Building a new production facility involves numerous interfaces, tight schedules and stringent safety requirements. Topas Advanced Polymers, the global market leader for cyclic olefin copolymers, engaged Mammoet to support the construction of its new COC production plant at the Leuna chemical site in Germany. Mammoet 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", said Jens Krawczynski, Managing Director of Mammoet Germany. Working closely with the client and other contractors, the team pooled resources across heavy lifting, installation work and internal transport to streamline site operations. "Bringing all crane, internal transport and installation services together at Mammoet helped to simplify the project’s processes," explained Marcel Fahnenstich, Site Manager of Topas Advanced Polymers. As construction progressed, activity on site increased and available space became limited, with multiple trades operating in parallel. This required precise coordination, a high level of safety awareness and the flexibility to accommodate short-term schedule changes to avoid delays.
Heavy lifts and precision installation
During the construction phase, approximately 500 plant components were moved and installed. The scope covered large and heavy items such as the reactor, columns, silos, tanks, heat exchangers and furnaces, as well as numerous smaller and sensitive units including pumps, skid systems and special equipment.
The installation of twelve silos presented a specific logistical challenge. They had to be erected immediately after delivery. When the transport sequence changed at short notice, Mammoet adjusted the installation plan, avoiding additional temporary storage and unnecessary heavy lifting. Due to the relatively low weight of the silos, up to 10 t, wind and weather conditions were closely monitored. The team made optimal use of available wind windows to ensure safe installation and adherence to schedule.
Further complex heavy lifting and installation tasks followed within a confined steel structure with minimal clearance, which demanded exact planning and execution. Smaller, sensitive components such as pumps and skids were transported safely to their positions, surveyed with millimeter precision, installed and aligned. Special equipment was used for skidding and accurate positioning.
Collaboration and outcome
By providing all lifting, internal transport and installation services through a single point of contact, Mammoet simplified project execution for the customer. High availability of cranes, transport and special equipment, an experienced international team and rigorous safety standards supported efficient site operations and schedule reliability. Close collaboration with all parties, combined with flexibility in the face of short-term changes, ensured that work progressed efficiently and on time. "Mammoet has been a reliable partner from the very beginning", said Marcel Fahnenstich. "Challenges were overcome together, constructively, with trust, and on equal footing."
With the new production facility, Topas Advanced Polymers adds capacity in specialty polymers. COC polymers are recyclable, which makes them a relevant component of sustainable products and the circular economy.
