Benefits of our internal bending machine

Although globally there is definitely still a future for natural gas pipelines, currently there is a strong movement in Western Europe that advocates for a drastic reduction in the use of fossil fuels, including natural gas. This shift in the industry gave us a reason to further explore other kinds of pipeline construction activities, for instance large diameter pipelines for (sea)water or pipelines used for district cooling and heating.

To a certain extent, the construction of these district heating pipelines is not that different from gas pipelines, as they both use steel pipe for transport of the medium. But there are some major differences regarding the following:

– The weld insulation of the pipes – because for district heating there are several centimeters of PU insulation and a PE casing pipe, as opposed to a 3LPE coating of a few millimeters for gas pipes.

– The bending of district heating pipe – because conventional bending (from the outside) is nearly impossible without compromising the integrity of the external insulation, factory made bends are mostly used.

Making factory bends is a time consuming and costly operation; first the bare steel pipe is bent, after which PE segments are brought around the pipe that all have to be weld together at exactly the right angle. After that, the inconsistent space between the steel pipe and the PE casing pipe is filled with PU-foam. As this is a time consuming and costly operation, Maats has been looking for a solution that simplifies the manufacturing of bends for district heating projects. The most obvious alternative to factory made bends would be to bend the pipes with a conventional bending machine. All Maats bending machines are equipped with load sensing operating hydraulics; the load sensing system assures that the force applied to the pipe is as low as possible, and therefore provides the greatest chance to prevent any damages to the jacket pipe and insulation.

Despite performing several tests, the conventional bending machines were not found suitable for bending the insulated pipes that are typically used for district heating and cooling (and for heated crude oil lines as well). As an alternative, it is possible to use pipes that have a higher density (stronger) foam, but still this is no guarantee that the force needed won’t damage the insulation, especially when the steel pipe has a wall thickness that is above normal.

Internal bending

The Maats IB is the first pipe bending machine in the world that is able to cold bend steel pipes from the inside, a technique ideal for pipes that have an external insulation, like those used for district heating and – cooling, for crude oil lines or for any other medium that has to remain within set temperature limits. It provides a high-quality alternative for factory made bends or external bending that was previously used for thermal insulated pipes. The new machine offers an improved flexibility and economy for any project using insulated pipes, anywhere in the world.

Quality and safety

When bending insulated pipe joints from the inside, the foam insulation and PE jacket pipe are left undamaged, meaning that the insulation values remain uncompromised. The internal bending process has no effect on any leak detection wires or duct for heat tracer cables being used. Because the machine works internally, it has the major advantage of having no moving parts outside the pipe during the whole bending process. Another advantage of the machine is that the pipe joint is fixed into position during the bending process, which reduces pipe handling operations with all related risks, throughout the process. As the bending process itself is largely automated, the risk of human error is minimized. This leads to a less time consuming and a cheaper operation in total.

Besides the fact that quality and safety is guaranteed, the Maats IB itself is conveniently build inside a standard 20’ container, making it easy to move to and on a jobsite. This makes the machine more flexible than any other machine that currently exists. The well thought out and compact layout makes it possible to start bending quickly after arriving on site.

Economic advantages

As stated before, the current process of making factory bends is time consuming and costly. On top of that, shipping bent pipe joints is much more expensive than the transport of straight joints. External bending, when technically viable, can only be done when using pipe joints with higher density foams, making pipes not only more expensive but also creating the need for a second pipe production line, a separate storage and separate quality controls. The Maats IB only has to have standard straight pipes supplied for all bends up to 16° and it can bend up to 12 joints per day, depending on pipe length, pipe diameter, wall thickness and steel grade.

Are you interested in the ordering or discussing the possibilities of internal bending machines (IB)? Contact us at +31 (0)547 260 000 or send a mail to info@maats.com.

Maats manufactures, sells and rents out high quality equipment for the construction of pipelines with all common diameters from 6 up to 60 inches. With branch offices in Indonesia (PT. Maats), partnerships in Algeria (Maats Afrique) and Turkey (Maats Insaat) and a close cooperation with the global network of Liebherr companies, Maats’ presence is truly global.

Benefits of rental

With increasingly large pipeline construction projects and a fluctuating market, maintaining a fleet of specialized equipment for pipeline construction is becoming a challenge. This makes the following advantage extra significant for the contractor: with the possibility to rent equipment, customers gain normally have access to well- maintained equipment that meets the latest emission requirements and safety standards. This leads to less maintenance and machine downtime, resulting in direct financial benefits for the project owner.

Low investment, high flexibility

Renting equipment also offers companies flexibility and a complete package of specialized equipment for all common diameters without having to invest in a whole fleet. This is especially useful for companies with limited budgets or working on incidental pipeline construction projects. Additionally, Maats guarantees flexibility, through the availability of many machines in different classes (lift capacity) and applications (bending, welding, pipelaying), the ability to provide transport to and from job sites, as well as equipment insurance and technical assistance at the job site. The rental process at Maats is efficient and automated. We can see exactly how many hours a machine is running by consulting the machine management system and automatically receive notifications when maintenance is required. This allows the technical assistance team to take swift and proactive action, in cooperation with the customer, to keep the machines up and running. Maats provides on-site service, meaning that the customer does not have to worry about regular interval maintenance.

The complete package

At Maats, companies can find a complete package of equipment, making one- stop-shopping the easiest option. Maats’ complete package holds specialized pipeline construction equipment for various applications. For example, bending machines (conventional horizontal pipe bending machines and Maats Internal Bending machines), pipelayers, welding tractors, line-up clamps, mandrels, roller cradles, etc. for all diameters. Renting these specialized machines allows companies to access the appropriate equipment at the right time and to focus on their core competences.

Maats and Liebherr

Maats worked with Liebherr in the last century to design and further develop the pipelayer as it is today. Liebherr has established itself as a pipeline specialist. Maats has opened up the pipeline region with Liebherr, which prior to the cooperation was not their specialty but is now part of their wide expertise. This has also led to Liebherr becoming a major supplier for this segment of equipment.

Reliable machines

An important reason for Maats to choose Liebherr is its exquisite reputation: supplier of reliable long-life equipment. Apart from a few machines from other suppliers, the pipe layers and welding tractors in our rental fleet are mainly Liebherr units. Depending on the requirements, Liebherr equipment has operating modes are available for maximum performance or particularly fuel-efficient operation. This has also led to Liebherr becoming a major supplier for this segment of equipment, makes the equipment trustworthy and maintenance effortless. At jobsites, this can also easily be carried out by Liebherr dealers.

Although at first glance these machines may be a bit more expensive to purchase, the benefit in the long run is especially high. Liebherr equipment is sustainable and meets high quality standards that ensure a long service life. In addition,

the world-wide Liebherr dealer network is friendly, fast, and convenient, with a proven track record in providing spare parts and mechanics when needed. Liebherr can deliver spare parts around the clock, regardless on the pipelayer’s location, parts can be ordered online at any time.

Know-how of the industry

An important aspect of the pipeline construction industry is the ageing of the skilled workforce, as many experienced key personnel are currently retiring and being replaced by those yet to gain experience. This requires the ability to provide quick assistance more often than in the past when problems arise on site.

Maats together with Liebherr can provide an engineer and parts quickly when needed; crucial to avoid project delays. In case of remote jobsites globally, Maats can rely on the vast network of the locally available Liebherr dealer network, enabling quick service and repair of machines out in the field.

In short, the cooperation between Maats and Liebherr has proven to be very successful, through the innovative and flexible approach of both companies. Combined with Maats’ and Liebherrs’ solid machinery of Maats and Liebherr and excellent service, they have acquired a strong position in the pipe laying and pipeline specialist industry.

Why frequent personal contact with customers and jobsites matters

Where necessary, Maats’ Technical Staff is called in to prevent or solve problems. Together with the customer, we look for the best solution and deployment of the machines required on their project. In addition, we search for the most economical deployment of machines on their jobsite.

As with companies that supply equipment to contractors, personal contact is essential to explain more about the service offered. For example, it can be helpful knowing the Liebherr dealer network, the local representation, so Maats’ mechanics do not have to drive unnecessarily long distances to repair a machine. This will save on down time, important for both parties.

Know your customer

When visiting customers at jobsites, often in remote locations, bringing in orders is not our main goal. It is an appropriate time to provide the service of “being there when you need us”, to getting to know each other better, and to catch up on the latest developments. To gauge how the client’s business is doing and to evaluate any wishes for the future. These conversations can ultimately lead to the client granting Maats their next project and getting business done faster.

Moreover, personal contact can increase trust and strengthen ties between Maats and the customer. This can ultimately lead to more satisfied customers and a greater level of trust between both parties. It is therefore important to invest in moments of direct contact. Once the contact is established, the client comes to Maats with questions and expectations, e.g. about a tender they intend to participate. To determine his price to put down in the tender, an in-depth study of the type of equipment for his work is needed. Together with the customer, we look for the best options, discuss the technical details and give advice on our equipment enabling the customer to take an educated decision on what equipment to rent.

If desired, we will meet with the customer in their facilities; however, we prefer to invite them to our Headquarters and vast equipment yard in Goor, the Netherlands. Customers get a glance of the available fleet, where they are able to test, check and experience the machines personally. Together we can look for alternative or customized options to suit their requirements best. At Maats, the customers are the most important party: their wishes determine the deployment of the equipment.

Exchange expertise

By choosing Maats as your rental company is specialized in pipeline equipment, a huge benefit will be the knowledge that becomes available to you. For example, we can send mechanics to job sites to share their expertise on how to handle the equipment safely and sustainably and provide tips for first trouble shooting and daily maintenance to keep the machines in top condition. This is significant for customer, the operator, the equipment, and the project, as well as for the owner of the equipment, Maats. However, gathering new insights works both ways, because it allows operators the opportunity to provide feedback on the machines. Thus, improvements can be made. Sharing knowledge is therefore not only important for customers, but also for improving the machines and the pipeline industry in general. We have had several good discussions with operators, resulting in improvement of equipment, service and on-site maintenance..”

Climate Neutral

Maats offers a climate-neutral rental formula, to compensate for the CO2 emissions of our fleet as well as our Headquarter together with all staff related movements. At the moment, we provide certificates. We aspire to switch to physically planting trees. In this way, we want to truly contribute to a cleaner world and in fact reduce CO2 emissions.

Diesel-powered alternatives

Maats acknowledges that it is difficult to develop electrically operated equipment for heavy construction, especially since our machines are often used far outside urban areas, where electricity is not always available. We are looking into several alternative fuels and are keeping a close eye on developments in this niche.

For equipment with a shorter economic lifespan, such as excavators, alternatives are already available. Such as electrically driven engines or hydrogen technology. These solutions are yet to be perfected and still involve some teething problems, but we will invest in these new technologies to offer our customers the best solutions.

Climate-neutral future perspective

Although sustainable solutions are still in their infancy, Maats believes it is important to be aware of the climate impact of our machines and to continue to invest in new technologies to reduce the impact on the environment. In that way, we give our customers access to appropriate modern equipment, so they can focus on their core competences.

Want to know more about climate-neutral rental? Feel free to contact us!

Insights from the Engineering department

Tom Stevens, who initially joined as an intern several years ago, has successfully progressed to become a fully qualified Engineer. His primary responsibilities involve the development and modification of machinery. Tom adopts a methodical approach, commencing with a blank A4 sheet to sketch out his ideas before creating detailed production drawings for our machine builders.

On the other hand, Gieljan Smits, holding the official title of Engineer, takes on a multifaceted role. With over 9 years of experience at Maats and taking over the position from his predecessor, he is now also responsible for work preparation, procurement, and cost calculations.

First Engineering Challenge

One of Gieljan’s early significant assignments was the conversion of a pipe layer into a more robust version. “Our existing pipe layer had a capacity of 80 tons, and it required an upgrade to 90 tons. While the task might not have been extensive, its immediate deployability was crucial due to high demand, making it a valuable assignment.”

Tom’s first assignment as an intern involved designing the Maats RL26 pipe layer. “It was an excellent project to embark on. Being able to witness the realization of the designed machines as I continued my work at Maats made the experience even more rewarding.”

Customization or Engineering?

At Maats, our engineers do not solely focus on designing entirely new equipment; they also specialize in customizing existing machinery. When queried about their preference between the two, both professionals find it challenging to make a definitive choice. Gieljan states, “Both are enjoyable to work on, but when customizing a machine, you see results quickly.” Tom adds, “The exciting part of engineering is starting with a blank sheet. Eventually, we construct it and witness the tangible end result.”

Major Project: Designing and Realizing the Internal Bending machine

A few years ago, Maats undertook a substantial project: the design and delivery of the Internal Bending Machine, the world’s first pipe bending machine capable of cold bending steel from the inside. For Gieljan, it marked a pinnacle in his career. “Meeting all the requirements for this machine posed an interesting endeavor.” Tom was primary responsible for the technical drawings and calculations. “We have already secured several orders for the Internal Bending Machine. It is safe to say that we have successfully brought the project to completion,” notes Tom.

Both gentlemen are among the few who actually operate the Internal Bending Machine. “In addition to being engineers, we act as operators and advisors, sharing specific knowledge with our clients to ensure the responsible use of the machine.”

Engineering means thinking in endless possibilities

According to the gentlemen, in the field of engineering, everything is possible. “The sky is the limit. But, of course, it must be technically possible and fit within the budget,” says Gieljan. “Of course, we do not just get started. We assess what is needed in the market or respond to our client’s needs,” Gieljan adds.

The Pinnacle of working at Maats

The diverse responsibilities that Gieljan manages contribute to the rapid pace of his days. “Because I have been closely involved in various aspects of the company in recent years, I have gained a lot of knowledge. I understand the machines and customer needs very well.” Tom finds fulfillment in his role because, at Maats, he witnesses the tangible outcomes of his efforts. “While many engineers mainly focus on calculations and drawings, I have the opportunity to witness the end result, conduct testing, and optimize the product. This is what I appreciate about working at Maats – we can conceptualize, draw, and observe the entire construction process first-hand,” concludes Tom.

Mentoring mechanics

Alex takes immense satisfaction in his role as a mechanic, fueled by a deep-rooted passion for his craft. For him, there’s no greater joy than imparting his knowledge to the next generation, paving the way for them to embark on a similarly fulfilling career path. “I find the work I do very enjoyable. I want to give young people, like Joep, the opportunity to learn everything about this wonderful profession.”

Alex took particular delight in instructing Joep about the intricacies of hydraulic systems within the machinery. “Joep is remarkably adept at grasping new concepts, which makes teaching him about pressure relief valves all the more enjoyable,” Alex shares. “He’s also fascinated by the workings of the welding tractor,” he adds. Joep chimes in, expressing his admiration for the versatility of the welding tractor. “It’s truly remarkable how this machine can adapt to various tasks,” he remarks, reflecting on the breadth of knowledge he’s gaining under Alex’s guidance.

Working together at Maats

In the one and a half years since Joep joined Maats, both he and Alex have experienced significant growth. Joep’s eagerness to learn has not only enriched his own skills but has also influenced Alex’s approach to task explanation. “I used to rush through explanations when repairing something. Joep’s thoughtful questions have taught me the value of taking the time to explain things calmly,” Alex reflects. Joep, in turn, acknowledges Alex’s expertise and appreciates the opportunity to learn under his guidance. “Alex has a clear process in his mind, and he explains it well when I ask questions,” Joep adds.

As Joep gains confidence in the workshop, he values the freedom given to him to explore tasks independently. “I’m grateful for the freedom to take initiative and try things on my own,” Joep shares. “When I’m assigned a task, I’m encouraged to give it a shot and see how far I can go.” Alex commends Joep’s proactive approach and willingness to seek clarification when needed. “Joep isn’t hesitant to ask questions or seek help if he’s unsure about something,” Alex observes. “His curiosity and eagerness to learn are praiseworthy.”

Feeling at home

At Maats, both Alex and Joep find themselves in a welcoming environment that feels like home. “Being part of this exceptional team means balancing hard work with moments of humor,” Joep shares. Reflecting on his 14-year journey with Maats, Alex remarks, “I joined this company through a referral, and I’ve never looked back.”

The camaraderie also extends beyond the workplace, with team members supporting each other in personal endeavors. Recently, Alex took the time to teach Joep how to replace the clutch in his car. “Learning how to replace my car’s clutch was a rewarding experience,” Joep recalls. “Alex guided me through the process, and I completed the task independently. It’s moments like these that make working alongside Alex so enjoyable.”

All-round mechanic at Maats

In just another year and a half, Joep will earn his diploma, officially marking him as an ‘All-round mechanic.’ With this achievement on the horizon, Joep envisions a future at Maats. “If the experience continues to be positive for both sides, I would like to stay at Maats,” he shares.

Alex echoes Joep’s sentiments, expressing his hope that Joep chooses to remain with the company beyond his apprenticeship program. “Naturally, I hope Joep decides to stay; individuals as enthusiastic and dedicated as Joep are rare to come by,” Alex affirms, emphasizing the value of Joep’s passion and commitment to the team.

Working at Maats

The Finance Department at Maats is about more than just numbers. Through their various roles and responsibilities, Cheryl, Erik, and Han complement each other, forming a cohesive and effective team. As Han puts it: “Our strength lies in our teamwork and trust in each other’s expertise. This not only makes our work efficient but also enjoyable.”

Ready to drive the future of pipeline construction? At Maats, we’re seeking passionate professionals eager to contribute to our tradition of engineering and innovative solutions. Step into a world where your skills foster global impact. Explore opportunities at Maats and build extraordinary projects with us.

Interested in a career at Maats? Contact us to explore the possibilities!

About our finance department…

The careful handling of figures, ensuring financial accuracy, and fostering effective collaboration are in capable hands with our Finance Department. Meet Han, Cheryl, and Erik—the key individuals who ensure the smooth operation of our financial administration. In this article, they share insights into their roles, the challenges they encounter, and what drives them in their work.

Han Romp, our Chief Financial Officer, has been with Maats for 17 years and holds responsibility for the financials, annual accounts, and financing. While he oversees the entire operation, he emphasizes the importance of his team’s contributions. He depends on Cheryl Lonink, who manages accounts payable and payroll, and Erik Meuleman, who, as Assistant Controller, prepares reports and oversees inventory management. Han summarizes their collaboration succinctly: “Cheryl and Erik provide the financial data, and I handle the final processing. Without their work, I wouldn’t be able to do mine.”

Collaboration and Dynamics

Each of the three has their own area of expertise, but they work closely together to ensure everything is accurate. “We’re well attuned to each other,” says Cheryl. “Everyone understands their responsibilities, and we support one another whenever necessary.” Erik adds, “Because we’re such a small team, we collaborate frequently. It’s easy to consult with each other and ask questions, which makes our work more efficient.” Han agrees: “We keep each other on our toes. If something isn’t right, we address it immediately, discuss it, and resolve it without delay.”

What makes working at Maats so enjoyable?

All three agree: the variety and collaboration make the job enjoyable. Cheryl appreciates the diversity in her tasks: “One moment I’m handling invoices, and the next I’m working on ISO certifications or transport logistics—no two days are the same.” Erik particularly enjoys the challenge of working with numbers and interacting with various departments: “In a small company like Maats, communication lines are short. I’m in contact with almost every department to ensure that their work aligns with our financial administration.” Han values the balance between numbers and technology: “It’s not the same routine every day, and that keeps things interesting.”

A team that strengthens each other

At Maats, professionalism is combined with a positive working atmosphere. “We have an open culture where you can easily speak up if something isn’t right,” says Han. “This ensures that issues are resolved quickly.” Cheryl agrees: “We’re a small team, but it works well. Even after 18 years, I’m still enthusiastic about my job.”

The Finance Department at Maats is about more than just numbers. Through their various roles and responsibilities, Cheryl, Erik, and Han complement each other, forming a cohesive and effective team. As Han puts it: “Our strength lies in our teamwork and trust in each other’s expertise. This not only makes our work efficient but also enjoyable.”