The cargo was loaded on four separate voyages at the Yanda Module Yard in Jiangsu, China, with the largest piece weighing 690 metric tonnes, and measuring 28 metres in length, 17 metres in width, and 26.7 metres in height.

“This was a particularly challenging project which required the use of three of our vessels on four separate trips operating at their full capacity, including HHL New York, HHL Lagos, and HHL Valparaiso,” said Henry Woo, Head of Asia-Pacific (APAC), HANSA HEAVY LIFT.

“Lifting and rigging were particularly challenging for this project due to the height of the modules combined with the offset centre of gravity, with up to five lifting beams required for a single lift.

“Our team of in-house engineers managed this by developing innovative rigging solutions as well as enacting a careful loading and engineering plan.”

The decks of each vessel were extended to the aft and in some cases even to the starboard side to accommodate up to five modules per trip.

The over dimensional cargo required the installation of additional bow radars and the extra crew to double up bridge watches.

Due to the sensitivity of the structures and expected rough seas during the voyages, the lashing and securing of the cargo represented another challenge.

Such sensitivity required new types of sea fastening that had to be tested and certified by HANSA HEAVY LIFT.

Further measures were put in place to minimise the impact of the obstructed view from the wheelhouse.

Crews also faced strict draft limitations and narrow navigation channels on both ends of the voyages.

Modules had to be placed carefully onto the self-propelled modular transporter with minimum clearance in between each vessel’s hull and the fixed structures on the wharf to overcome the limited space on the jetty in Port Pirie.

Loading took place under adverse weather conditions in China, which included snow, rain, and freezing temperatures.

At the port of discharge, crews had to deal with temperatures of up to 45C in Port Pirie.

“We are proud to have completed the project with a smooth execution at every stage, resulting in a safe and on-time delivery of all modules,” said Jens Grever, Head of Cargo Management, Asia, HANSA HEAVY LIFT.

The Port Pirie Redevelopment Project will convert one of the world’s largest primary lead smelting facilities, operated by Nyrstar, to a multi metals processing and recovery facility.

Ben Williams, Project Co-ordinator, from Geodis added that HANSA HEAVY LIFT demonstrated a “very high level of engineering expertise and professionalism” throughout the entire process, from planning to delivery at the port of discharge.

“HANSA HEAVY LIFT took every detail into consideration, as well as keeping a clear and open line of communication throughout, once again proving themselves to be a reliable super heavy lift partner.”