The ambitious project to transport massive steel converters began in 2019 when a leading steel manufacturer sought to decarbonize its French operations. Ahlers Logistics was brought on board during the initial planning phase to handle the complex logistics of moving two converters and top cones, with a combined weight of 900 metric tons, to the Dunkirk facility.
Initially planned as a direct shipment from China to France, the project faced its first major pivot due to COVID-19 supply chain disruptions. The manufacturing location was shifted to Gijón, Spain, requiring Ahlers to completely redesign their logistics approach. This change brought new challenges, particularly due to the Spanish facility's limited port infrastructure, including a low-draft berth unsuitable for large vessels.
The complexity of the project increased when the decision was made to ship the converters partially assembled to reduce on-site assembly requirements. This choice significantly impacted the cargo weights, with individual units increasing from 260 metric tons to 395 metric tons. When placed in specialized transport frames, the final unit weights approached 450 metric tons, requiring careful engineering and custom solutions.
The last-mile delivery presented unique challenges in Dunkirk. The initial plan to use the commercial port was abandoned due to complications with piperack crossings and facility shutdown requirements. Instead, Ahlers utilized a private terminal, which became accessible after previously stored coal was cleared. This alternative route required only one piperack crossing and allowed for the use of specialized low-bed Self-Propelled Modular Trailers.
The actual execution in July involved precise coordination of multiple elements. The converters were loaded onto a pontoon in a single day to avoid tidal complications, followed by a four-day sea journey delayed briefly by adverse weather in the Bay of Biscay. At Dunkirk, a temporary ramp was constructed for cargo discharge, and extensive ballasting operations were performed to maintain stability during transfer operations.
The final phase involved a carefully orchestrated four-kilometer journey to the laydown area. This required removing street furniture, halting railway traffic for 24 hours, and constructing a special sand bed for the SPMTs to cross railway lines safely. The project demonstrated the critical importance of early logistics partner involvement and comprehensive planning in handling complex industrial cargo movements.
