7 Learnings From a 13km Slurry Pipeline Build
Working with Civmec on Mesa A, and UGL on Mesa J, we manufactured all the slurry piping and mining hoses for the pipelines and wet plants, then worked with them to ensure on-time delivery.
Here are seven challenges the construction teams faced, and how they overcame them to make the RVS project a success:
1. Streamline project management
Tight project management is the key to completing a project of this size. The RVS team wanted to be sure that their piping manufacturer was able to keep up with the volume and pace of production, and not let them down. At the same time, they wanted a collaborative relationship with open lines of communication.
They liked that we follow agile project management methodologies: it meant that we could respond to design pivots and changes to schedules to still produce the best possible outcome for the project.
2. Reduce manufacturing risk
The RVS project team didn’t want to be let down by manufacturing delays. To reduce their risk, they chose slurry piping built by one manufacturer, made in Australia.
The polymer-lined slurry piping, Abrasiguard, and mining hose, Slurryflex, are both made in Australia at the same factory, so they had peace of mind that the orders would be delivered on time, ready for install.
3. Oversee quality
One of the priorities for Civmec and UGL was to manage quality control and assurance during the manufacturing process.
We follow a QAP program and create an ITP for every project—each reflective of the client’s piping specification. There are eight inspection checkpoints throughout production. Clients like that they can inspect the process at our manufacturing facility in Brisbane for full visibility.
With our quality control process, the RVS team could be confident they would get piping that exactly matched their specifications.
4. Keep to project schedule
The project schedules were tight. They needed a manufacturer who had both the scale and capacity to get the job done on time.
13km of polymer-lined slurry piping, and 270 slurry hoses had to be on site in 22 weeks. This was a big ask for any business during the COVID-19 pandemic, given the global supply chain issues.
Our Australian factory had the required production capacity and the ability to deliver directly from our manufacturing facility. We manufactured 500m of piping per day, and finished the process in just 28 days.
This photo shows the 18-metre-long spools on our factory floor. We’re the only piping manufacturer in Australia able to produce 18-metre polymer-lined pipe—the longest in the market.
5. Simplify inventory
Keeping track of inventory arriving on site from different suppliers at different times can be a logistical nightmare for large-scale projects like RVS. This shouldn’t hold up construction.
We helped the RVS team simplify their inventory by supplying everything together, such as the gaskets and releasing agents.
We delivered them to site neatly bundled up with the pipes and hoses in a complete package, ready for install.
6. Ensure low-stress delivery
Late delivery makes the job so much harder. You just want to know your order will arrive on site, on time.
By working with us, Civmec and UGL could be confident knowing their project order would be transported direct to site, on time, with no damage.
All our items were delivered on time, undamaged, in an organised way that suited the installation schedule. This made life easier and more stress-free for the project managers.
7. Install support when needed
Our team of piping specialists were available for tech support during installation, so there were no delays or install issues.
We provided guidance, such as best practices on how to safely torque up bolts, and post-installation support, and maintenance when they needed it.
Successful project delivery
There are lots of things you have to consider to make sure your project comes together. We were pleased to help manufacture, and deliver a slurry piping system of this scale so Civmec and UGL could successfully commission the pipeline and plant.
Rio Tinto has been happy with the result—already improving production, capacity, and quality for this operation.
We’re proud to have partnered with Civmec, UGL, Calibre, and Rio Tinto on this project.
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