Engineering precision for mining’s most demanding challenges

Comprehensive structural, mechanical, and electrical engineering services for six mobile machines (two stackers, two reclaimers, two shiploaders) for a major mining operator in the WA Pilbara region. This project enabled aging equipment to safely handle higher-density ores while maintaining compliance with modern standards. It included detailed fatigue assessments and upgrade recommendations for reclaimers, addressing high-fatigue damage stemming from the original OEM design.

A field inspection and engineering assessment of an aging bucket wheel reclaimer to evaluate compliance with current standards, reduce operational risks, and extend the equipment’s service life. By exceeding the original design capabilities of the OEM, the analysis delivered actionable recommendations for safety, efficiency, and cost reduction. This empowered the client to plan for long-term maintenance and eventual replacement strategies.

In-depth analysis of a forced oil lubrication and cooling system for a bucket wheel drive at a Pilbara mining site. This included hydraulic network modelling to verify lubrication flow rates, troubleshoot pump performance, and address reliability challenges. Preliminary CFD analysis provided insights into oil behaviour during machine motion, culminating in recommendations to minimize downtime and improve operational reliability.

End-to-end coordination and engineering oversight for replacing the front end of a bucket wheel reclaimer with a rotatable spare, utilizing SPMTs for transport. Our involvement covered execution through to load testing, ensuring a seamless return to service. Detailed punch lists and our expertise in maintenance tasks contributed to high-quality execution and reliable operation post-changeout.