Engineered heavy lift and transport major, Mammoet, has played a major role in the construction of UPM Biochemicals’ biorefinery in Leuna, Germany. It is UPM’s first biorefinery to produce wood-based biochemicals, making a step ahead towards a sustainable future, where recyclable products will be made from biochemicals, replacing fossil chemicals. 

In its latest case study, Mammoet said it has supported this unique construction project from the very beginning as a general contractor for most of its transport, lifting and installation scopes. This has helped to optimise the critical path of the project and increase the efficiency of its construction.

Moving large and heavy components such as columns, evaporators, reactors, tanks, and chromators was planned using Mammoet’s 3D engineering tool; Move 3D. This allowed the team to perform a lot of engineering in advance, overcoming many obstacles before even setting foot on site.

Among other tasks, Mammoet installed ten columns, delivered 20 tanks, and created a special rigging scheme for lifting silo roofs.

Heavy columns

Mammoet used its large crane technology to install ten columns weighing from five to 170 tons. The columns were stored in installation order on a narrow pre-assembly area to avoid swinging over stored components.

As the construction work progressed, the large construction site became increasingly cramped. Therefore, all the work had to be carefully planned and coordinated with the other trades on the site. For instance, the main boom of the crawler crane had to be shortened, and the dredging mats had to be repositioned before the largest column, weighing 170 tons and measuring 65 metres, could be installed safely in a restricted area.

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Transport study, special rigging, flexible schedule

A study was done to find the best transport route for 20 GPI tanks, each weighing 21 tons and with a height of 23 metres. The tanks could only be transported upright in a vertical position, with a transport width of 7 metres. The tanks were pre-assembled and loaded onto two SPMT axle lines with an auxiliary structure, and each tank was weighed down with 40 tons of additional ballast. The tanks were transported safely to the installation site and lifted onto their foundations.

Two 30-metre diameter silo roofs, each weighing 58 tons, were lifted using a special rigging scheme with 18 anchor points and a 70-degree angle to avoid material deformation risks. Almost no wind was needed. The mobile crane was moved according to the schedule between the lifts.

Mammoet’s team adapted to changes in column installation and performed additional lifting work within schedule using their own crane and transport fleet. They reacted quickly to changes and installed all essential components on time. The UPM Leuna biorefinery will bring in a new, sustainable era for the chemical industry.

Jonas Bartzschke, Branch Manager at Mammoet in Leuna, Germany, said, “We not only successfully contributed to the construction of the biorefinery with our crane, transport and installation solutions. We were also able to use our experience to help manage the complexity, optimise the critical path and increase the efficiency of the construction. Above all, we are proud to be part of this groundbreaking project that will pave the way for a more sustainable chemical industry.”