PROJECTS
Roy Hill Iron Ore Project
Budget:
Completed:
Client:
$9.5 billion
May 2004
Posco (Australia)
The Roy Hill Iron Ore Project was a $9.5b mega project for the construction of a 55mtpa mine, port and rail operation in the Pilbara region of Western Australia.
Posco, a Korean steel producer (sixth largest in the world) and holding equity in the Project, also wanted to
perform the construction.
As Project Manager for Posco and mentor to Korean Project Managers, Topmen were responsible for the
design, estimating, scheduling, contracting, client liaison, and early works associated with the four primary
project packages.
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Mine and processing plant
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Railway and train unloader
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Port – dry side stockpiles – stockpile stacking and reclaiming
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Port – wet side- overland conveyor and wharf and ship loading
Roy Hill Village
Budget:
Completed:
Client:
$32 million
May 2004
Posco (Australia)
Topmen repaired and renovated 998 permanent accommodation units in Roy Hill Village, ensuring they remained operational for the operations personnel.
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The accommodation units were purchased by Roy Hill and manufactured overseas. The design was too flexible and was not suitable for shipping from overseas. When the units arrived, many sustained considerable damage.
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The extensive work involved the replacement of ceilings, flooring, fire alarms, water heaters, and furniture. Managing logistics was a significant challenge to ensure the seamless accommodation of personnel during the renovation process.
Roy Hill Overland Conveyor Foundations
Budget:
Completed:
Client:
$33 million
Mar 2015
McConnell Dowell
The 5 million tonne stockpile area was connected to the port ship loader services a two berth wharf with a
4 kilometre, 12,700 tph elevated overland conveyor. Topmen oversaw the construction of the conveyor and road crossing footings for the overland conveyor.
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The high ambient temperatures required considerable care to maintain the integrity of concrete structures and the prevention of cracking. This project saw the use of low heat concrete, pouring at night, and monitoring of internal temperatures of the structure to ensure concrete temperatures were optimal.
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Gorgon LNG Plant Project
Budget:
Completed:
Client:
$42 million
Oct 2011
Holcim (Australia) Pty Ltd
Holcim (Australia), part of a worldwide concrete and quarrying business, was awarded a contract for the supply of concrete for the $60b Gorgon LNG Plant in an A-Class Reserve on Barrow Island, Western Australia. This project required a suitable on-site concrete batching plant.
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A prerequisite to construction was in compliance with the Chevron and the Western Australian Government
environmental requirements for working in an A-Class reserve, including a number of unique quarantine
and logistics conditions.
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Topmen’s role was to provide and lead a team to realign the establishment and construction phases of a
$42 million Wet Mix Concrete Plant, including a 120 tph wet batch mixer, a 50 tph ice plant and associated
support equipment.
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Services for the Project included supplying project personnel, project and construction management,
design, contracts management, procurement and scheduling. At the end of the assignment, Topmen was
responsible for recruitment, mentoring, and training of ongoing operations personnel.
Lang Hancock Rail & Hope Downs Village
Budget:
Completed:
Client:
$750 million
May 2010
Rio Tinto
The Lang Hancock Rail, Hope Downs Village and Teal Sidings Projects were for the construction of a 58 km heavy haulage rail line, train loading facilities, five rail sidings, a 550-room permanent accommodation village and a 33 km sealed access road.
Topmen was responsible for the design, contract management, procurement, construction, commissioning,
handover and close-out of the Projects.
After completing the projects, Feasibility and Detailed Engineering Studies were conducted for a 100 mpta
expansion of the Rio Tinto iron ore heavy haulage rail network system.
Telfer Gold Project
Budget:
Completed:
Client:
$1 billion
Sep 2004
Newcrest Mining
The Telfer Gold Project was a fast-track project for designing and constructing a 20mtpa open cut, underground mine, and concentrator. At the time, it was the single biggest gold mine in Australia.
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Topmen managed and administered contracts for the design and construction of the Underground Mine, including a raised bore shaft, headframe, ventilation system, and both surface and underground facilities.
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Subsequently, the appointment was revised to include all Project Contracts for the construction phase’s finalisation, including the EPCM contracts for the mine, concentrator, and surface infrastructure. This scope included the development of the new Village and its subsequent expansion.
FMG Iron Ore Project
Budget:
Completed:
Client:
$3 billion
May 2007
FMG
The FMG T45 Expansion Project was the green field construction of mine, rail, port infrastructure for the mining, transport, and shipping of 45 mtpa of iron ore.
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Topmen provided project and contracts management and client liaison services for the civil works for a 55 mtpa car dumper (11,250 tph), rail crossings and conveyors.
Most of the 18,000m3 of concrete was 20 metres below sea level, and it was critical that the works were of a high standard to prevent saltwater ingress.
OPR Port & Rail
Budget:
Completed:
Client:
$1.5 billion
May 2012
Posco E&C Pty Ltd
Prior to the Roy Hill Project commencing, a Technical Due Diligence Report was prepared for Posco to evaluate the $4.5b OPR Port and 550 kilometre Rail Project in mid-Western Australia in which investment was being considered.
The recommendation was not to invest, which was subsequently followed.
Bronzewing Gold Project
Budget:
Completed:
Client:
$270 million
Jan 1996
Great Central Mines
The Bronzewing Gold project was for the design and construction of a 1.3 million tonnes per annum opencut mining and gold processing facility in the Eastern Goldfields of Western Australia.
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Topmen was appointed as the Client Representative, primarily focusing on preparing, facilitating, and overseeing contracts for the supply, procurement, and construction of key components, including the process plant, power station, and accommodation village.
Safety Infrastructure Overhaul
Budget:
Completed:
Client:
$.5 million
Jan 2023
Western Australian Specialty Alloys
Topmen was contracted to implement a safety infrastructure plan at Western Australian Specialty Alloys.
Work included evaluation of the existing infrastructure, recommendations for modification to ensure
equipment complied with local and international standards, and obtaining relevant Government approvals.
All work was completed over 18-months without disrupting the ongoing 24-hour operations.
Topmen also undertook several other safety projects, including designing a transport cradle for 16-tonne
products, carrying equipment within the works and modifying cooling towers and wastewater treatment
plants.
Topmen continues to support WASA with a number of ongoing safety based projects.
