Summary
The Challenge
Mantoria managed the relocation of two oversized refinery reactors and 39 accessory units weighing more than 1,217 MT, including one reactor that became the heaviest unit ever lifted using ship’s gear in BBC Chartering’s history. The project also required continuous nitrogen monitoring to preserve reactor integrity throughout transportation and storage.
The Solution
An engineered project cargo approach utilizing a 4,100-ton floating crane, a multipurpose heavy-lift vessel, specialized stowage planning, and custom lashing arrangements.
The Result
Safe loading, ocean transport, and discharge into bonded storage in South Korea, completed with zero reported incidents and full reactor preservation maintained end to end.
Client
Canadian Oil and Gas Company.
Industry
Energy / Oil & Gas
Scope
Heavy-lift cargo supervision, vessel loading coordination, marine surveying support, stowage planning, cargo securing, and reactor preservation management.
Route
- Port of Higashiharima, Japan
- Sebang Gwangyang Dock, South Korea
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The Technical Challenge
Moving Over 1,200 MT of Critical Equipment
The project involved transporting critical process equipment consisting of oversized reactors and numerous accessory components:
- 2 Reactor Skids
- 4 Accessory Skids
- 35 Accessory Cases
- Total Cargo Weight: 1,217.73 MT.
Key Hurdles:
- Record-Breaking Heavy Lift: one reactor represented the heaviest cargo ever lifted by ship’s gear within BBC Chartering’s operating history, requiring exceptional lift planning and execution.
- Asset Preservation Requirements: reactor condition had to be maintained through continuous nitrogen pressure monitoring, inspections, and adjustments during transit and storage.
- Heavy-Lift Requirements: the reactor units could not be handled using conventional cargo loading methods and required a dedicated floating crane.
- Operational Coordination: multiple stakeholders (the shipper, vessel operator, surveyor, stevedores, and crane operators) had to work within a tightly controlled loading window.
- Cargo Integrity: high-value industrial equipment required careful lifting, stowage, and securing procedures to ensure safe ocean transportation.
The Mantoria Solution
Precision Heavy-Lift Execution
Mantoria coordinated all critical aspects of the loading operation to ensure cargo was moved safely from berth to vessel.
Strategic Equipment Selection
Because of the reactors’ size and weight, specialized lifting assets were required.
- Heavy-Lift Loading: the reactors were lifted using the floating crane, with a lifting capacity of approximately 4,100 tons.
- Ocean Transport: cargo was loaded aboard the heavy-lift multipurpose vessel MV BBC SPRING.
Specialized Reactor Preservation Program
Beyond transportation, Mantoria implemented a preservation strategy to protect the reactors throughout the relocation process.
- Continuous monitoring of reactor nitrogen pressure levels.
- Routine inspections throughout the voyage.
- Corrective adjustments whenever pressure levels required intervention.
- Ongoing preservation management during bonded storage in South Korea.
Risk Mitigation & Execution Highlights
- Pre-loading inspections and surveyor oversight throughout the operation.
- Dedicated heavy-lift procedures for the two reactor units.
- Separate loading strategy utilizing vessel cranes for accessory packages.
- Detailed stowage planning within the vessel’s cargo hold.
Secure Transport Begins with Proper Stowage
- Record-Setting Heavy Lift: one of the reactor skids became the heaviest reactor ever lifted using ship’s gear in BBC Chartering’s history. Successfully completing this operation required detailed engineering reviews, lift calculations, cargo weight distribution analysis, and experienced heavy-lift supervision.
- Preserving Critical Processing Equipment: unlike conventional project cargo, the reactors required active nitrogen preservation management. Mantoria coordinated inspections and pressure monitoring throughout the transport and storage phases to maintain equipment readiness and prevent internal contamination.
- Multi-Layer Securing Methodology: cargo was secured using steel wire rope lashings, web belts, and welded steel plate stoppers designed to prevent cargo movement during ocean transit.
- Heavy-Lift Vessel Compatibility: the vessel’s multipurpose design provided the cargo hold dimensions and lifting capability required for large industrial equipment.
- Surveyor Verification: marine surveyors confirmed that all cargo was properly stowed and adequately secured before vessel departure.
Quantitative & Qualitative Results
Despite the complexity of the heavy-lift operation, the shipment was completed successfully.
- 1,217.73 MT Successfully Relocated: all reactor and accessory cargo transported and placed into storage safely.
- Record-Breaking Lift Achieved: successful execution of the heaviest reactor lift ever performed using ship’s gear in BBC Chartering’s history.
- Zero Cargo Damage: cargo integrity maintained during lifting, ocean transport, discharge, storage, and preservation activities.
- Continuous Equipment Preservation: nitrogen monitoring and inspection program protected the reactors during transit and storage.
- End-to-End Project Cargo Management: single-source coordination involving heavy lift, marine transport, terminal handling, storage, and preservation.
The team at Mantoria always provide top tier service. Fast quotes, fast replies and always ready to help with any of your freight needs. They are competitive with their pricing and stay on top of your freight. No worries when Mantoria is in control of my shipments.
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FAQ
How do you transport oversized and heavy industrial equipment?
Oversized and heavy equipment is typically transported using a combination of heavy-lift cranes, breakbulk or project cargo vessels, specialized trailers, and engineered loading and securing methods. Each shipment requires a customized transport plan based on the cargo’s dimensions, weight, and destination.
What industries use heavy-lift and project cargo services?
Heavy-lift and project cargo services are commonly used by the energy, oil & gas, mining, infrastructure, manufacturing, power generation, and construction sectors when moving large or critical equipment.
What should companies look for in a project cargo logistics provider?
Companies should look for experience in heavy-lift transportation, multimodal logistics, risk management, regulatory compliance, cargo engineering, and end-to-end project coordination to ensure safe and on-time delivery.
Why choose Mantoria for project cargo and heavy-lift logistics?
Mantoria provides end-to-end project logistics solutions, including heavy-lift transportation, breakbulk shipping, cargo supervision, engineered transport planning, storage solutions, and global project cargo coordination for complex industrial shipments.
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