Dampier REC2E Bucket Wheel Corrosion Repairs

Client Rio Tinto

Service  Specialised Services

Location Western Australia

Market

Mining & Industrial

Commodity Iron Ore

Overview

Following the identification of significant corrosion and section loss across 10 crossbeams, Linkforce delivered structural repair and protective coating works to the REC2E Bucket Wheel at Rio Tinto's Dampier operations. Rather than replacing the affected sections, the team developed an engineered over-plating repair methodology aligned with the asset's remaining operational life. This approach reduced project cost and schedule impacts while maintaining the integrity of a critical ore handling asset.

Service Delivery Area 

• Balance Machinery

• Mechanical & Structural

• Fabrication

• Protective Coatings & Structural Integrity

• Access Solutions

• Transport & Logistics

Value Added 

• Experienced project team with extensive corrosion remediation and structural repair expertise

• Alternative repair methodology developed in collaboration with the client and engineering contractor, reducing project cost and schedule impacts

• In-house fabrication capability supporting the manufacture and installation of steel over-plates

• Agile execution approach that successfully managed equipment breakdowns and adverse weather conditions without compromising delivery outcomes

• Dedicated scaffold design capability providing safe and efficient access to critical repair areas

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

Outcome 

Linkforce successfully repaired 10 corroded bucket wheel crossbeams through the fabrication, installation and welding of engineered over-plates, followed by abrasive blasting and application of protective coatings to RTIO specifications. Supported by Certificate 10 welding supervision, NACE Level 2 coatings inspection and comprehensive QA documentation, the works restored the structural integrity of critical bucket wheel components while avoiding full section replacement. Completed one day ahead of schedule and outside the planned major shutdown, the project delivered significant cost savings and maintained operational readiness across a key stockyard asset.