage specialist can help a mining operation by transporting, installing and later on removing the processing equipment for any tailings recovery operation.

With possibilities like these available, mining companies can work with local communities and government bodies to everyone's benefit. Prosperous mining activities can continue thanks to clean-ups and mine expansions, while local people get to keep their homes, businesses and buildings of cultural importance.