In February 2012, BHP approved a $3.6bn iron ore mine development near Newman. Over 1500 tonne of steel and 6km of handrail required fabrication and painting locally.
The project required a 2.5 class blast, then an Ethyl Silicate Zinc applied to 75 microns – this is suitable for typical mine-site structures in non-corrosive areas like the Pilbara, which are classified as ‘rural arid environments’.
The job required rigorous inspection to ensure it met the specifications without deviation, and – as with most rapid growth projects – it was needed in a short timeframe.
The conditions this project was processed in were exceptional – the huge increase in demand for the mining sector meant many applicators had filled their capacity, yet the job schedule required large quantities, fast.
With the cold, wet weather and tight deadlines, some applicators were having trouble with curing and excessive film builds, resulting in ‘mud-cracking’ – a serious defect.
The end-client urgently needed the project completed in order to capitalize on the profitable Chinese market.
Luckily, the project managers knew where to turn…
With three facilities in Perth, including new workshops dedicated for handrails and beam processing, Ferro-Clean was able to process large amounts of the job without any impact on existing operations. The result was high throughput, while maintaining high standards of quality.
The paint inspector noted ‘it was a relief to go to a paint yard where the standards exceeded the specification’.
BHP achieved production 6 months ahead of schedule, and officially opened the mine on 23rd April 2014.