1,100 axle lines used, over 50% of them from Goldhofer
Starting in August 2022, Prism Logistics, one of India’s leading project logistics companies, embarked on a record-breaking transportation project that concluded in July 2023. This ambitious project involved the transportation of massive columns and reactors from Hazira, Dahej, and Mangalore to Pachpadra, Rajasthan.
With dimensions reaching up to 55 meters in length, 10 meters in width and height, and weights of approximately 750 tons per unit, a total of 34 over-dimensional cargoes were transported over a challenging 600 km route. In total, the project saw the movement of 12,582 tons of heavy cargo. Prism meticulously prepared and organized this monumental task, utilizing around 1,100 axle lines and more than 115 self-propelled modular transporters (SPMTs), over 50% of which were Goldhofer axles.
The initial phase involved shipping the cargo from Hazira, Dahej, and Mangalore by sea to Mundra. For the first time in India, Prism employed side-loading and side-unloading techniques using Goldhofer’s self-propelled PST modules. These advanced modules provided the precision and maneuverability necessary to handle the complex operation in confined spaces effectively.
Starting in December 2022, the cargo departed from Mundra Port in seven convoys towards the Rajasthan Refinery, a major refinery-cum-petrochemical complex in Barmer, Rajasthan.
The road journey from Mundra to Barmer, covering 600 km, presented significant challenges. Prism’s teams had to navigate five railway level crossings in Gujarat and one in Rajasthan.
Coordination with Indian Railways was essential to secure permits and temporarily close routes at the level crossings. Additionally, Prism needed to secure permits for the temporary shutdown of numerous high-tension and regular electricity lines—more than 1,000 in total—to ensure safe passage for the convoys. Skilled technicians removed road furniture, including poles, culverts, welcome boards, city navigation boards, electric wires, and small structures over highways, promptly resolving any issues that arose during the journey.
One of the most formidable challenges was crossing the Narmada River Canal, which supplies water from Gujarat to Rajasthan. Prism required political liaison between the two states to obtain an official permit to stop the water flow for 15 days. This allowed for the construction of two steel bridges, each with a capacity of 1,500 tons, in record time, ensuring the convoys could cross the canal.
Another significant challenge was navigating a 135 km single-lane road from Gudamalani to Balotra. With convoys extending over 2 km in length, regular traffic was significantly disrupted. Prism’s teams worked tirelessly to cover the route as quickly as possible. Additionally, Prism constructed a major bypass at Balotra to cross the Luni River, avoiding the existing road bridge.
All 34 over-dimensional cargoes safely reached their destination in Barmer, Rajasthan, in a record time of 364 days. A dedicated team of over 400 professionals, including civil, mechanical, and marine engineers, and naval architects, designed and executed innovative solutions for this unprecedented project. This project is not only a milestone in Indian logistics but also contributed significantly to infrastructure development and employment.
Jean-Philippe Martin, Director of Sales International Business at Goldhofer, commented on the success: “We are honored that Prism Logistics, one of the largest project logistics companies in India, chose to rely primarily on Goldhofer’s transportation solutions for this record-breaking milestone in heavy haulage history. Our primary goal is to establish a partnership with our valued customers that is based on reliability and innovation. We are successful when our customers are, and we therefore congratulate Prism Logistics on the impressive completion of the project.”
Prism Logistics’ monumental efforts were also recognized at the Heavy Lift Awards 2023, where they won the prestigious Goldhofer-sponsored category “Overland Transport Provider of the Year.” The judges were impressed by the sheer scale of the project, the size of the cargoes, and the distances covered, overcoming numerous obstacles and challenges to ensure success.
