Category Archives: Case Study

Supplying Equipment for Ground-Mounted Solar PV Farms in Bugallon

The Philippines has been actively expanding its deployment of ground-mounted solar photovoltaic (PV) power plants, harnessing the benefits of high solar irradiance. This approach is seen as a promising way to diversify the energy mix and reduce reliance on fossil fuels. In the Bugallon area, numerous solar farms of various sizes have been constructed in recent years, making a significant contribution to the region’s power grid. This has meant that the construction of these ground-mounted solar PV power plants demands efficient and reliable solar piling and material handling solutions. Today, we proudly highlight our achievements in supplying equipment for one of the solar farms located in Brgy. Salomague Sur, Bugallon, Pangasinan, through Cross-Link Electric & Construction Corporation, formerly known as Cross-Link Electric Corporation.

What challenge are we facing on-site?

The site primarily consists of a flat surface, with some areas showing an inclination of approximately 15 to 20 degrees, making navigation with conventional equipment difficult. The land is hard and contains many stones beneath the surface. Solar PV modules are bulky and can be heavy, requiring specialized equipment for safe and efficient handling, while purlins, though lighter, are often long and unwieldy.

What solutions do we offer?

◉　Solar Pile Driver

Our Solar Pile Driver, known as Screw Pile Machine, is revolutionizing the installation of ground-mount solar systems. This crawler hydraulic drilling rig harnesses innovative construction technology and a climbing mechanism, adjustable to accommodate slope heights of up to 45 degrees, enabling the execution of solar engineering projects on challenging terrains.

Embracing a range of photovoltaic construction technologies, the equipment excels in screw pile drilling, spiral hole drilling, rock down-the-hole (DTH) hammer operations, and ramming pile installations. With its hydraulic components featuring imported original parts, the machine achieves remarkable performance and exceptional stability.

Its compact design features a mast with a telescopic compensation function, enhancing borehole stability as it operates, while being supported firmly on the ground.

This solar piling machine stands as a testament to reliability, efficiency, and versatility, proudly recognized as the strongest mountainous solar drilling rig in the Philippines. Furthermore, its capabilities extend to various applications, including anchoring, water well construction, water conservation projects, power plant establishment, open-pit mining, road building, and various other blasting hole operations.

◉　Telehandler

Our Manitou MT-X 1840 telehandler has an impressive lifting capacity of up to 4 tons and can reach a height of 17.55 meters. This capability enables the effective handling of numerous solar photovoltaic (PV) modules or a substantial quantity of purlins, ensuring confidence in performance and reliability. Its extended reach and height enable efficient unloading from delivery trucks and precise placement of materials within the project area, even over obstacles.

With a generous ground clearance of 42 cm, short turning radius of 4.01 m, four-wheel drive, and three steering modes (four-wheel steer, two-wheel steer, and crab mode), the telehandler is easy to maneuver in the varied and sometimes challenging terrain of the solar farm. The outriggers and frame leveling system ensure that handling loads is performed safely.

Additionally, the telehandler is equipped with various attachments, such as pallet forks, jib, and platform basket, allowing for seamless transitions between loading, unloading, and hauling tasks.

The telehandler’s deployment followed a systematic workflow:

  • Unloading: Upon arrival of delivery trucks, the MT-X 1840 efficiently unloaded crated solar PV modules and bundles of purlins. Its precise control allowed for careful handling, minimizing the risk of damage.
  • Staging and Storage: Materials were then transported by the telehandler to designated staging and temporary storage areas within the project site, ensuring organized material flow and easy access for installation teams.
  • Hauling to Installation Points: As installation progressed, the telehandler hauled the modules and purlins from the staging areas directly to the specific rows and arrays where they were needed. This direct-to-point delivery significantly reduced manual labor and installation time.
Results and Benefits

The utilization of the rented Solar Piler Driver and Telehandler MT-X 1840 yielded significant benefits for the Bugallon Solar Power Plant project:

  • Increased Efficiency: Solar ground screw piling works and material handling operations have been significantly optimized, leading to faster pile driving activities, unloading, and transportation, thereby enhancing the overall efficiency of the project.
  • Reduced Labor Costs: They both minimized the need for extensive manual handling or traditional piling methods, reducing labor requirements and associated costs.
  • Enhanced Safety: By mechanizing heavy lifting and piling works, the risk of injuries to workers was substantially reduced, creating a safer working environment.
  • Minimized Material Damage: The precise control and stability of the telehandler helped prevent damage to fragile solar PV modules and valuable purlins during transport. Unlike traditional pile driving methods that might use excessive force, our solar pile driver is designed to apply a controlled and consistent driving force. This prevents overdriving, buckling, or deformation of the piles.
  • Improved Project Timeline Adherence: These effective equipment played a crucial role in keeping the project on schedule, helping to avoid expensive delays.
Conclusion

This example highlights the value of renting solar pile driver and telehandler for the installation and material handling challenges faced by ground-mounted solar PV farms in Bugallon. By leveraging advanced, reliable equipment specifically tailored for solar projects, the construction has been able to significantly improve operational efficiency, reduce installation timelines, and lower overall costs. MAYON’s rental services offer flexible and affordable options along with 24/7 support without the need for large capital investments, making the Philippines’ renewable energy projects more accessible and scalable nationwide.

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Heavy Lifting Solutions: 150T Crawler Crane Supports Mauban Jetty Port Construction

The Jetty Port construction project in Mauban, Quezon, is being carried out for ACEN (formerly AC Energy) to support their Isla Wind Farm initiative, which aims to establish a wind farm in the area. As a partner of Prime Metro BMD Corporation (PrimeBMD), the company primarily responsible for the Jetty Port construction, Mayon Machinery (MMRI) takes pride in our contribution to delivering exceptional heavy lifting solutions that support renewable energy development in the Philippines, particularly during the construction process. To ensure seamless operations and overcome various site challenges, a 150T Kobelco 7150 crawler crane was deployed to provide the necessary lifting capacity and support.

150T Kobelco 7150 Crawler Crane Supports Mauban Jetty Port Project
Challenges:
  • Difficult Transportation to Site:

Transporting the crane itself to the construction site presents a major hurdle. The narrow, mountainous terrain, steep slopes, and potentially poor road conditions significantly complicated the logistics. Specialized transport vehicles and meticulous route planning were applied to navigate these obstacles safely and efficiently.

  • Coastal Location and Unstable Ground:

The jetty’s coastal location introduced additional complexities. The ground near the sea was likely unstable, requiring careful consideration of soil conditions and potential ground shifting. This instability affected the crane’s positioning and the overall stability of the construction process.

To effectively manage these risks, the project team implemented several strategies:

  • Robust Site Assessments: Daily evaluations of site conditions ensured that the team was aware of any changes in terrain stability or weather patterns that could jeopardize safety.
  • Adherence to Safety Protocols: The use of a comprehensive safety plan, including personal protective equipment (PPE) and guidelines for safe crane operation, was paramount. Workers were trained to recognize and respond to potential hazards, particularly in unstable areas.
  • Collaboration with Experts: Working alongside geotechnical engineers and local authorities, the construction team ensured that all operations complied with safety regulations, focusing on protecting workers and equipment throughout the project.
The Kobelco 7150 – A Solution for Challenging Conditions:
  • Exceptional Lifting Capacity: The crane’s impressive lifting capacity of 150 tons allowed for the efficient handling of heavy components, accelerating the construction process.
  • Superior Stability: The crawler base provided unmatched stability on uneven terrain, minimizing the risk of accidents and ensuring the safety of both personnel and equipment.
  • Precise Control: The crane’s advanced controls allowed for the accurate placement of components, crucial for maintaining the structural integrity of the jetty.
  • Lifting off power pack and vibro equipment
  • Lifting and erection off set pile
  • Lifting off I-beam
Conclusion:

The successful completion of the Mauban Jetty Port’s construction will highlight the importance of choosing the right heavy-lifting equipment for challenging environments. Our 150T Kobelco 7150 crawler crane not only delivered the necessary power and precision but also played a pivotal role in mitigating the inherent risks associated with the project’s location. Trust MMRI to support your success from small to large-scale infrastructure projects throughout the Philippines.

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During The Construction of The SMC Cement Batching Plant in Calatagan, Batangas: A 500T Terex-Demag CC2500-1 Crawler Crane in Operation

The Mayon Machinery (“MMRI”) team together with MOF (“MOF Company Subic, Inc.”) has recently completed another project at the site of the SMC cement batching plant by successfully transferring heavy kiln shells from the barge using 500T TEREX-DEMAG CC2500-1 crawler crane.

Project Overview

San Miguel Corporation (“SMC”) is one of the largest and most diversified conglomerates in the Philippines, originally founded in 1890. Its cement business has been conducted through its subsidiaries for over 50 years and has a total nominal annual production capacity of approximately 17.5 million MTPY of finished cement. To reduce dependence on imports and avoid delays in the delivery of critical infrastructure projects in the region, SMC has started construction of one of its cement batching plants in Calatagan, Batangas.

In preparation for the lifting of the heavy kiln shells, our team has been coordinating with the MOF from the planning stage through to the practical process.

The MMC REBECAH barge cannot position itself as shown in the lifting plan, so MOF instructed the team with the new plan and positioned the barge alongside the jetty receiving platform.

Placing steel mats for the superlift tray in preparation for lifting the heavy kiln shells with a working radius of 24.5 meters, after which the barge will move forward to approach the next item to be lifted.

Locating the crane on the jetty required a high degree of precision. The positional constraints relating to the special steel mats combined with the lift capacity requirements, led the team to select a 500T TEREX-DEMAG CC2500-1 crawler crane to perform heavy lifting duties.

The Terex-​Demag CC 2500-1 Crawler Crane has a 500T lifting capacity with a maximum boom length of 84 m and a derrick length of up to 139 m. This crane has an exceptional boom system optimized for high lifting and superlift operation. Its counterweight, superstructure, and superlift tray all add up to a total weight of 375 tons.

Outcome

MMRI met all of the challenges the clients faced and at a fraction of the cost of larger alternatives. Our fleet of rental cranes, the largest in the Philippines and Asia region, is designed to be versatile and adaptable to different sectors, in particular the loading of heavy items from barge to jetty without the aid of a barge crane. Contact us today for your heavy-lifting crane service including transport, lift, and installation with our most experienced operators, thus ensuring the utmost safety and efficiency throughout the project.

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Silent and Vibration-Free Installation at First Philippines Industrial Park (FPIP)

We have recently completed a fantastic installation of sheet pile walls at the site of CCT Constructors Corporation (CCT) – a general contractor for Brother Industries Philippines, Inc. Factory Building Expansion.

The construction consisted of using an F111 Silent Piler, capable of handling 400mm wide sheet piles, to install U-shaped sheet piles (17–27 m long) to form retaining walls in the construction of a new factory building.

The Press-In Method for sheet piling installation was specified in the project plans due to the adjacent proximity to the existing factory.

Giken F111 Silent Piler_CCT_Brothers Philippines Factory Building Expansion

Giken F111 pushed the piles with silent and vibration-free while maintaining tight tolerances and speed of construction.

  • Press-in Method on Giken F111 to install the sheets into the soft soils
  • Sheet Piling Installation for Factory Building Construction

If you have been impacted by natural disasters, your current sea wall is under-engineered, or you are looking for structural repairs to your retaining wall, just give us a call. We specialize in Seawalls, Lake Walls, Flood Defence Walls, Retaining Walls, and much more using top-of-the-range equipment such as the Giken Silent Piler. If you are a contractor looking to rent a Giken Silent Piler like CCT, we can help. As an official Giken dealer, we also offer new Silent Pilers and repair services. You can trust Mayon Machinery as your empirical equipment subcontractor throughout the Philippines from the very early stages of each project.

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Implant™ Method Adopted for Use in Pasig-Marikina River Channel Improvement Project (PMRCIP)

Giken Implant Structure – the necessary for disaster prevention and/or mitigation

Aims to further mitigate flooding due to the overflow of Pasig and Marikina Rivers, thereby facilitating urban development and enhancing the sustainable environment along the river, the Department of Public Works and Highways (DPWH) in partnership with the Japan International Cooperation Agency (JICA) was started implementing the project from the year 2000 to present. The Japanese contractor Toyo Shimizu Joint Venture, consisting of Toyo Construction. Co., Ltd. and Shimizu Corporation, has carried out the improvement project by widening and dredging the river as well as constructing embankments, river walls, and drainage facilities by the advanced Implant™ Method developed by GIKEN which is introduced and supplied by Mayon Machinery. This method is adopted in executing Silent Piler press-in and extraction F111 which is vibration-free, noise-free construction, without interfering with the lives of residents, and the accuracy of construction. With this method, piles are also held at a lower position and closer to the tip so that force is transmitted properly down the pile when pressing it into the earth. Displacement of the tip of the piles is less likely as well, which reduces the need for corrective action, making this method of construction highly accurate and fast.

F111 Silent Piler (Super Crush Mode)

Silent Piler Range: U Sheet Piles 400mm wide

Max. Installation Force: 800 kN

Max. Extraction Force: 900 kN

Stroke: 850 mm

Pressing-in Speed: 2.0 ~ 43.5 m/min

Drawing-out Speed: 1.5 ~ 32.3 m/min

Operation: Radio Control

Movement: Self-Moving

Power Unit Type: EU300K4

Silent Piler Weight: 10,600 kg

Super Jet Reel Weight: 820 kg

Total Machine Weight: 11,420kg

Main Features:

  • Modular design
  • Optimizing work efficiency for adjustable to various soil conditions and working conditions
  • Longer operational life and higher functionality due to the new control system
  • Pile installation into hard ground
  • Outstanding environmentally-friendly design
  • Scientific execution of press-in work and advanced IT functions by monitoring
Silent Piler (Crush Mode)
Silent Piler F111 (Sheet Pile Installation)

As one of the Philippines’ leading driven sheet pilling suppliers, Mayon Machinery has built its reputation in providing the best products quality, and excellent services whether you rent or purchase a new/used Giken Silent Piler. Contact our team today for further assistance!

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