IMAGINE A WORLD WITHOUT MINING & METALS

Own a mobile phone, surf the web, use public transport, or fly overseas on your annual holiday?
Then you're already a fan of the Mining & Metals sector.

We'd like to know how to build a solar panel farm, wind turbine, or an electric car without a Mining & Metals industry.

It's an amazing industry full of talented people, and we're proud to be a part of it.  At Project Control we've spent a lot of time working in this space, building Process Plants and Materials Handling Facilities for nickel, copper, gold, coal, and bauxite mines. We've also built the world's largest Bulk Solids Handling Facility, taking it from 66 million tonnes to 145 million tonnes per annum. Over a dozen Stackers and Reclaimers, 8 Process Plants, 2 Aluminium Smelters, 6 Ship-loading Berths, and much more.

Our experience is your competitive advantage.  Accurate, on time Project Control.

SHIPLOADER RECOVERY

NEWCASTLE | MINING & METALS
Achievement: Return to service within 9 months
Client: NCIG
Builder: FLSmidth
Location: Newcastle
One of NCIG's two shiploaders was blown off its rails and damaged on November 16 2020, which caused the terminal to have a 30% reduced export capacity. Project Control Pty Ltd were engaged to develop a recovery program with FLSmidth with the aim of returning the damaged shiploader to service as fast as possible.
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It was quickly established that a full replacement taking approximately 18 months would not satisfy this requirement. A repair strategy was implemented resulting in a return to service within 9 months.

LIDDELL COAL EXPANSION (FOR XSTRATA)

NEWCASTLE | MINING & METALS

Achievement: Accelerated construction phase from 10 months to 7 months
Client: Xstrata
Builder: Downer EDi Engineering
Location: Newcastle
Completion Date: July 2008
Provided planning using Primavera P3 from engineering through to procurement and construction. The project included the design and construction of a 100t/h Coal Prep Plant and associated ROM/RAW/Product and Reject Conveyors.

Our role was to get the project to Mechanical Completion by 21MAY08 which required us to accelerate the construction phase from 10 months to 7 months. Our weekly focus on schedule allowed all parties (eng/proc/subcontractors) to see the impact their decisions were having on others. Despite many hurdles along the way, it was a pleasing result to have achieved this difficult milestone.

PORT WARATAH COAL SERVICES (FOR BECHTEL)

NEWCASTLE | MINING & METALS
Achievement: Completed 10 months early
Client: Port Waratah Coal Services
Builder: Bechtel
Location: Newcastle
Completion Date: Oct 2007
Provided Cost and Planning assistance from Feasibility Study through to Project Completion. This was our 3rd project with PWCS and 5th with Bechtel.

The project involved the construction of Conveyors, Transfer Houses, Berm and Pad, utilising a combination of Preload and Dynamic Piling, all intended to increase PWCS capacity from 90mil to 110mil t/year.

ANGLO COAL / BMA GLOBAL

| MINING & METALS
Achievement: Estimate gained Board Approval
Client: Anglo Coal
Builder: BMA Global
Location: 
Completion Date: Oct 2007
Provided Cost and Planning assistance from Feasibility Study through to Project Completion. 

Starting with detailed estimates from various companies in very different formats, we developed a full project estimate which enabled gap analysis. risk assessment, contingency, and escalation in an easy to interrogate format. This estimate was then used to obtain Board Approval and became the basis of the baseline schedule.

WORLEY PARSONS

| MINING & METALS
Implemented and maintained the Worley Parsons Cost Management Tool called "InControl" across all current projects within NSW (over 400 projects). We were responsible for the training of existing and new users, and to report the health of all projects to senior management.

We provided planning support to all major projects which included;
  • OneSteel Alliance Newcastle (20mil) - P3e/InControl
  • Hydro Aluminium (30mil) - MS Project
  • Tomago Aluminium (20mil) - P3e/InControl
  • Rocla WREX Project - Suretrak/InControl
  • Caltex Kurnell Refinery - P3 v3.1/InControl
  • Aughinish Smelter upgrade (Ireland) - P3 v3.1
  • OK Tedi Gold Mine Expansion

SHELL OIL / AJ MAYR

 | MINING & METALS
Client: Shell
Builder: AJ Mayr
Location: Newcastle
Completion Date: Oct 2005
AJ Mayr were contracted to fabricate and deliver 39 individual preassembled Oil and Gas modules for two of Shells refineries (Geelong & Clyde).  These modules combined Fire Rated & Galy Structural Steel, Vessels, Pipework, and E&I. The company had to increase its original workforce 10 fold and maintain safety and quality to the highest standards.

This project did not go according to plan when client supplied drawings and equipment were delivered very late. However, throughout the project AJ Mayr were able to reflect the impact of these late deliveries on the overall project completion, ensuring that AJ Mayr were well protected in the event of any future liquidated damages claim. In fact, our planning records assisted AJ Mayr win an $11mil claim against the client.

Manpower requirements were always forecasted to ensure we had good productivity, and the weekly % complete and earned value (hours) were continually monitored against our baseline, which helped identify those areas that were directly affecting the critical path.

GORO NICKEL ​PROJECT-INCO
(FOR BECHTEL/​HATCH/TECHNIP)

NEW CALEDONIA | MINING & METALS

Total Project Value: $3,500 mil
Completion Date: Jan 2004
The project reached >40% engineering and 5% construction before the client suspended this project (Dec02) following a budget blow-out. We returned to work directly for Inco for another 8 months  until a new JV was established.

Our role included;
  • Building the overall schedule from a Level 2 to a fully integrated Level 3/4 (EPC).
  • Helping to manage 12 planners from different backgrounds and skill levels to develop a fully integrated Primavera schedule.
  • This schedule consisted of 16,000 activities (as 16 sub projects) and included Engineering, Procurement, Contracts, Permits, Construction, and Commissioning.
  • The schedule was used to measure and report the progress on a 2 weekly basis, and to provide commodity and manpower curves.
  • Monthly we provided a full Schedule Review including manpower, commodity, and cost curves.
  • The schedule was used to quantify the effect the increased budget had on our manpower levels, and our project completion date.

NEWEIPA PROJECT
​(FOR BECHTEL)

WEIPA | MINING & METALS
Completion Date: May 2003
Our role included;
  • Pickup the original Tender program and develop a resources Level 3 EPC schedule.
  • Produce and action a 90d look ahead, early works plan, and show the effect that increasing scope was having on our ability to complete the works within the project timeframe.

COMALCO WEIPA
​(FOR BECHTEL)

WEIPA | MINING & METALS
Total Project Value: ​$18mil
Completion Date: Dec 2001
We were responsible for the creation and maintenance of a Master Construction Schedule.

The scope of this project was to assist Comalco manage 119 individual projects to completion. This project provided the Weipa facility with the ability to mine A Grade Bauxite more economically than in the past. One of the major challenges was to maintain the focus on all potential high risk areas to achieve completion of critical elements on time.