Express Global Logistics (EXG) have handled the heavy lift load-out and offshore installation for a major liquid cargo berth extension.

"Complex marine infrastructure projects demand more than the movement of heavy structures. They require detailed engineering, precise equipment deployment, marine coordination, and complete control over every stage of execution. For this major liquid cargo berth extension project, Express Global Logistics (EXG), together with its group company Megaload, successfully executed a comprehensive heavy-lift load-out and offshore installation campaign involving multiple critical marine structures."

The project involved the handling of 18 heavy-lift structures, including concrete topsides, jackets, berth platform structures, and LPU decks. Individual cargo weights ranged from 45mt to nearly 700mt, with some of the largest structures measuring up to 35.5m in length, 21.6m in width, and 25.2m in height. The campaign required the deployment of 48 SPMT axle lines, specialised barges, and marine tugs to execute the load-out and marine transportation operations safely and efficiently.

Engineering and Planning Before Execution

Given the varying dimensions, weights, and centres of gravity of the structures, every movement was treated as an individual engineered operation. Detailed transport calculations, axle load distribution assessments, ballast plans, sea-fastening studies, and load-out methodologies were prepared before mobilisation.

Each marine operation underwent a dedicated stability assessment based on the cargo configuration and barge characteristics. Customised ballast plans and sea-fastening arrangements were developed and reviewed to ensure safe cargo transportation. Detailed method statements, risk assessments, contingency plans, and coordination with the Marine Warranty Surveyor (MWS) formed an integral part of the pre-execution planning.

The use of 48 SPMTs enabled controlled handling of the heavy structures from the fabrication and staging areas to the load-out location. Precise axle load distribution was particularly important while manoeuvring the cargo and maintaining stability during the transfer onto the barges.

Heavy Lift Load-Out and Marine Transportation

The project involved multiple load-outs across different barge configurations, requiring flexibility in both engineering and execution. Each structure was positioned and transported based on its individual centre of gravity, structural configuration, and load distribution requirements.

Following the SPMT movement, the cargo was transferred onto the designated barge through controlled load-out operations. Stern-on mooring arrangements were planned according to the jetty conditions and barge geometry to maintain positional stability during the transfer.

Once the structures were positioned onboard, engineered sea-fastening arrangements were installed to secure the cargo for marine transportation. Ballasting operations were continuously managed to maintain the required vessel trim, draft, and stability throughout the operation.

The marine transportation phase required close coordination between the barge, tug operators, shore teams, marine crews, and project engineers to ensure safe movement of the heavy structures.

A Key Engineering Milestone: 466mt Trestle Installation

One of the most technically demanding aspects of the project was the installation of a 466mt trestle structure. Considering the site constraints and operational requirements, EXG adopted an Alternate Lifting Strand Jack System rather than relying on conventional heavy-lift cranes.

The solution was incorporated into the project planning from the initial stage, allowing the team to develop a controlled lifting and installation methodology well before execution.

The operation involved a controlled 6m vertical lift, followed by the transition of the trestle into the load-out configuration for marine transportation. Once offshore, the structure underwent a further controlled lift of approximately 8m before being positioned onto the pre-installed pile caps.

The entire operation was carefully synchronised with approved tidal windows, wave height limitations, and wind speed parameters. Continuous monitoring and precise coordination between the lifting, marine, and offshore teams ensured accurate positioning of the structure.

Managing Challenges Through Prepared Engineering Solutions

The campaign involved several operational challenges, including the handling of multiple heavy structures, varying barge configurations, limited manoeuvring areas, tidal restrictions, and strict offshore environmental parameters.

However, these operational constraints were identified during the planning stage itself. Customised engineering solutions were therefore developed in advance, including dedicated ballast plans, sea-fastening studies, stern-on mooring arrangements, and cargo-specific SPMT configurations.

For the trestle installation, redundant lifting arrangements, real-time load monitoring systems, remote-controlled operations, and detailed lift simulations were incorporated into the methodology to enhance safety and operational control.

The execution schedule was also carefully coordinated to optimise equipment utilisation and minimise marine spread duration, ensuring that the operations progressed efficiently without unnecessary downtime.

Project Outcome

Through meticulous planning, detailed engineering, and disciplined execution, EXG and Megaload successfully completed the handling and load-out of 18 major heavy-lift structures along with the specialised offshore installation of the 466mt trestle.

The successful execution demonstrated the group's capabilities across SPMT transportation, heavy-lift load-out, marine engineering, barge operations, sea fastening, ballast management, and offshore installation.

"This project stands as a strong example of EXG's ability to deliver complex marine infrastructure logistics through a combination of specialised equipment, advanced engineering solutions, proactive planning, and precise execution—ensuring that every transition, from yard movement to offshore installation, is carried out safely and under complete operational control."

http://www.exglogistics.com