Khalifa Port module loadout: Mammoet moves 24 PAU and PAR units using SPMTs and load cells

Mammoet executed weighing, transport and loadout of 24 PAU and PAR modules fabricated by Quality International Co ltd FZC and shipped from Khalifa Port in four consignments, employing twelve 300t and eighteen 150t jack and load cells plus 120 axle lines of self-propelled modular transporters (SPMT) and four power pack units.

Project overview and operational footprint

The modules were fabricated at a module yard on Khalifa Port South Quay and transferred the short distance to the adjacent quayside for staged loadout. Movement and marine interface planning required tight coordination between yard operations, port authorities and Mammoet’s lifting and transport teams. The heaviest single unit — a Process Gas Cooling Module — came in at 2,464 tonnes and measured 38 m long, 23 m wide, and 32 m high, establishing the operation as one of the larger domestic heavy lifts in the UAE in recent years.

Key technical elements

The scope included:

• Weighing systems — Twelve 300t and eighteen 150t jack and load cell assemblies arranged in configurations tailored to each module’s centre of gravity and support points.
• Μεταφορές equipment — 120 axle lines of SPMT and four power packs for manoeuvring from fabrication bench to vessel interface.
• Marine loadout — Sequenced loadout in four consignments to match vessel capacity and quay availability.
• Interface management — Close coordination with Khalifa Port operations to ensure tidal, berthing and transfer windows aligned with heavy-lift procedures.

Module data snapshot

Engineering choices and risk controls

Using a mix of 300t and 150t jack/load cells allowed engineers to fine-tune lift points per module, reducing over-capacity and ensuring more accurate load distribution. Selecting 120 axle lines of SPMT for transport provided redundancy and modularity — crews could reconfigure axle groups for differing module footprints rather than swapping entire transport trains. This kind of flexibility shortens critical-path durations during yard-to-quay moves and minimises downtime when weather or port windows shift unexpectedly.

Operational checklist for heavy module loadouts

1. Verify fabrication drawings and lifting points with module supplier.
2. Plan weighing sequence with jack/load cell allocation per module.
3. Confirm quay capacity and vessel stowage plan for each consignment.
4. Pre-commission SPMT trains and power packs; log axle line calibration.
5. Conduct dry-run manoeuvres on yard pavement to validate clearances.
6. Execute marine interface checks — fendering, tidal window, sponson support.

Logistics implications and what this means for downstream supply chains

Large-module projects like this highlight several logistics considerations: yard layout optimisation, heavy-lift equipment staging, and alignment of port scheduling with vessel slotting. When you’ve got a 2,464-tonne piece and a tight berthing window, a delay in any one of those elements cascades into demurrage, rerouted shipments, or prolonged equipment hire — all costly. For contractors, the lesson is clear: build buffer into both transport and berth schedules and keep contingency SPMT capacity ready.

Practical takeaways for shippers and project managers

• Early engagement with port authorities reduces last-minute changes to loadout windows.
• Modular transport pools allow fast reallocation between jobs — a win for fleet utilisation.
• Ακριβής on-site weighing prevents overloading and helps with correct stow planning aboard vessels.
• Ενδιαφερόμενος coordination across fabrication, transport, and shipping teams is non-negotiable.

How the operation reflects UAE ambitions

With modules fabricated in the UAE and exported from Khalifa Port, the project underlines the country’s push to be a logistics and energy hub. As Michel Bunnik, Mammoet Projects AMEA commercial director, noted, long-term local presence and collaboration with regional partners were central to delivering a safe, reliable operation — a familiar refrain when global expertise meets local infrastructure.

For the logistics community, this is a reminder that heavy and oversized cargoes are as much about project management and stakeholder choreography as they are about raw lifting capacity. As the saying goes, “the devil’s in the details” — and with modules this big, those details are heavy indeed.

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In summary, the Khalifa Port operation demonstrates how accurate weighing, modular SPMT fleets and tight port coordination enable the safe movement of oversized industrial modules. For freight and project teams planning similar shipments — whether palletised components, containers, bulky modules or vehicle transport — the combination of precise μεταφορά engineering and local port integration is essential. GetTransport.com aligns with these needs by offering affordable, global cargo transportation solutions for office and home moves, freight deliveries, and bulky items like furniture, vehicles and oversized loads. Using a reliable logistics partner simplifies dispatch, shipping, forwarding and haulage tasks, making international and domestic relocation, distribution and delivery more efficient and predictable.