DIFFICULTIES WITH TRANSPORT
Used in critical processing equipment, the heat exchangers are used to heat or cool equipment by transferring heat between two fluids without mixing them. Heat exchanges are critical components in mining and industrial operations, helping keep machinery running at the right temperature and preventing overheating.
The client required transport frames to improve operations including:
- Road transport between workshops and site
- Repeated loading and unloading cycles
- Forklift and crane handling
- Temporary storage during shutdown activities
The size, weight and sensitivity of the heat exchangers meant that any movement or instability during transport could increase the risk of damage, delays and additional maintenance costs.
Risks Involved with Heat Exchanger Transport
Plate heaters are large, heavy components that are difficult to manoeuvre — making them challenging to transport safely around site. Their size and weight introduce several high-risk hazards, including lifting operations, working at heights and the use of elevated work platforms (EWPs) during installation. Without a purpose-built transport solution, moving these assets can increase risk to both the heat exchanger and the teams managing them. The lack of suitable transport frames also extends handling timeframes, impacts maintenance productivity and the overall project efficiency.
Heat Exchanger Frames
DAYWALK worked with the team to review the handling and transport requirements for the heat exchangers.
The recommendations identified several key priorities, including:
- Secure restraint points for transport compliance
- Improved load stability during handling
- Protection of critical exchanger surfaces
- Compatibility with existing site lifting equipment
- A reusable solution that could support future shutdown programs
Custom engineered frames were built to reduce issues with heat exchanger transport and streamline operational capabilities.
The frames prevented prevent tipping, unnecessary handling, and component damage.
Custom Engineered Heat Exchanger Frames
DAYWALK designed and supplied custom heat exchanger transport frames engineered specifically for the application.
Key features included:
- Certified transport frame construction
- Dedicated load restraint points
- Forklift access pockets
- Crane lifting compatibility
- Engineered support locations to minimise stress on the exchanger
- Heavy-duty steel design suitable for repeated use in harsh mining conditions
The frames were developed to provide consistent support throughout transport, storage and site handling operations.
Heat Exchanger Transport Solutions
Following implementation of the DAYWALK heat exchanger frames, achieved:
- Better protection for critical heat exchanger components
- Faster shutdown logistics
- Streamlined movement and staging of equipment
- Reduced movement during road transport
- More controlled crane and forklift handling
- Increased efficiency with handling and transport
- Safer lifting and handling operations
- Reusable asset management for longevity and flexibility
- Frames available for future maintenance campaigns
Operational Improvements
This project demonstrated how purpose-built transport frames can help eliminate common handling issues associated with large process components. By replacing general support methods with engineered DAYWALK frames, the site gained a more repeatable and controlled process for moving high-value heat exchangers across maintenance and shutdown activities.
