Engineering Marvel Amid Operational Constraints
In a remarkable feat of precision engineering, heavy-liftspecialist Mammoet has executed the initial phase of a critical infrastructureupgrade at thyssenkrupp Steel's oxygen steel plant in Duisburg. The projectinvolves replacing 19 massive crane girder beams, each measuring between 30 and45 meters in length, standing 5 meters tall, and weighing up to 160 metrictons. This modernization effort presented extraordinary challenges due to theconfined working environment and the imperative to minimize productiondisruptions at one of Europe's largest steel manufacturing facilities.
Meticulous Planning Prevents ProductionParalysis
Mammoet's approach to this complex undertaking began monthsbefore the first lift, with extensive planning sessions to develop a precisesequence of operations within the cramped casting hall. The company leveragedits proprietary Move3D engineering platform to create detailed digital modelsthat identified potential obstacles, assessed height limitations, andvisualized all crane positions and maneuvers. This proactive digital strategyeliminated the need for time-consuming on-site adjustments that could haveextended production downtime, demonstrating how advanced simulation technologyis transforming heavy industrial projects.
Mobile Cranes Execute Initial Beam Replacements
For the first construction phase, which involved replacingseven of the nineteen crane girder beams, Mammoet deployed a combination ofpowerful mobile cranes. Two Liebherr units, an LTM 1750-9.1 and an LTM 1650-8.1,handled most of the heavy lifting for the first five beams. Due to the limitedspace within the casting hall, these massive structures had to be transportedupright using two six-axle Self-Propelled Modular Transporters. This approachrequired precise coordination between lifting and transport teams to ensure thesafe movement of components weighing as much as a commercial aircraft.
Custom Gantry Solution Overcomes AccessibilityChallenges
When faced with beams inaccessible to conventional mobilecranes, Mammoet's engineers developed a bespoke gantry system that showcasedthe company's problem-solving capabilities. This custom solution featured twotowers supporting transverse skid tracks across the hall, with a longitudinalbeam equipped with two movable strand jacks installed on these tracks. Theinstallation of this specialized system presented its own challenges, as itneeded to be erected over existing plant components that could not be dismantled.Three additional mobile cranes, a Grove GMK 6450-1, a Grove GMK 5250L, and aLiebherr LTM 1095-5.1, were brought in to construct this temporary liftinginfrastructure.
Innovative Load Distribution Protects FacilityInfrastructure
One particularly challenging aspect of the project involvedpositioning a heavy crane over a basement area beneath the casting hall. Toaddress this structural concern, Mammoet implemented an innovative loaddistribution solution using extra-long mats that transferred the Grove GMK6450-1's operational forces to the building's side walls rather than directlyonto the floor above the basement. This engineering adaptation protected thefacility's structural integrity while enabling the necessary lifting operationsto proceed safely.
Synchronized Precision Maneuvers Under Load
The two crane girder beams handled by the custom gantrysystem required an intricate choreography of synchronized movements. Each beamwas initially lifted by two strand jacks and moved across the skid trackstoward the hall center. The beam was then carefully transferred in stagesbetween the strand jacks and mobile cranes, with the 750-metric ton capacityLTM 1750-9.1 and the LTM 1650-8.1 working in precise coordination. The confinedspace necessitated multiple telescoping adjustments of both mobile cranes whilesupporting the massive load, a delicate operation requiring exceptionalcommunication between all team members.
Collaborative Success Sets Stage for FuturePhases
René Xyländer, Director Operations at Mammoet in Germany,emphasized the importance of teamwork in the project's success: "Thecooperation between all parties involved and the Mammoet teams in Europe andGermany was crucial to the success of this project. The 3D engineering and theunique technical solution with several mobile cranes and a customized gantrysystem helped to meet the tight schedule." With the first constructionphase now safely completed on schedule, preparations are underway for thesecond phase of the crane girder replacement program, which will continuethyssenkrupp Steel's modernization efforts at this critical productionfacility.
Key Takeaways:
* Mammoet successfully replaced seven 160-metric ton cranegirder beams in the first phase of a 19-beam modernization project atthyssenkrupp Steel's oxygen plant in Duisburg
* Advanced 3D modeling technology eliminated on-sitemodifications, saving valuable production time and ensuring precise executionin the confined casting hall environment
* A custom-engineered gantry system with movable strandjacks provided access to otherwise unreachable beams, demonstrating innovativeproblem-solving for complex industrial challenges
