Mammoet moves huge crusher for Codelco

Mining equipment is huge and heavy, and it is always being moved from one place to another. Once resources have been mined, the equipment must be demobilized and moved to another location to start its work all over again.

But moving mining equipment is a complicated process, as was the case for Codelco, Chile’s state-owned copper mining company that operates mines near the city of Calama.

The crusher was extracted from its housing using skid tracks and skid shoes, before being lifted into the air high enough for SPMT to move underneath. Photo: Mammoet

Codelco sought support from Mammoet to move key crusher parts from one site to another, about 4.5 kilometers away. There were 16 components to be moved, and the six largest pieces make up the main part of the crusher system that extracts materials from mines and breaks them down into smaller pieces.

Codelco had never carried out an operation of this size before. It approached Mammoet for guidance on the best heavy lifting and heavy transport equipment, as well as engineering solutions to achieve its goal. Engineers at Mammoet proposed a series of different extraction methods to allow the key components to relocate as whole units – reducing cost and resulting in the project finishing earlier than expected, according to Mammoet.

This project marked the first time Mammoet had worked directly with Codelco, and the first time that this site had needed to relocate a crusher. Planning the route, methodology and the heavy lifting and transport equipment to carry out the operation was the first step, with engineers at Mammoet supporting throughout every stage.

“We worked with Codelco for a year and a half on the planning,” said Mammoet sales manager Vanessa Labana. “We created all the route plans and drawings and supported them to answer all the questions and considerations they had to face on site. For example, the correct slope, turn ratios, and width of the road to facilitate the fastest transport route.”

One of the biggest challenges was sourcing and mobilizing the equipment and personnel for a project of this scale. Mammoet’s team pooled its global resources, using self propelled modular transporter (SPMT) that came from Malaysia, skidding systems from the USA, and additional equipment was sourced from Colombia.

Different approaches

There were six key components to relocate, and the method for removal and transporting was different for each. Most were lifted using climbing jacks and then relocated with SPMT fitted with support beams. For the drive system, this same approach was used, but with the addition of a skidding system. This was used to slide the component 12 meters, before it could be jacked down into its final position. The two heaviest items to perform heavy transport and heavy lifting for were the silo (1,100 tonnes) and crusher itself (1,300 tonnes), with the latter being the most complex of the six cargo movements.

“We created a support beam that was especially adapted for this cargo,” said Labana. “We had to make some alterations to our original beams by applying lead reinforcements on top, at the four lifting points, to prevent deformation”.

A team of 70 people, and a total of 160 axle lines of SPMT, eight skid shoes (500 tonnes), eight jacking systems (400 tonnes), as well as support beams, rails, and lashing, were used across the project. Photo: Mammoet

The crusher was extracted from its housing using skid tracks and skid shoes, before being lifted into the air high enough for SPMT to move underneath. Lashing was used to add additional support and hold everything in position during the 4.5 km journey. An area close to the demobilization location was created to allow the crusher to be rotated 180 degrees so it would be in the correct position for installation.

Once it arrived at the installation site, the earlier process was repeated in reverse, with SPMT trailers lowering the cargo onto skid tracks to slide it back into its new position. The gallery unit was also a challenge, due to the ground soil not being completely level, with a 1 per cent slope. As a result, two hydraulic jacks were used to perform heavy lifting on its back end at three different intervals to keep everything level as it was skidded forward.

The operation was completed in just over a month, taking less time than was expected, mainly due to crusher parts being removed as complete units. This allowed the mine to get back up and running quickly. Labana said Mammoet managed the team, equipment and engineering steps to deliver the project safely and efficiently; mobilizing everything to site on time and avoiding costly delays and penalties. A team of 70 people, and a total of 160 axle lines of SPMT, eight skid shoes (500 tonnes), eight jacking systems (400 tonnes), as well as support beams, rails, and lashing, were used across the project.

“If this project had been done this in a conventional way, Codelco would have needed to cut and disassemble the equipment, and this would have taken a lot of time”, Labana explained. “This is the first time Codelco has done something like this. With us, they have a partner for future projects due to trust in our experience, equipment and background.”

Chile's state-owned copper mining company Codelco sought support from Mammoet to move key crusher parts about 4.5 kilometers away. There were 16 components to be moved. Six huge pieces made up the main part of the crusher system that extracts materials from mines and breaks them down into smaller pieces. Photo: Mammoet