As the global specialist in pipeline mats and crawler crane mats, Ko-Mats GmbH has embraced the opportunities presented to it by the wind industry. It provides end-to-end solutions for many of the challenges that turbine logistics companies face, through a large stock of mats for sale or hire. We spoke to the company’s August Oude Hengel…
PES: The monopiles used in offshore turbines are getting bigger by the year. How do your products cope with the massive forces involved?
August Oude Hengel: Based on the properties of the different materials and their weight, contractors have a wide scope of different timber varieties. The physical properties of the timber species are the basis for the performance of the timber mats.
Depending on the duration of the project, the weight of the different materials and equipment, and how the mats should perform, one can choose anything from European softwoods up to tropical hardwood. We have built up a strong name for tropical hardwood mats, and enjoy an especially strong position worldwide. Furthermore, we can serve any continent with tropical timber mats as we ship them with containers. Our two different production locations offer huge shipment benefits from a cost point of view
PES: Let’s talk about preventing accidents. Can you explain a little about how your products help to improve dockside safety?
AOH: In recent case studies, 40% of all crane accidents are either due to bad load spreading or bad ground conditions. Timber mats in general are a very cost-effective and easy way of minimising these risks (especially tropical timber mats). In most of the European nations, regulations have been made (or are being made) that say that timbers mats must be used as standard during heavy lifts, just to prevent accidents.
An investment made in a set of timber mats is surely not a loss. In most cases, the project can be executed more efficiently and the safety is up to the maximum standard.
PES: Out of interest, what are the ground conditions like in the docks where you operate? Is this a factor for you?
AOH: Depending on the age of the port, the quays have different bearing capacities. To meet the current requirements, as loads are getting heavier and bigger pieces are handled in one piece, ports subscribe to the project that peak loads per m2 may not exceed more than X ton/m2. In normal conditions, the recently-developed ports have quay sides with concrete or asphalt which is good enough, in combination with the timber mats, to meet any requirement. In fact, the timber mats also protect the infrastructure in the ports as well, and this means that after the project no additional costs will come from repairing the site.
PES: What different materials do you use and what are the characteristics of these materials?
AOH: We have two production locations, with our main production base situated in Germany. Here we have invested in the latest CNC technology to make the world’s best matting machine available. Depending on the project requirements, we can offer a whole range of different timber species, all with their own benefits. Furthermore, as timber mats are being used for a number of different applications, we produce timber mats of pine up to the strongest tropical timber species. We have selected a number of tropical timber species which are the strongest in the world – our main criteria are the bending strength, grain, durability and elasticity.
PES: Can you explain how the process works with regards to initiating and carrying through a project? At what stage would you typically become involved?
AOH: In most cases, the project has been planned already and is starting up. It is then up to the project partners themselves or the supplier of the lifting/crawler crane machinery to determine who is responsible for meeting the port requirements.
In the cases where a project is going to take seven to eight months or longer, it is worthwhile to invest in buying mats rather than renting them. In most cases, the timber mats are used as temporary crawler crane road in the port or on deck of pontoons.
Depending of the scope of the project, the mats are supplied at the first stage, or shortly after the crane arrived. In most projects the timber mats are being used multipurpose. For temporary roads, this would be to bear heavy parts such as blades and or turbines and as protection for the heavy machinery used during the project.
PES: Given your increasing role in the offshore sector, what’s your assessment of the market right now? Are things improving from your perspective?
AOH: The world is constantly developing and the need to look for energy resources and renewable energy recourses will keep on going for the foreseeable future. This presents a lot of construction activities in many different segments and both onshore as well offshore. This need to look for additional energy resources is the motor behind an industry where heavy lifting, project forwarding and constructions sites go hand-in-hand. Timber mats play what is sometimes a crucial role from a safety point of view, as well as a way to enhance efficiency in the usage of heavy equipment.
PES: Where does your competition come from and how do you guard against losing business?
AOH: Competition comes from different angles. Mats can be made of plastic or steel, whereas neither are able to beat the timber mats in general and certainly not form a CO2 perspective. Either the physical properties of the material are not good enough, or the size of the material needs to be so different to meet the same properties as timber, making it either too heavy to transport or the comparative logistics cost exceed the costs involved in using mats.
Timber still holds a very strong position in the construction market and is often undervalued. We also constantly review our production methods and are looking for new materials to enlarge our product portfolio.
PES: You’re based in Germany, but where are your prime markets? Are there any ports that you’re looking to exploit further?
AOH: Our prime markets have been in and around Europe, Western Europe primarily. Our clients, however, are looking also for international projects as well, which is helping us to explore more of the world. Our company is based just on the border with The Netherlands and Germany, making international logistics easy as major Ports like Rotterdam and Antwerp are not far away.
As our other production location is situated in Guyana (Latin America), we are very well set up to serve any port in the world. We are very proud to have supplied almost every continent with our timber mats. As the world is getting smaller and smaller because of internet and international communication we are going the exploit the international markets as well and are always open for business opportunities.
PES: What are your thoughts about prospects for the coming year with regard to your organisation, and the wind industry in general?
AOH: The wind turbine producers are focussing on increasing the ROI for investors and on creating new technologies and products. This will help big investment groups to play safe and invest in wind energy for its green credentials and to become part of the solution of the global need for more energy. The offshore wind industry is developing with the same speed and there are still a lot of projects due to start. We see a lot of opportunities for our company to develop in the coming years.
Case study: Ko Mats and Windpark Noordoostpolder
Ko Mats have recently supplied 700 timber mats (size 150 x 5,000) on a sale or and buy-back agreement to the massive Windpark Noordoostpolder, Netherlands.
Perhaps unsurprisingly for Holland, the large (Enercon) turbines will be erected in an area below sea level. And as conventional techniques have proven time and again, timber mats offer the best solution as temporary transportable working platforms and construction roads up to the location of the turbines.
Ko Mats stepped-in with an option to quickly supply tropical timber mats, which are an even better option in severe conditions. The mats were evenly distributed and laid out according the site manager’s instructions.
And given that the windmills are being erected alongside the line of the coast, the transport of the different components is a complex logistical puzzle – just one of the three blades weighs up to 75 tons on its own. In fact, to lift the different components heavy crawler cranes are used. The crawler cranes are also well equipped with tropical timber mats and occasionally with steel mats.
In brief: KO-MATS’ notable projects
Windpark Noordoostpolder
Enercon have laid the foundations for 38 E-126 turbines,part of a major Dutch 86-turbine wind farm.
Amrumbank West
KO-MATS are heavily involved with this major project (288MW) from developer E.on in the North Sea.
West of Duddon Sands
A major project, it will comprise 108 wind turbines with a total installed capacity of 389MW and ensure clean energy for more than 300,000 UK households.
Butendiek
Located in the German Bight, Butendiek offshore wind farm consists of 80 wind turbines, each with a capacity of 3.6 MW.
