Mammoet was tasked with the load out of seven modules for offshore construction specialist Estaleiros do Brasil.
The modules were being built in Brazil and destined for FPSO integrations abroad; the challenge was to have the modules in active production as soon as possible.
The modules – some weighing up to 2,200 tonnes, each with dimensions exceeding 30 m x 18 m in size – were to be transferred from the quay to a waiting ship. Phase one of the project would transfer the first four modules, and phase two the remaining three.
A challenge presented itself during the first phase, as there were limited feasible jacking points available underneath the module. These are strengthened areas, built into a module’s design, that allow it to be lifted from underneath by large jacking systems. As there was not sufficient time to reinforce the structure of each module, an alternative solution had to be found. Hydraulic heavy-duty trailers provided the answer.
Each module would be lowered sequentially using the hydraulic course of the trailers rather than traditional jacking equipment. In turn, each module was weighed, jacked-down to the correct grillage height, then loaded-out onto the ship within a precise timeframe.
Phase two of the operation, which included the three final modules, was successfully completed a few months later. During this phase, only the weighing and load-out was required. To complete this scope, Mammoet’s team mobilised the same 96 axle lines of PST/THP trailers as previously used, a large selection of weighing and auxiliary equipment, and staff from every corner of the Americas to ensure the job was done on time.
During phase two, the largest module measured over 29.9 m in length and nearly 38 m in height; each module tipped the scales at 2,200 tonnes.
Mammoet project manager, Alvaro Campos, said: “One of Mammoet’s greatest challenges was the mobilisation time since we were asked to deliver with very short notice and the required equipment was in various locations across Brazil.
“We managed to get everything to site on time thanks to the hard work of a very professional crew and we pulled out a safe execution, which was praised many times by our final clients and brought them much relief.” Both phases were effectively delivered for end customers Modec and Cameron/SBM respectively.