Located at Mining Area C, approximately 120 km north-west of Newman in the Pilbara region of Western Australia, the South Flank iron ore mine is a $4.5 billion development. It’s one of the largest iron ore mines in the world, with a production capacity of 80MTPA.
DBM Vircon was engaged to support several aspects of the project, providing digital engineering, construction modeling, design, and detailing support. At peak, the project utilized over 240 DBM Vircon resources across six global offices: Perth, Brisbane, Vancouver, Auckland, Manila, and Chennai. DBM Vircon was engaged from 2018 to 2021, delivering:
- Over 80,000 drawings and 116,000 fittings
- Millions of accurate metadata attributes
- More than 16,000 tonnes of structural steelwork models and drawings
DBM Vircon’s Scope of Services
Digital Engineering
As part of the integrated project team, DBM Vircon worked within BHP’s digital delivery team, ensuring that digital engineering principles supported Design for Manufacturing and Assembly (DfMA). Digital Engineering deliverables included:
- Data Audits and Monitoring to validate model integrity for fabrication and construction.
- Extracting Model Data for IPT Distribution, ensuring seamless digital workflows between design and fabrication teams.
- Material Take-Offs (MTO) (Site-Wide) that informed early procurement and off-site fabrication strategies.
- Model Federation and View Reports to improve clash detection and optimize prefabrication processes.
- Data Visualization & General Reporting to enhance decision-making in modular assembly.
- Development of a BHP database to support streamlined and standardized data management across all project stakeholders.
- Engineering Support (IFF File Management) for efficient data transfer between engineering, fabrication, and construction.
- Processing 50 facilities for MTOs, covering over 2,000 modules, ensuring accuracy in pre-assembled components.
Digital Engineering Solutions:
- Backend processing expedited data extraction for modular fabrication.
- Development of a platform to manage data overrides, ensuring fabrication-ready information.
- Creation of an interface to control MTO outputs, improving modular fabrication sequencing.
- Clear and structured audit reports for ESPs, facilitating off-site manufacturing efficiency.
Design and Construction Modeling
DBM Vircon’s approach integrated design and construction modeling to facilitate modular fabrication and assembly, reducing rework and improving overall efficiency. This included:
- Early Engagement & Delivery Strategy Review
- Conducted investigations, reviews, and reports on integrated delivery strategies aligned with DfMA.
- Evaluated workflows, software, and methodologies to improve integration between engineering and shop detailing, optimizing off-site fabrication.
- Provided recommendations that shaped the project’s modular design and detailing delivery approach.
- Structural Design, Detailing & Construction Modelling
- Developed integrated 3D models optimized for prefabrication of:
- Material Handling Inflow Circuit (primary crushing, surge bin facilities, and 16km of overland conveyors)
- Outflow System (stockyard storage, sampling, train loadout facilities, and associated conveyors)
- Ore Handling Plant (secondary crushing, product screening, coarse ore stockpile, and conveyors)
- Collaborated with Fluor and Worley (formerly Jacobs) to streamline modular construction workflows.
- Offshore Fabrication Workshop Coordination Support
- Deployed resources to fabrication yards in China to support modular fabrication accuracy and quality.
Project Execution & DfMA Deliverables
- 350,000+ man-hours of modeling and detailing support, ensuring optimized prefabrication.
- Assisted in the development of 650+ multidisciplinary modules, reducing on-site assembly complexity.
- Integrated construction modeling expertise at 30% design completion, minimizing rework and enhancing reliability.
- Managed and controlled all vendor equipment and associated data within the 3D model, ensuring prefabrication compatibility.
- Controlled 70-110 metadata fields per vendor item, critical for accurate assembly.
- Concept animations demonstrated constructability proof-of-concept and maintenance strategies, optimizing modular deployment.
- Developed module data reports to manage manufacturing, logistics, and installation, including:
- Isometric Views & COG Reports to ensure transportability and lifting feasibility
- Construction Sequences with color-coded assembly plans for streamlined on-site work
- Lifting and Transport Reports facilitating safer and more efficient module installation
- Vendor Equipment Integration Reports ensuring alignment with prefabricated assemblies
Lessons Learned for Future projects
- Early integration of design and detailing improves prefabrication efficiency, reducing fabrication and construction issues.
- Clear workflows and communication protocols prevent duplication of effort and minimize rework in modular construction.
- Understanding fabrication, construction, and offshore modularization is critical for efficient execution.
- Strategic resource allocation optimizes efficiency, ensuring specialized teams handle prefabrication-sensitive tasks.
