- BGC Contracting Office
- BGC Contracting Branch
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- Construction Project
Iron Duke Linear Stacker
Through active site leadership and instilling a thriving health and safety culture from day one, the site team have record zero LTIs and zero MTIs to date, whilst meeting all key milestones and project KPIs.
Ore stockpiling and blending at SIMEC Mining’s Iron Ore Mine (Iron Duke) in the Middleback Ranges is undertaken via a liner stacker that runs along a rail system. The rail track formation is currently showing different signs of bearing capacity and drainage failure. This, together with corrosion issues on the rail and sleepers, has resulted in the failure of sleepers, cracking of the rail track, along with subsidence and misalignment which is affecting stacker operations.
SIMEC is planning to increase production on the downstream plants and high reliability of the crushing plant is required; hence the need to remediate the current condition of the stacker rail tracks. SIMEC’s objectives for the construction phase are:
- The safe execution of the construction works
- Minimising stacker shutdown period by completing the repair works in stages and, maintaining operation of the stacker during construction with minimal shutdown periods
- The successful achievement of milestone and practical completion dates.
Under competitive tender and based on our extensive knowledge of the Iron Duke site through our long-term mining contract, BGC Contracting have been appointed as the Head Contractor to complete these critical upgrade works. Our scope includes:
- Deconstruction of the existing rail system under live working conditions
- Installation of 106 precast concrete 96 250PFC tie-beams
- Installation of 800 metres of new rail
Operation of the rail stacker will continue during the rail deconstruction and rebuilding process by conducting the works in two separate shutdowns, equal to half the length of the 1km long rail system. The challenges facing the construction crew include working in close proximity to a live conveyor and operation of equipment within tight corridors either side of the live plant operation. In addition, extreme heat and dusty conditions will also provide challenging working conditions for our team. Through active site leadership and instilling a thriving health and safety culture from day one, the site team have record zero LTIs and zero MTIs to date, whilst meeting all key milestones and project KPIs.