BHPB NEWCASTLE STEELWORKS

PROJECT PROFILE

CLIENT

BHP Billiton Ltd

LOCATION

Newcastle, NSW

INDUSTRY

Mining

DURATION

Feb 00 – May 04

SERVICE

Industrial Demolition & Deconstruction; and Asbestos & Hazardous Materials Removal

PROJECT OVERVIEW

Major Projects Group has the distinction of undertaking one of the largest demolition projects ever conducted in Australia in the demolition of the Newcastle BHP steelworks. With a value of over $30 million, the BHP steelworks demolition was a complex project, and our Group helped to ensure that it proceeded with minimal risk to workers involved with the project.

The demolition began at the steel works in February 2000, some months after the main steel making operations closed, and continued for another three years.

SCOPE OF WORK

This complex project included the removal of 120 buildings, 64 of these being major structures such as No. 3 & 4 blast furnaces, Basic Oxygen Steelmaking (BOS), boilers, furnaces, numerous chimneys, stoves and massive workshops. Major Projects Group was not only responsible for the removal of all steel structures but also the removal of asbestos and other hazardous substances.

UNIQUE CHALLENGES
 Removal of major industrial structures.

 Hazardous material removal.

 Largest demolition project ever conducted in Australia

 Demolition without the use of explosives.

CUSTOMIZED SOLUTIONS

No explosives were used in the BHP steel works demolition. Major Projects Group used a mechanical process to strategically weaken large structures and then controlled the collapse in a safe manner, reducing occupational health and safety risks. Seven story high ore bridges, weighing 1000 tonnes, were successfully collapsed using this method.

Local workers were sourced to form a project team of 24 to bring down and process the entire Steelworks in 24 months. Only 9 machines were used to complete the project including three 160 tonne excavators equipped with specialist demolition attachments.

RESULTS

An important aspect of the project was the high level of recycling of materials that was achieved. An estimated 106,000 tonnes of steel and 40,000 tonnes of concrete were demolished processed on the site. The only materials taken to the Council Dumps were human generated waste such as packaging and food scraps, broken timber, broken glass etc. In excess of 99% of all materials from the demolition work was recycled. All ferrous scrap was recycled, with the majority processed for consumption at Sydney & Port Kembla. Non-ferrous metals such as copper & brass were exported to Asia. Brick and concrete rubble was processed for ‘clean-fill’ and was stockpiled for future use on-site.

The majority of machinery was also scrapped as worldwide tendering showed no interest (due to the number of steelworks closing around the world) and most was beyond the capacity of museums and heritage interests to accommodate.

Major Projects Group used 351,520 man hours over the period of the contract without an incident. The entire site was cleared within the two year program at no cost to BHP Billiton.

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