Our Projects

Hall Hub Primary Crushing Plant

Client
Category

Location
Commodity

Fortescue
Iron Ore
Pilbara, Western Australia
Iron Ore
December 2023 scaled Hall Hub Primary Crushing Plant 1

The plant was a duplicate of the Hopper 9 and Hopper 10 crushing plant projects previously delivered by a joint contracting group of Primero, RCR and OFI. The material difference with the Hall Hub plant is the inclusion of a fixed mechanical rockbreaker into the plant.

This project was executed using an internal agreement between the parties in the NRW MET Group rather than traditional subcontract arrangements.

The successful delivery of the previous FMG Primary Crushing Plant projects Hopper 9, Solomon Queens and Hopper 10 resulted in this project being sole sourced to the contracting group, which was led by RCR.

SCOPE:

Primero’s scope contained the site construction of the earthworks, concrete, structural steel, mechanical and piping works. The plant consisted of the following key components:

  • Underground conduit and piping.
  • A steel ROM wall, backfilled with 13,000 m3 of compacted soil, anchored by 5 large pre-cast concrete anchors.
  • Structural blinding and minor site-poured concrete structures.
  • Modular steelwork installation up to 40t.
  • Modular platework installation, including 60t ROM bin modules and ore transfer chutes.
  • Mechanical equipment installation including apron feeder (160t), vibrating grizzly screen, primary mineral sizer (120t), discharge conveyor, rockbreaker, tramp metal magnet, process water pumps and tanks.
  • Process water piping system, approximately 800m of piping.

HIGHLIGHTS:

Primero’s scope within the project was delivered on budget and on schedule. The key highlight is the safety performance, as there was a very small amount of incidents relative to industry and business trends with no significant injuries sustained. The project ran for notable 119 consecutive days on site without a recordable incident.

This was the first project executed by Primero, RCR and OFI following the acquisition of OFI into the NRW MET Group alongside the previously acquired Primero and RCR. The successful delivery is a showcase of the capability of the group with a fully integrated EPC delivery structure.