Roy Hill FDR101 Apron Feeder Overhaul

Client Hancock Iron Ore

Service  Shutdown & Maintenance

Location Western Australia

Market

Mining & Industrial

Commodity Iron Ore

Overview

Linkforce delivered a major overhaul of the FDR101 Apron Feeder at Hancock Iron Ore's Roy Hill operation, replacing ageing components that had remained in service since the asset's original construction. The project involved the refurbishment of critical mechanical systems, including chains, pans, impact rails, skirt liners and drive sprocket segments, to improve reliability, restore performance and reduce the risk of unplanned downtime. Executed within a shutdown environment, the works required innovative planning, specialist mechanical expertise and agile problem-solving to address unforeseen site conditions.

Service Delivery Area 

• Balance Machinery

• Mechanical & Structural

• Fabrication

• Access Solutions

• Transport & Logistics

Value Added 

• Experienced execution team with extensive apron feeder maintenance and shutdown delivery expertise

• Innovative planning and engineered methodologies that enabled the safe and efficient execution of complex refurbishment works

• Agile response to unforeseen site conditions, including equipment modifications and additional structural repairs identified during execution

• Strong collaboration between mechanical, hydraulic and maintenance personnel to maintain shutdown progress and minimise schedule impacts

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

Outcome 

Linkforce successfully completed the replacement of apron feeder pans, chains, impact rails, skirt liners and drive sprocket segments, restoring the condition and performance of the FDR101 asset. When site conditions revealed undocumented design changes, hydraulic system constraints and structural defects, the team developed and implemented practical engineering solutions, including in-situ ski frame modifications, hydraulic bypass installations and structural weld repairs. The project was completed safely, achieved all shutdown milestones and improved the long-term reliability and maintainability of a critical ore handling asset.