Christmas Creek TLO Bin Roof Structural Remedial Works

Client Fortescue

Service  Project Delivery

Location Western Australia

Market

Mining & Industrial

Commodity Iron Ore

Overview

Following the identification of significant corrosion within the Christmas Creek Train Load Out (TLO) Bin roof structure, Linkforce delivered critical structural remediation works to restore the integrity of a key train loading asset. The project involved the replacement of three-quarters of the bin roof and associated corrosion-affected steelwork, supported by an alternative execution methodology that reduced project risk and accelerated delivery. Through integrated planning, fabrication and access solutions, the works were completed safely and efficiently within a live operational environment.

Service Delivery Area 

• Mechanical & Structural

• Fabrication

• Access Solutions

Technical Highlight – Access Solutions 

• Developed a suspended scaffold system that enabled the replacement of three-quarters of the bin roof through an external construction methodology.

• Reduced scaffolding materials and labour requirements by approximately 75% compared with conventional internal access methods.

• Removed the need for extensive internal scaffolding by suspending access systems directly from the bin structure.

• Produced detailed scaffold work packs incorporating access requirements, design drawings, dimensions, material schedules and execution methodology.

• Designed the access solution to accommodate cyclone season conditions while maintaining safe access to complex work fronts.

Value Added 

• Experienced project team supported by in-house planning, fabrication and scaffold design expertise.

• Detailed work packs incorporating access design, execution methodology and material requirements.

• Innovative access methodology delivering a reduction of more than 300 man-hours compared with the client's conceptual design.

• Extensive equipment capacity supported by more than 5,000 tonnes of available scaffolding inventory.

• Proactive planning to manage cyclone season risks and maintain delivery certainty.

• Certified management systems aligned with ISO 9001, ISO 14001 and ISO 45001 standards.

Outcome 

Linkforce successfully removed and replaced corrosion-affected structural steelwork within the upper section of the TLO bin, restoring the integrity of a critical train loading asset. Through the implementation of an innovative access and construction methodology, the project achieved a 75% reduction in scaffolding materials and labour requirements and eliminated the need for multiple shutdown campaigns. Delivered 25 hours ahead of schedule and with more than 300 man-hours saved compared with the original concept, the works improved constructability, reduced disruption to operations and demonstrated the value of integrated project delivery.