Heavy lift specialist Mammoet has helped install Germany’s first large-scale carbon capture and utilisation (CCU) plant for the cement industry, using 3D engineering to navigate tight spaces and complex construction logistics at Heidelberg Materials’ Lengfurt site.
The CCU facility, being developed by Linde Engineering in partnership with Heidelberg Materials under the Cap2U joint venture, marks a major step in efforts to decarbonise cement production—a sector known for its high emissions. The plant is designed to capture and liquefy carbon dioxide from the production process for further industrial use.
Given the space constraints and coordination required among multiple contractors, Linde Engineering brought Mammoet into the project at an early stage. This early involvement allowed the team to carry out a detailed feasibility study a year ahead of construction. Using its proprietary 3D modelling tool, Move3D, Mammoet mapped out the site’s existing infrastructure and potential challenges, allowing all parties to better plan lifting and installation activities.
The heart of Mammoet’s solution was a 750-tonne crawler crane, chosen for its ability to operate efficiently within the limited working area. Detailed planning ensured the crane’s track could be kept compact, reducing disruption on-site.
Mammoet’s scope included the transport of large components, defining work zones for pre-assembly, and setting up the crane for heavy lifting. The team also suggested layout adjustments to the plant’s design to streamline installation—recommendations that ultimately saved time and reduced costs for the client.
The most complex lift involved the 100-tonne absorber column, which was first raised in a tandem lift and then rotated nearly 180 degrees before being carefully guided into position behind a structure. The column, 55 metres long, had to be precisely aligned and secured to its foundation.
This was followed by the installation of a 67-tonne stripper column, four tanks weighing 72 tonnes each, and a 178-tonne heat exchanger. The crawler crane’s flexibility in lifting a variety of components without needing intermediate transport proved key to maintaining efficiency.
In the final weeks before execution, Mammoet adapted the crane’s configuration to support pre-installation work and parallel construction activities. This last-minute change helped further compress the construction schedule.
The success of the project was credited to detailed 3D planning, early coordination, on-site engineering oversight, and a strong collaborative approach between Mammoet, Linde, and Heidelberg Materials.
The Cap2U plant, once operational, will serve as a model for how heavy industry can integrate carbon capture technologies while keeping construction safe, efficient, and cost-effective.