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Heavy lift specialist Mammoet has wrapped up the relocation of a massive 3,100-tonne Marion 8050 dragline at the Peak Downs coal mine, operated by BHP Mitsubishi Alliance in Queensland, Australia. The project moved the giant excavator 27 kilometers across the site, showcasing advanced transport techniques that slashed downtime and boosted efficiency for one of the country’s busiest coal operations.
The dragline, a workhorse in open-pit mining, digs up vast amounts of earth to expose coal seams. But its size makes self-movement slow and cumbersome—like trying to walk a skyscraper across a field. Traditionally, these machines crawl at a snail’s pace, covering just one kilometer every 12 hours. That inefficiency prompted BMA to call in Mammoet, experts in oversized cargo shifts, to handle the job with modern tools.
Engineers started by lifting the dragline using eight JS500 jacking towers. These hydraulic systems raised the machine 2.5 meters off the ground in a controlled manner. Once elevated, workers positioned it onto a fleet of Self-Propelled Modular Transporters, or SPMTs. Configured in a 5-by-28 line setup, these trailers spread the weight across 560 tires, keeping ground pressure under nine tonnes per square meter. This prevented the unit from bogging down in the mine’s varied terrain.
SPMTs, essentially remote-controlled platforms with independent wheels, allowed the team to haul the dragline at speeds up to five kilometers per hour. Imagine coordinating a convoy of trucks that move as one, powered by onboard diesel engines. This setup eliminated the need for extra gear like portable power stations or trailing cables, which older methods required. BMA prepared the route by placing steel mats over soft spots, ensuring the transporters stayed stable. In Queensland’s scorching heat, Mammoet added a canopy and air-conditioned control box to the lead SPMT, keeping operators focused and safe.
One of the toughest challenges came at the Aurizon rail crossing. This line carries coal from multiple mines to export ports, making it a vital artery. Any prolonged disruption could halt shipments and rack up huge losses. Mammoet had a tight 72-hour window during a scheduled shutdown to build a temporary ramp, cross the tracks, and restore everything. They nailed it without a hitch, avoiding delays that might have stretched into months.
The whole operation, which could have dragged on for over a month using conventional walking techniques, finished in just 10 days. Teams averaged eight kilometers per day, a pace that minimized interruptions to coal production. This speed not only saved time but also reduced wear on the dragline itself, as SPMTs provide a smoother ride than the machine’s own tracks.
Compared to past approaches, the JS500 jacking system stood out for its simplicity. Older methods used climbing jacks and stacks of timber, demanding more labor and equipment. The new towers needed fewer units and cassettes—small support blocks—that cut setup time and removed risky manual handling. Safer for workers, quicker for the project.
This marks only the second time in Australia that SPMTs have relocated a dragline this way. The first happened in 2017, also by Mammoet for BMA at another site. It underscores how specialized logistics can transform mining operations, where every hour of uptime counts.
Laura Ewen, Mammoet’s branch manager, explained the rail crossing’s importance: “One of the key reasons that BMA reached out to us was because the Aurizon rail crossing is a critical line, transporting coal for export from various mines.”
Jack Whittaker, project manager at Mammoet, highlighted the jacking benefits: “The JS500 system requires fewer jacking towers and uses cassettes. This saved a lot of time, resulted in less equipment and removed the need for manual handling.”
The project drew on Mammoet’s global experience in heavy transport for mining. From oil rigs to wind turbines, their engineers tackle loads that defy gravity. At Peak Downs, the relocation ensured the dragline could resume stripping overburden sooner, supporting BMA’s output in a competitive market.
Industry watchers note how such innovations address mining’s pain points: high costs, safety risks, and environmental pressures. By shortening moves, companies like Mammoet help mines operate with less fuel and fewer emissions per ton of coal extracted.
Queensland’s coal sector, a powerhouse for Australia’s economy, relies on these feats to stay productive. Peak Downs, one of the largest metallurgical coal mines, produces millions of tonnes annually for steelmaking worldwide. Keeping equipment in the right spot without long halts keeps the supply chain flowing.
