3D Engineering and Mammoet Crawler Crane Precision Drive CCU Plant Construction at Heidelberg Materials’ Lengfurt Site

30-Second Takeaway

Mammoet played a critical role in constructing Germany’s first large-scale carbon capture and utilization (CCU) plant at Heidelberg Materials’ Lengfurt site by combining early-stage engineering expertise with advanced 3D planning. Using its proprietary Move3D platform and a 750-ton crawler crane, Mammoet safely installed oversized columns, tanks, and heat exchangers within extremely confined conditions. Early engagement enabled optimized crane positioning, reduced site congestion, improved safety, and significant time and cost savings demonstrating how digital engineering and heavy lifting expertise are accelerating low-carbon industrial projects.

Mammoet is actively contributing to the decarbonization of the industry by delivering safe and efficient solutions for the transportation and installation of heavy objects. This commitment was exemplified during the construction of the first large-scale Carbon Capture and Utilization (CCU) plant at the Lengfurt site of Heidelberg Materials, a leading global manufacturer of building materials.

Leveraging its extensive engineering expertise and years of experience, Mammoet was engaged by Linde Engineering to devise a comprehensive lifting and installation strategy for a range of large components.

Engaging early in the process promotes effective planning.

The confined space and the involvement of multiple contractors necessitated meticulous planning of workflows, interfaces, and construction timelines. A comprehensive feasibility study was conducted a year prior to the execution phase, during which various solution options were thoroughly analyzed and evaluated.

Utilizing a 3D model of the existing cement plant, Mammoet's team effectively employed its proprietary engineering platform, Move3D, to visualize the intricate processes, spatial requirements, and potential conflicts within the confined construction site. This visualization enhanced the understanding of the planned operations for all stakeholders and facilitated improved coordination.

The implementation of a 750-ton crawler crane emerged as the most adaptable and efficient solution for the safe and timely lifting and installation of large components within the constrained construction environment. With the aid of three-dimensional planning, the crawler track for the crane was minimized, thereby reducing the impact of lifting operations.

Mammoet's strategy encompassed the delivery of large components to the construction site, the planning of pre-dressing areas within the swing radius of the crawler crane, and the setup of the crane for heavy lifts.

By engaging early in the process, Mammoet's team was able to offer invaluable recommendations for modifying the layout of the CCU plant to meet installation requirements. Furthermore, the spatial considerations were integrated into the overall construction site logistics, resulting in a safe, efficient, and seamless execution that ultimately saved the customer both time and costs.

Ensure secure installations with a versatile crawler crane solution.

Initially, the 100-ton absorber column was erected in the pre-dressing area utilizing a tandem lift technique. The load was maneuvered nearly 180 degrees on the crawler crane's hook and transported approximately 20 meters to its designated installation position. At this location, the column required meticulous guidance behind a building before it could be accurately positioned, aligned, and secured to the foundation within the steel structure.

Given the absorber column's 55-meter length and the intricate nature of the lifting operation, this represented the most formidable heavy lift encountered during the project.

Subsequently, the installation process included the 67-ton stripper column, four tanks each weighing 72 tons, and ultimately, the 178-ton heat exchanger.

Mammoet's crawler crane solution provided several essential benefits. The crane's flexibility enabled it to safely lift loads of various sizes and weights over extended distances, thereby eliminating the need for intermediate transport on site. To facilitate pre-installation and concurrent construction of the steel structure, the crawler crane's configuration was modified shortly before the project's commencement, resulting in significant time savings.

The early engagement of Mammoet, combined with 3D engineering, diligent oversight by planning engineers on-site, and a collaborative approach characterized by openness, solution orientation, and trust, played a pivotal role in the project's success.

About Mammoet

Mammoet is a global leader in heavy lifting, engineered transport, and installation solutions, supporting the world’s most complex industrial, energy, and infrastructure projects. With roots dating back more than 200 years, Mammoet has built an unrivaled reputation for executing technically demanding lifts in confined, high-risk, and high-consequence environments.

The company operates one of the largest and most advanced fleets of crawler cranes, ring cranes, SPMTs, and heavy transport equipment in the world, enabling lifts well beyond 3,000 tonnes. Mammoet is also a pioneer in digital lift engineering, utilizing proprietary tools such as Move3D to simulate crane configurations, load paths, ground bearing pressures, and site interfaces before execution.

Mammoet plays a critical role in the energy transition, supporting projects across carbon capture and storage (CCS), carbon capture and utilization (CCU), offshore wind, hydrogen, nuclear, and industrial decarbonization. Through early contractor involvement and precision planning, Mammoet helps clients reduce risk, shorten schedules, and improve safety while delivering measurable cost efficiencies.

Website 🔗 https://www.mammoet.com

About Heidelberg Materials

Heidelberg Materials is one of the world’s leading manufacturers of cement, aggregates, ready-mixed concrete, and building materials, operating in more than 50 countries with thousands of production sites worldwide. Formerly HeidelbergCement, the company is at the forefront of transforming the construction materials industry toward low-carbon and circular production models.

The company has made carbon capture technologies a cornerstone of its sustainability strategy, recognizing cement production as one of the most challenging sectors to decarbonize. Heidelberg Materials is actively investing in carbon capture, utilization, and storage (CCUS) technologies, alternative fuels, and innovative production methods to significantly reduce CO₂ emissions across its operations.

Projects such as the CCU facility at Lengfurt demonstrate Heidelberg Materials’ commitment to combining industrial-scale innovation with real-world execution, supported by advanced engineering, heavy lifting expertise, and cross-industry collaboration.

Website 🔗 https://www.heidelbergmaterials.com

About Linde Engineering

Linde Engineering is a global leader in industrial gas processing plants, hydrogen technologies, and decarbonization solutions, delivering complex EPC (engineering, procurement, and construction) projects worldwide. As part of the Linde Group, the company leverages decades of experience in chemical processing, cryogenics, and large-scale industrial systems.

Linde Engineering is a key driver of carbon capture, carbon utilization, and hydrogen infrastructure projects, supporting industries such as cement, steel, chemicals, and energy as they transition toward lower-emission operations. The company provides end-to-end solutions from conceptual design and feasibility studies to detailed engineering and plant construction.

In CCU projects like the Lengfurt facility, Linde Engineering plays a central role in plant design, process integration, and construction management, ensuring captured CO₂ can be safely processed, liquefied, and reused at industrial scale.

Website 🔗 https://www.linde-engineering.com

About Cap2U (Capture-to-Use)

Cap2U (Capture-to-Use) is a joint venture between Heidelberg Materials and Linde, established to design, build, and operate industrial-scale carbon capture and liquefaction facilities. The initiative focuses on capturing CO₂ emissions directly at the source and converting them into usable industrial products, rather than storing them permanently underground.

The Cap2U project at the Lengfurt cement plant represents a major milestone for carbon utilization in Germany, demonstrating how heavy industry can integrate advanced capture technologies into existing production environments. The project combines process engineering, heavy lifting, modular construction, and digital planning to overcome space constraints and operational challenges.

Cap2U serves as a model for future CCU deployments across Europe, showing how collaboration between material producers, engineering specialists, and heavy lifting experts can accelerate decarbonization while maintaining industrial competitiveness.

Website🔗 https://www.heidelbergmaterials.com

Website🔗 https://www.linde-engineering.com

Project Highlights & Crane Operations

• Crawler crane capacity: 750 tonnes

• Largest lift: 178-ton heat exchanger

• Tallest component: 55-meter absorber column

• Heaviest vertical lift: 100-ton absorber column (tandem pre-dressing lift)

• Engineering tools: Mammoet Move3D (3D simulation & clash detection)

• Key benefit: Eliminated on-site rehandling through long-radius lifting

Frequently Asked Questions

Why was 3D engineering critical for this CCU project?

The Lengfurt site presented severe space constraints with multiple contractors operating simultaneously. Mammoet’s Move3D platform allowed engineers to simulate crane movements, load paths, and interfaces in advance reducing risk, avoiding clashes, and improving coordination.

Why was a crawler crane selected instead of mobile cranes?

The 750-ton crawler crane offered superior load handling, long-radius lifting, and the ability to move loads directly on the hook. This eliminated the need for intermediate transport and reduced overall site congestion.

What were the most challenging lifts?

The most demanding lift was the 55-meter-long, 100-ton absorber column, which required a tandem pre-dressing lift, a 180-degree rotation on the hook, and precision placement behind an existing structure.

How did early contractor involvement benefit the project?

Early engagement allowed Mammoet to influence plant layout, crane access routes, and pre-dressing zones resulting in safer lifts, faster execution, and measurable cost savings.

How does this project support decarbonization?

The CCU facility captures and liquefies CO₂ emissions from cement production, directly supporting Heidelberg Materials’ and Linde’s sustainability and carbon-reduction goals.

U