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Roy Hill Project

Australia

Client: Samsung C&T
CAPEX: AUD $10 Billion
Location: Pilbara, Western Australia
Project Duration: 2014-2015
Key Services: 3D BIM Modelling, Animation, Integrated Design

Projects Details

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.

PDC have been engaged by multiple contractors for various scopes of work. PDC were originally engaged, through Laing O’Rourke, to audit the fabrication drawings supplied by other detailing contractors for package 3, Port Landside. The lack of progress and the multiple errors PDC were finding resulted in Laing O’Rourke increasing PDC’s scope to the 3D modelling and shop detailing of a large portion of the scope. The Port Landside (package 3) includes a twin car dumper for rail unloading and stockyard with one stacker and two reclaimers. The Port Marine (package 4) through McConnell Dowell, includes 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 tonnes.

The PDC scope for package 3 Port Landside included in excess of 5000t of the 3D modelling and shop detailing of structural, mechanical steelwork including plate work components. 

PDC also provided input regarding model plan breakdown to assist the constructability and modularisation process. PDC was also contracted to convert a screening building model to Australian sections for fabirication by a local fabricator.

This scope was completed on a aggressive schedule of 8 weeks due to schedule impact caused by design and previous detailing errors.

PDC designed and detailed the transport steel for the following structures for Package 3 Port Landside for Samsung:

  • TFS104 Drive and Transfer Station
  • TFS116 Transfer Station
  • TFS122 Drive & Transfer
  • SBG004-18-01 to 04 Modules
  • TFS041 Transfer Station
  • TFS042 Transfer Station
  • MRT-SM2001 Sampling Monorail Support Structure

Decmil Australia contracted to PDC 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.

PDC was then engaged by McConnell Dowell to complete the 3D modelling and shop detailing of package 4 consisting of the wharf and overland conveyors. 

Samsung has since engaged PDC 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.

Projects Challenges/Highlights

  • Schedule was accelerated during a 6 week period to over 40 resources and issued over 5,000 tonne of steelwork.
  • Utilised a global work sharing platform.
  • PDC supplied Interim Quantities and Values to Laing O’Rourke to allow for progress reporting and invoicing.
  • PDC’s experience and expertise in managing and minimising 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 minimise the impact and cost of change.
  • PDC’s was able to optimise the bulk fuel containment to minimise bunding, oily water treatment and disposal requirements.
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