Dyckerhoff Cement Plant from Germany to the Urals

Customer Profile

Dyckerhoff, within the group of companies belonging to the Italian Buzzi Unicem Group, is a specialist for innovative building materials solutions in the field of cement and concrete. Since 1864, Dyckerhoff has produced Portland cement, hydraulic binders and specialty products. Dyckerhoff’s operative business is divided into three divisions: Germany/Western Europe; Eastern Europe, which includes Poland, Czech Republic, Slovakia, Russia and the Ukraine; and the USA.

Customer Challenge

Dyckerhoff needed a reliable partner that could handle the heavylift and out-of-gauge transport of an entire cement plant from Germany to Siberia. The plant equipment to be moved included 50,000 cubic meters of cargo and two round 150- ton cement mills. The final destination for the transport was in a remote location that lacked basic infrastructure. Another obstacle in the transport of this cement plant was customs clearance. Strict local regulations require the commitment and professionalism of customs experts, especially when it comes to the delivery of large equipment, delivered in partial consignments.

Agility’s Solution

A team of Agility specialists from Germany and Russia developed a solution for Dyckerhoff after a feasibility study was presented. The study showed the natural routes - consisting of waterways and overland trucking - were best for this particular transport, the project was executed in two phases. In phase one, 17 vessels were dispatched in Germany and travelled to St. Petersburg by sea. Agility was able to clear the shipment through customs without offloading. The vessels then proceeded down the Volga-Balt River, covering over 1,500 kilometers to Perm for overland transportation to the final site. In phase two, another 9 vessels were addressed and cleared in St. Petersburg port, where cargo was reloaded to rail wagons and sent to the final destination directly.

Agility created a second solution for the two 150-ton cement mills. They traveled on one of 17 aforementioned vessels from Germany to St. Petersburg. Once in St. Petersburg, the mills were dropped off in Dzerzhinsk and reloaded onto barges. The barges carried the cargo down the river to the Polazna quay, where it was offloaded onto trailers with the Ro-Ro method, which required construction of a berth and a road, in order to connect the improvised quay and a main motorway. Heavylift of the mills covered over 650 kilometers to Sukhoi Log, crossing approximately 30 bridges and 30 viaducts. To do this, more than 200 power lines were lifted and many gas pipelines had to be cut down. Agility’s team of experts was able to safely relocate the cement plant for Dyckerhoff allowing the company to continue its development in Siberia.

Special Services for Dyckerhoff

• Feasibility study, which was critical in defining the route
• Arrangement of optimal routes and transportation rates
• Customs clearance at customs terminal of Saint Petersburg under a classified conclusion
• Construction of piers and road enhancements
• Temporary elimination of obstacles hindering movement of large-scale items