ArcelorMittal venture in Liberia will quadruple the company’s iron ore production in the country

Forship Group, in partnership with HMSWeb Information Technology, is participating in a strategic ArcelorMittal project in Liberia (AML): the construction of a new concentrator plant that will increase the company’s annual iron ore production from 5 to 20 million tons — with 75% of the output being processed within the country. The contract marks Forship’s return to the African continent, where it began operations in 2009 with Vale’s projects in Mozambique.

Forship Group will be responsible for all phases of commissioning the mining company’s concentrator plant (one of the largest iron ore processing facilities in Africa), covering everything from mechanical completion and technical documentation to performance testing and final validation with the client, using HMSWeb© as the main control tool.

“The scope of work is broader than what we delivered for this client in Brazil, at the Serra Azul mine, in Minas Gerais, as we will also be involved in the management, engineering, and planning of the commissioning process for the project in Liberia,” highlights the Operations Director, Marco Antonio Kronemberger.

Project Challenges

Project Manager Danilo Martins highlights the main challenges of this venture, ranging from commissioning culture to technical difficulties.

“Establishing a solid commissioning culture in a project that is already under implementation requires alignment among all stakeholders — client, contractors, and suppliers — to ensure an organized and safe transition from construction to operation.”

Among other challenges, he points out the remote location of the plant, which affects immediate supplier support as well as access to logistical and technical resources.

“Planning must account for extended lead times for mobilization and contingencies. Additionally, we are starting commissioning in a context of delays in civil construction and electromechanical assembly. This increases the complexity of sequencing activities and underscores the importance of collaborative and dynamic planning,” the manager emphasizes.

Qualified Team

By applying lessons learned from similar ventures — such as Vale’s project in Moatize, which included the railway connecting the coal mine to the port of Nacala-a-Velha — Forship is confident in the performance of its team, which brings hands-on experience in complex projects.

“Part of the team worked directly on the Mozambique project, bringing with them expertise in punch list management, control of commissionable systems, supplier coordination, and effective transition to assisted operation,” emphasizes Danilo.

According to him, 22 professionals will be assigned to Liberia — the Commissioning Coordinator, 11 electrical engineers, and 9 mechanical engineers, as well as one planning technician. They will be supported directly by a contract assistant based in Brazil.

Thanks to the consolidated and recognized expertise from the similar Vale project in Mozambique, Forship Group expects to expand its role in ArcelorMittal’s operations, including participation in the development of rail and port infrastructure. “We believe our performance at the concentrator plant will serve as the best reference to strengthen this partnership, contributing to operational excellence also in the railway and port fronts of the project,” concludes Operations Director Marco Kronemberger.