Express Global Logistics (EXG), member to the Worldwide Project Consortium (WWPC) in India, 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 45 ton to nearly 700 ton single piece weight, with some of the largest structures measuring up to 35.5 metres in length, 21.6 metres in width, and 25.2 metres in height. The campaign required the deployment of 48 SPMT axle lines, specialized barges, and marine tugs to execute the load-out and marine transportation operations safely and efficiently.
Engineering and planning before execution
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.
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.
One of the most technically demanding aspects of the project was the installation of a 466 ton 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 6-metre 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 8 metres before being positioned onto the pre-installed pile caps.
The entire operation was carefully synchronized 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.
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 specialized offshore installation of the 466 ton 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 specialized 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.
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www.exglogistics.com
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