Commencing in September 2025 and continuing through to March 2026, the project required detailed planning, coordination and execution across multiple transport modes and stakeholders. The stator was initially collected in Wroclaw and transported via rail using a specialised Schnabel wagon configuration to the Port of Gdansk. This method enabled the safe and efficient handling of the cargo during the initial inland leg of the journey.

As Vanguard managed the entire end to end shipment, they were responsible for coordinating all involved parties, including rail operators, ship owners and port service providers, ensuring seamless integration between each phase of the project.

Upon arrival at the port, the stator was carefully offloaded and transferred into a temporary handling area using a jacking system, where it was prepared for onward shipping. Vanguard coordinated the loading and shipment from Gdansk to the Port of Richards Bay, South Africa, ensuring strict adherence to handling and securing requirements throughout the voyage.

The vessel arrived in South Africa during a period of port embargo, requiring careful planning and contingency management. Vanguard utilised their own laydown area within the Port of Richards Bay to safely discharge and stage the stator, ensuring the project remained on schedule despite external constraints. At Richards Bay, the stator was offloaded using Vanguard’s Self Propelled Modular Transporters (SPMTs) in a 10 axle 4 file configuration and moved to a designated laydown area within the port.

From there, it was transported over approximately 700km to Matla Power Station using a 24 axle, 4 file trailer configuration, demonstrating Vanguard’s capability to manage long distance overland transport of abnormal loads. The road transport phase presented significant challenges. The route traversed the escarpment of South Africa through KwaZulu-Natal, a region often referred to as the “valley of 1000 hills,” characterised by steep gradients and demanding terrain. This required substantial traction and careful planning, with four trucks used to both pull and push the load and required configurations to be adjusted throughout the journey to safely manage ascents and descents.

In addition, varying and often poor road conditions, combined with some of the most severe storms experienced in the region this year, extended the South African overland transport duration to approximately three weeks. Once at site, Vanguard executed the final and most critical phase of the operation. Due to space constraints, the stator was initially transported on a 10 axle 4 file SPMT configuration before being transhipped onto a 6 axle 4 file combination for final positioning. The unit was then manoeuvred into position, before being lifted and installed using Vanguards 800ton hydraulic gantry system.

This precise placement required careful coordination, engineering expertise and strict adherence to safety procedures. “This project demonstrates Vanguard’s ability to deliver complete project solutions, from project cargo, international transport and port operations to overland transportation and final installation. By managing every stage of the process, Vanguard ensured efficiency, reliability and the highest standards of execution for complex heavy lift projects.”