MINING BROCHURE

WORLDWIDE HEAVY TRANSPORTATION AND LIFTING

 CONTENTS
TOGETHER, WE ARE...
04 Overview
06 Mining Operations and Process Facilities
Our people are at the heart of ALE’s business: dedicated professionals who work
08 Maintenance
with our clients to achieve the very best results. How do our people make us smarter?
Because we employ imaginative people in every aspect of our business. People who 12 Material Handling
work together to challenge the conventional, develop innovative solutions for complex
problems and push the boundaries to make the unworkable work. 18 Turnkey
20 Front End Engineering & Design (FEED)
21 Risk Management in ALE through HSQE
ALE is a responsible business with a strong moral core. From the people who make
24 Sectors
up the ALE team, to the clients we work for across the world and the local community
whose daily lives we may impact, the safety and well-being of these individuals and 25 Services
their environment is our most important concern. This ethos permeates every aspect
of our business. By taking collective responsibility and working together to mitigate 26 Equipment
risk in every project we undertake, we can build a safer future. 27 Innovation Series

We haven’t become one of the world’s foremost experts in heavy transportation

and lifting by thinking small. By investing in the latest technologies and employing
the best people in the business, we’ve grown over more than 30 years, earning the
fundamental reputation as a global leader across a breadth of sectors and markets.
No matter the size or scale of a project, our people take a flexible approach that our
clients can depend upon to deliver a bespoke and agile service unique for them.
Our people work together to create innovative solutions, to achieve the unachievable
and ultimately make it happen.

2 Together, we are Smarter, Safer, Stronger 3

 OVERVIEW
The mining sector is a key area for ALE and we provide a variety of
techniques and services to address different mine development and
operational challenges.

With vast experience in mining projects and the engineering expertise to allow clients to
explore more cost-effective construction methods and mining operations, ALE can provide
complete solutions to the challenges faced in this industry.

An appreciation of the control of loads and their distribution, a fleet of Self-Propelled

Modular Trailers (SPMTs) and cranes, proven expertise in lifting, skidding and jacking
techniques and meticulous project management means we are well equipped to move
enormous structures with minute precision.

ALE is always looking at innovative solutions and designing bespoke equipment to ensure
that the best result for the client is found, this innovative thinking and close working with
the client can often change the project to save on time and costs.

4 Together, we are Smarter, Safer, Stronger 5

 MINING OPERATIONS AND
PROCESS FACILITIES

ALE has the transport equipment and experience to execute the

movement and on-site relocation of modularised plant components
and mobile mining plant and equipment.

This typically includes manoeuvring crushers, conveyers, excavators, draglines and other
process equipment when the mine or process facilities are being expanded or relocated
according to the mining strategy. Our innovative equipment fleet allows us to reduce
downtime of the tracked plant and relocate items safely between locations and provide
cost savings on road preparation and maintenance. We also have the innovative solutions
to work within confined spaces and to industry-leading safety standards.

6 Together, we are Smarter, Safer, Stronger 7 7

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 MAINTENANCE

ALE has the specialist lifting equipment to perform on-site maintenance of

different mining plant and equipment.

Our high capacity cranes, lift’n’lock lifting systems and jacking systems are a more favourable option to
traditional mobile jacking systems as mobilisation costs are reduced and safety risks are mitigated as loads
are statically supported, alleviating any risk of working under suspended loads. Our unique and innovative
Mega Jack, Mega Jack 800 and Mega Jack 300 systems provide a quicker and safer option as they are
remote-controlled and minimise personal interaction and manual handling.

8 Together, we are Smarter, Safer, Stronger 9 9

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 Maintenance

CASE STUDY
Transportation and installation of flow enhancement hoppers, Australia

OVERVIEW: ALE has completed the transportation and
installation of two 145t hoppers for the TLO Fines Flow
Enhancement Project in Western Australia.
SERVICES REQUIRED: The hoppers had to be transported
from a storage position of 1,100mm stool height, which
was located 100m from the foundations, along a sloped
path. The transport also included a 90° carousel to align
the hoppers to the foundations.
A multiple lashing system ensured the stability of the
system for stand-by, including storm and wind issues, as
well as for service condition. Spirit levels were installed
to monitor the levelling of the assembly. The installation
assembly was designed to minimise the work at height and
other typical risks related to lifting operations.
To provide the flexibility and manoeuvrability needed, ALE
used 24 axle lines of SPMT in a 2 x 2 file 12 configuration
to transport the hoppers. ALE used a lift‘n’lock system
mounted onto the trailers to install the hopper.
ALE had to overcome the challenges of operating in a
live BHP mine site, complying with very strict safety and
environmental requirements. There was limited ground
preparation permitted (levelling and compaction), due to
the short time of the shutdown. Flexibility was needed to
accommodate a limited site area and many interferences
with other contractor activities.
There was no allowance for the installation of tracks
onto the ground, beside the foundations, because of the
interference with the client activities on the foundations
of the hoppers. Subsequently, the hoppers were installed
just under the existing conveyor in a very small installation
area. This avoided the use of any crane for the installation
and the derigging of the hoppers.
This was the first time this methodology had been
executed so efficient engineering and operational
experience was needed to obtain the permit to proceed
from FAST and BHP.

The hoppers, with approximate dimensions of 11m x 9m

x 4m, were installed at ground level within the 10mm
tolerance. The installation of both hoppers was safely
performed within the client’s timeframe, without any
impact on the surrounding activities. ALE only had 48 hours
only to complete the two installations and to leave the
installation area. Each hopper was picked up, transported,
positioned and derigged in a single shift.

10 Together, we are Smarter, Safer, Stronger 11


MATERIAL HANDLING
ALE has a proven track record of installing,
relocating, or decommissioning of heavy
stock piling and handling of port infrastructure
and components, such as stackers, reclaimers
and shiploaders.
ALE has a global fleet of equipment, with some of the
most advanced SPMTs and cranes, to enable the safe and
successful transportation, lifting and assembly of mining
components at ports.
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CASE STUDY
Transportation of a crusher, Chile
OVERVIEW: ALE has completed the transportation
of a crusher, weighing 720t, at Minera Escondida,
near Antofagasta, Chile.
SERVICES REQUIRED: The crusher was loaded
onto 36 axle lines of SPMT in a configuration
of 6 file 12.
ALE transported the crusher a total of 6km
on SPMTs.
During the move, ALE overcame steep up-hill and
down-hill gradients. At certain points on the route,
ALE transported the crusher on an up-hill gradient
of approximately 11.4% and down a slope of 12%.
The manoeuvres took approximately five hours
to complete.
Together, we are Smarter, Safer, Stronger 13 13
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 Material Handling
CASE STUDY
Excavator move, Australia
OVERVIEW: ALE has successfully transported
a 6060 excavator, weighing 570t, over 12km at
the South Walker Creek Mine, near Strathfield
in Queensland.
SERVICES REQUIRED: ALE was also required to
provide and lay-out the load-spreaders, mats and
wedges. These enabled the loading and offloading
of the excavator at both ends.
ALE positioned the mats in the morning, before
positioning the excavator on top of the mats.
The excavator was then positioned on top of 27
axle lines of SPT and the loading platform was
raised. The trailers were prepared for the move
by lashing.
The excavator was then transported over a
distance of 12km over three hours. Once in
position, the excavator was offloaded and ready
for work.
The move was completed within one working day.
Together, we are Smarter, Safer, Stronger
CASE STUDY
Transportation of stacker and
reclaimer modules for the
Nammuldi mine project, Australia
OVERVIEW: ALE received and transported 190 stacker
and reclaimer modules as part of the Nammuldi mine
expansion project.
SERVICES REQUIRED: As part of the expansion of the
Nammuldi iron mine, 190 modules were received at
Port Hedland in two shipments between November 2013
and January 2014.
Some of the modules have been received from the ship
cranes directly on the road trailer arrangements, while
some others have been received on self-propelled trailers
and stooled-off at the port laydown. For most of the major
modules, dedicated transport grillage had to be designed
and checked by ALE engineers; the steelwork design for
some items had to consider also the need for stooling off.
The modules were then transported by road 500km
from the port of Port Hedland to its final destination at
Nammuldi mine site, where they would be assembled.
A total of 20 steel beams and 60 steel stools were used
to transport and store the modules.
42 of the modules measured up to 52m long, 10m wide,
7.5m high and weighed 150t. Because of the size, these
were subject to road transport restrictions and the convoy
required a pilot and a main road traffic warden escort.
The biggest movement was of the 150t reclaimer boom,
which measured 72m long, 7.4m high, 9.5m wide and
weighed 297t gross mass. To move the boom, ALE utilised
two prime movers, 18 axle lines of conventional trailers
and 18m of deck spacers.
The last of the counterweights and small cargo was
delivered in early April 2014.
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 Material Handling
CASE STUDY
Transportation of an electric shovel, Australia
OVERVIEW: ALE has successfully transported a
1,400t electric shovel within the Bowen Basin area
of Queensland, Australia.
SERVICES REQUIRED: The 1,400t electric shovel was moved
approximately 35km using 54 axle lines of SPMT.
As the onsite transportation had to be scheduled around
the removal of powerlines to adjoining mines, ALE needed
to ensure there was a swift turnaround by utilising the
most time-effective method of relocating the electric
shovel. ALE completed the transportation in seven days
while overcoming the challenges that are part of working
on an operating mining site.
Movements of this nature, involving large mobile plant on
SPMTs, results in significant savings in maintenance of the
running gear of the plant and in down-time of high-value
equipment on operating mine sites.
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CASE STUDY
Jacking, transportation and load-out of two
autoclaves, New Caledonia
OVERVIEW: ALE has successfully performed the jacking
and transportation of two autoclaves, weighing 605t
each in New Caledonia.
SERVICES REQUIRED: ALE first loaded the autoclaves
onto the SPMTs at the New Caledonia storage site,
using the SPMTs’ hydraulics to jack them up ready for
onward transportation.
The autoclaves were then transported from New Caledonia
to the Port of Prony jetty using 72 axle lines of SPMT. The
3.8km route was particularly challenging as it involved
travelling over 2km on a 10% gradient descent.
They were then loaded-out onto a heavylift vessel, along with
the SPMTs, and shipped to Port Pirie in South Australia.
Once they arrived at the port, ALE loaded-in the autoclaves
using the same SPMT configuration and transported them
into storage.
It took approximately one month to complete.
Together, we are Smarter, Safer, Stronger 17
 Material Handling
CASE STUDY
TURNKEY RGP6 Jimblebar mine project in Port Hedland, Australia
OVERVIEW: ALE were tasked with the
receiving, storage, and land transportation
of 230 modules, with weights ranging
ALE is a full solutions provider and the between 5t and 240t.
turnkey service includes full engineering
assessment and design of any bespoke SERVICES REQUIRED: The 230 over-sized
and over-mass modules were used to
lifting equipment. construct the RGP6 Jimblebar Iron
Ore project.
Our extensive equipment fleet and experiences Fabricated in China, these modules were
means we are a ‘one-stop-shop’ and have the shipped from Tianjin to Port Hedland,
capabilities to execute projects from start to finish, Western Australia. The 230 modules were
from barging and handling modules at the port, and received in over 11 shipments, with the
the transportation to site, to the on-site manoeuvres first received in June 2012 and the last
modules were delivered to site in Newman
and installation.
by late February 2013.
The modules were received on SPMTs
at Port Hedland Port Authority (PHPA),
before being transported within the
PHPA grounds and set on stools to await
ground transportation on conventional
trailers. Configurations of both SPMTs
and conventional trailers was dependent
on each modules’ dimensions and weight
– the latter to accommodate for Western
Australia’s axle-loading restrictions. The
largest module was 42.5m long, 13.5m
wide, 14.5m high and 227t in weight and
the largest trailer configuration comprised
of a 4 file 28 row (6.3m wide, 42m long).
Transportation from Port Hedland to the
Jimblebar Mine site (totalling 450km) was
split into four segments, each requiring
one night of travel time. The first of which
saw the modules (one per trailer) travel
18 Together, we are Smarter, Safer, Stronger
in convoy from Port Hedland to Boodarie
– a staging area located 25km outside
of Port Hedland. From here convoys to
the Jimblebar site are formed, with the
highest priority items given precedence
in earlier convoys to site.
As public roads were utilised for ground
transportation, and Western Australia
law states that cargo over 8.5m wide
cannot travel during daylight hours,
ALE organised and conducted night-time
convoys within a rolling road-block under
the guidance of Police Traffic Escorts.
ALE faced the challenge of reserving and
obstructing public roads and required
the cooperation of multiple public
stakeholders and external bodies.
ALE had to work alongside various
transport companies to determine suitable
transport dates and road- access into
and out of the world’s largest bulk export
harbour every night a convoy took place
on the road. The route also had to negotiate
multiple railway crossings of various mining
companies in a prompt manner as to not
cause delay to their deliveries.
ALE had a dedicated SPMT crew
located at the Jimblebar site on a
full-time basis, equipped with 40 axle
lines of SPMT trailers and 12 axle line
of compatible spacer decks. As modules
were placed on stools upon arrival at
Jimblebar, SPMTs then transported
the modules to various site locations –
sometimes up to 5km in distance.
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 FRONT END ENGINEERING & DESIGN (FEED)
With a pedigree in innovative engineering and an active R&D facility, ALE has always been
known for developing new solutions to meet future needs. In other market sectors ALE is
actively involved in the FEED process.

Over the years we’ve added to our world-class engineering skills-base through the acquisition of several successful
specialist companies, and now we have more than 200 highly qualified engineers working at locations across the globe.
This experience means we’re well equipped to support the full FEED process, working through complex technical and
logistical issues at an early stage to eliminate expensive changes later on.

Our FEED capabilities form a crucial part of the service we offer. ALE has contributed to many high profile projects that have
been right at the forefront of global trends in their sector. We are able to adapt to ever-changing industry requirements,
evolving safety standards and scope changes as the project gathers definition during the design process, while at the same
time providing solutions which are as cost-effective and safe as possible. As a result, we’re able to work closely with our
clients from an early stage to establish what’s required and provide practical engineering advice. This advice can lead to
savings later, either in time or cost, as the changes are included in the design phase, instead of modifications later.

Some of our FEED services typically include, but are not limited to, the items below:

• Physical route surveys to determine maximum practical
equipment weight and dimension information
• Investigation of environmental conditions affecting the
heavy lifting and transport discipline
• Road layout and route improvement studies
• Advice on local regulatory issues relating to the movement
of large and indivisible loads to the job site
• Equipment lifting and installation studies to determine the
most cost and schedule effective methods of sizing and
placing equipment
• Design of rigging and lifting equipment
• Outline design of new build site construction jetties
• Selection of optimum shipping methods and identification
of suitable vessels or barges
• Logistical studies to ensure that transportation and
installation scope support the project schedule
• Design and input to design of transportation support steel
and lifting and lashing/securing points
• Assistance in modularisation studies to determine the
maximum practical extent man hours can be removed
from the job site

20 Together, we are Smarter, Safer, Stronger 21 21

 RISK MANAGEMENT IN ALE THROUGH HSQE
We recognise that the industries and
sectors that we operate in present
challenges in terms of managing risk.
Our passion is fuelled by our history
and foundation in protecting our people,
environments and assets all over the globe.
ALE is cemented in a context of over
30 years of evolving Risk Management
though maturing legislation, international
standards and client requirements. We
as ALE see the value in a safer working
environment for all and we want to
capitalise on our history and better
mitigate industry risks.
By investing in our constantly evolving
internal infrastructure, we are able to
maintain our competitive advantage with
industry leading initiatives that allow us
to implement and use breakthrough tools
to identify, assess and act upon all levels
of risk to our people, environments and
assets. This has given us the ability to
identify areas that require attention as well
as nominate single areas of concern to
target resources.
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ALE are committed to lead the industry
and influence all of our clients and
subcontractors in a united approach to
achieving an incident and injury-free
mindset. In order to achieve this, we
have developed and adopted many of
the leading systems and processes that
are seen as industry best practice and
available techniques.
We have ensured that our core systems
which shape the way we operate are
certified and proven to comply with ISO
9001 and 140001, as well as OHSAS 18001.
ALE know that it is imperative to not only
attain the certification but to also have a
robust assurance process in place to ensure
that the standards are met and maintained.
At ALE, we realise that this journey is not to
be taken in isolation, therefore we stand by
the fact that together we are safer.
Together, we are Smarter, Safer, Stronger 23 23
 SECTORS SERVICES

CIVIL MINERALS & METALS NUCLEAR BALLASTING CRANE LIFTING ENGINEERING JACKING

OFFSHORE OIL, GAS & PETROCHEMICAL PORTS LIFTING SYSTEMS LOAD-IN & LOAD-OUT LOGISTICS MARINE ENGINEERING

OFFSHORE INSTALLATION SKIDDING TRANSPORTATION TURNKEY OPERATIONS WEIGHING

POWER GENERATION RENEWABLES SHIPYARDS

24 Together, we are Smarter, Safer, Stronger 25

 EQUIPMENT INNOVATION SERIES

CRANES
SKID SYSTEMS WEIGHING SYSTEMS

SPECIALIST CRAWLER MOBILE

BALLAST SYSTEMS JACKING SYSTEMS

TRANSPORTATION MEGA JACK AL.SK CRANES ALL TERRAIN TRANSPORTERS

GIRDER FRAME MODULAR TRAILERS BARGES AUXILIARY, ANCILLARY &

ACCESS EQUIPMENT

SPMT SPT
HYDRO DECK MEGA JACK 800
LIFTING SYSTEMS

26 Together, we are Smarter, Safer, Stronger 27

INFO@ALE-HEAVYLIFT.COM
WWW.ALE-HEAVYLIFT.COM

WORLDWIDE HEAVY TRANSPORTATION AND LIFTING