Efficient support in the construction of a state-of-the-art production plant for COC polymers

Building a new production facility is a complex undertaking with numerous interfaces, tight schedules, and high safety requirements. Since any delay can lead to a later start of production, processes must be planned precisely and interfaces coordinated seamlessly.

TOPAS Advanced Polymers relied on Mammoet's expertise to build its new, state-of-the-art production plant at the Leuna chemical site in Germany. Mammoet’s team was responsible for planning and executing all crane services and equipment installations - including internal transport from the interim storage area to the construction site.

“With our extensive experience in large-scale and complex installation projects, our international team of skilled experts, and our modern crane and transport fleet, we were able to provide reliable support during the construction phase”, says Jens Krawczynski, Managing Director of Mammoet Germany.

Pool resources, optimize processes

Working closely with the client and other contractors, the Mammoet team took on key tasks in the planning and execution of all heavy lifts, installation work, and internal transport. This ensured the efficient use of resources and seamless operations on the construction site.

“Bringing all crane, internal transport and installation services together at Mammoet helped to simplify the project’s processes,” explains Marcel Fahnenstich, Site Manager of TOPAS Advanced Polymers.

As construction progressed, activity at the site steadily increased, while available space became limited. Numerous trades worked in parallel, requiring a high degree of precision, coordination, and safety awareness.

At the same time, flexibility was needed to react to short-term schedule changes and avoid delays.

Efficient installation with maximum precision

During the construction phase, around 500 plant components, including large and heavy items such as the reactor, columns, silos, tanks, heat exchangers, furnaces, and numerous smaller and sensitive units like pumps, skid systems, and special equipment, had to be moved and installed.

The installation of twelve silos posed a particular logistical challenge. They had to be installed just after their delivery. When the transport sequence changed at the last minute, Mammoet adjusted the installation plan. This avoided additional temporary storage and heavy lifting.

Due to the relatively low weight of the silos (up to 10t), close monitoring of wind and weather conditions was required for their installation. The team made optimal use of the available wind windows and ensured that all silos were installed safely and on schedule.

Further complex heavy lifting and installation work followed in the confined steel structure with minimal clearance, demanding exact planning and execution.

The smaller, sensitive components, such as pumps and skids were also moved safely and efficiently to their installation position. They were surveyed with millimeter precision, installed, and aligned. Special equipment was used for skidding and exact positioning.

A trusting collaboration

With its strong track record in large and complex installation projects, high availability of cranes, transport, and special equipment, an experienced international team, and the highest safety standards, Mammoet was able to simplify its customer’s project through the provision of all lifting, internal transport and installation services through a single point of contact.

Close collaboration with all parties and a high degree of flexibility in the event of short-term changes ensured that all work could be carried out efficiently and on schedule.

"Mammoet has been a reliable partner from the very beginning", highlights Marcel Fahnenstich. “Challenges were overcome together – constructively, with trust, and on equal footing.”

With its new production facility, TOPAS Advanced Polymers is setting another milestone in the manufacturing of specialty polymers. COC polymers are recyclable, which makes them an important part of sustainable products and the circular economy.