Roy Hill

CLIENT: Samsung C&T
LOCATION: Pilbara, Western Australia
project overview:

The Roy Hill project is an iron ore mine, rail and port project in West Australia’s Pilbara region. The mine itself will process 55 million tonnes per annum (Mtpa). The project consists of 4 packages. Package 1 includes the Mine Process Plant, package 2 includes Rail. Package 3 and 4 cover the Port Landside (stockyard) and Port Marine.

DBM Vircon’s Scope of Work:

  • DBM Vircon was engaged by multiple contractors for various scopes of work on this project.
  • First engaged through Laing O’Rourke, DBM Vircon was to audit the fabrication drawings supplied by other detailing contractors for package 3, Port Landside. Due to a lack of progress and the multiple errors DBM Vircon was finding, Laing O’Rourke increasing the scope to 3D modeling and shop detailing of a large portion of the project scope.
  • The Port Landside (package 3) includes a twin car dumper for rail unloading and stockyard with one stacker and two reclaimers. The scope for this portion included in excess of 5,000 tons of 3D modeling and shop detailing of structural, mechanical steelwork including TFS104 Drive and Transfer Station, TFS116 Transfer Station, TFS122 Drive & Transfer, SBG004-18-01 to 04 Modules, TFS041 Transfer Station, TFS042 Transfer Station and MRT-SM2001 Sampling Monorail Support Structure.
  • The Port Marine (package 4) scope came through McConnell Dowell and included a dedicated two berth facility capable of receiving, stockpiling, screening and exporting the iron ore. It has the capacity to store over 2.3 million tons. DBM Vircon was then engaged to complete the 3D modeling and shop detailing of package 4 consisting of the wharf and overland conveyors.
  • Decmil Australia contracted to DBM Vircon to supply design for two bulk fuel farms, Rail Fuel Yard and the Mine Fuel Yard and refuelling facilities at the Mine Services area and Go Line.
  • DBM Vircon also provided input regarding model plan breakdown to assist the constructibility and modularization process. DBM Vircon was also contracted to convert a screening building model to Australian sections for fabrication by a local fabricator.
  • Samsung later engaged DBM Vircon to consolidate all the subcontractors’ models into one overall fully intelligent Navisworks model. This model will be used for facilities management and will be the single point of truth for all drawings and data.

Roy Hill Project Highlights & Challenges:

  • This project scope was completed on an aggressive 8 week schedule due to schedule impacts caused by design and previous detailing errors.
  • The schedule was accelerated during a 6 week period to over 40 resources and issued over 5,000 tons of steelwork.
  • A global work sharing platform was utilized
  • DBM Vircon supplied Interim Quantities and Values to Laing O’Rourke to allow for progress reporting and invoicing.
  • DBM Vircon’s experience and expertise in managing and minimizing the impact of changes was vital to controlling project costs. We had the ability to resolve design issues and worked collaboratively with design and fabrication teams to minimize the impact and cost of change.
  • DBM Vircon was able to optimize the bulk fuel containment to minimize bunding, oily water treatment and disposal requirements.

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