In November 2020, AusGroup commenced works on the assembly and construction of 33 trusses for a 9km overland conveyor for a Nickel Mine in the South Western Region of Western Australia.

The project works include construction of a new Primary Sizing Station and 9km overland conveyor to transfer primary sized ore to the existing plant for processing.

AusGroup's scope of works included provision of Construction Engineering and Supervision resources, Labour, Plant and Equipment required to facilitate Structural, Mechanical and Piping installation works for onsite of the Primary Crusher Building, Sizer Building, Transfer Stations, 9km Overland Conveyor and Piping services. AusGroup also provided personnel as part of an integrated construction management team for supporting the construction management, health and safety, materials and logistics team providing materials management, onsite transport, cranage and logistics services to broader site construction group.

In addition to the site scope of works, AusGroup was further awarded an offsite preassembly and modularisation works package. This work was completed in their newly established modularisation yard located adjacent to their existing Fabrication workshop at 4 Beach Street Kwinana, with the work scope including, materials management and assembly of free issued containerised structural steelwork and mechanical components, complete with walkways, handrails and idlers as well as the alignment the quality verification of 33 separate truss sections varying in length from 12 to 50m.

Assembly of 33 x pre-fabricated truss sections

The project scope involved the full assembly, alignment, construction, verification and preparation for transport for all 33 pre-fabricated truss sections over a 5 month period at AusGroup's Kwinana Hub. Each of the truss sections were fabricated overseas and shipped to Kwinana where they were organised, assembled and outfitted with grating, handrail and idler rollers.

AusGroup's newly expanded Kwinana Hub can now offer clients over 40,000m2 of offsite laydown area, large specialist fabrication, construction and assembly bays all at one site. This allowed AusGroup to streamline processes and systems for this truss assembly project whilst optimising safety and keeping the project more cost effective for FQM.

Each of the modular conveyor sections were then organised, assembled and outfitted with grating, handrail and idler rollers.  Each of these 33 sections were:

• 25m long x 5.5m wide x 2.8m high
• Each weighing 18 tonnes

Quality signoff on each individual truss section was required prior them being transported to site to ensure time and installation efficiencies were maintained for the client during on site installation.

Project Highlights

• Streamlined process to ensure Just-in-time sequencing order for transportation to site to best manage site resources and lay down areas
• Pre-transportation quality checks and rectification to ensure all client mandated quality metrics were adhered to
• Timely delivery to client despite reduced labour availability due to market conditions
• Access to metropolitan labour sources without the need for FIFO or camp accommodation.

Click below to access a time-lapse video of the project.