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Customer: BHP Contract: Design, procure and construct Location: Port Hedland, Western Australia   |
Fast Facts:
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The Ore Car Repair Shop (OCRS) - Buildings and Facilities project included the design, procurement and construction of a 11,000 m2 workshop, 1,600 m2 air-conditioned warehouse, gatehouse and associated facilities, including a wastewater treatment plant. Located at Mooka, approximately 30 km from Port Hedland, the workshop now services BHP’s extensive fleet of ore cars.
MCD's scope of work was truly multidisciplinary and included design, site establishment and access, civils, structural, rail, mechanical and piping, electrical, architectural, communications and process equipment installation.
INNOVATIONS AND BENEFITS
The workshop has a number of innovative, state-of-the-art technology elements, one being the Automated Guided Vehicles which transport components and ore car bodies around the workshop for scheduled preventative maintenance before being reassembled and returned to operation.
The project team supervised the installation and energisation of the specialist process equipment, which was procured by BHP and novated to McConnell Dowell.
The project also had a high degree of interfacing works with subcontractors for various work activities. A collaborative work culture was implemented on the site to ensure all parties – McConnell Dowell and the various subcontractors – were not disadvantaged due to limited access. To assist, McConnell Dowell provided additional labour resources to support subcontractors in achieving their construction programme, for example by moving materials around the site to facilitate works.
Early value engineering during the Tender Phase, which resulted in a cost competitive offer, involved seeking capital and construction time efficiencies through workshops with the key design and project personnel. These personnel subsequently worked on the project, thereby securing the chain of knowledge and ensuring a quality outcome.
BUDGET AND SCHEDULE PERFORMANCE
The project was delivered on-budget with approximately 50 variations of BHP initiated variations granted post contract award. As such, construction scheduling had to be regularly re-sequenced to maintain on-time delivery – particularly with the high level of interfacing works.
