PROJECT: Shiploader Structural Refurbishment

INTEGRAL carried out the design of a Shiploader structural refurbishment at a major coal export terminal to address structural integrity issues on the 40+ year old machine. The project aimed to extend the serviceable life of the machine for another five to ten years, until its’ planned replacement. This involved detailed FE modelling and assessment of the shuttling structures, main frame and tripper to allow repairs and for replacement and temporary works to be carried out safely. INTEGRAL worked closely with the client and site contractor to provide the most cost and time effective solutions possible.

PROJECT: Portal Reclaimer 6-wheel Equaliser

INTEGRAL assisted a coal mining client to jack a 6-wheel equaliser on a portal reclaimer to carry out structural repairs that required bogies to be removed. We designed temporary propping steelwork and analysed the existing equaliser structure using a plate element FE Model. The jacking, propping and repair procedure we prepared ensured that the structure was not overstressed during repairs.

PROJECT: Road Culverts

INTEGRAL completed a detailed condition survey and structural assessment of 12 road culverts in the Mackay region. We used NDT equipment, including a covermeter (rebar location), Vernier callipers, ultrasonic thickness tester, Schmidt hammer (for indication of concrete compression strength) and Corromap (Half-Cell Corrosion Potentials) to determine the condition of the concrete and steel structures. Structural capacity assessment of the insitu culvert structures was carried out to the AS5100 Bridge Design Code and recommendations on temporary strengthening and repairs were provided.

PROJECT: Rotary Breaker Station

INTEGRAL was engaged to design upgraded supports for a rotary breaker station at a coal mine in Central Queensland. The existing 30+ year old breaker structure had suffered significant cracking to major support girders that had reached their fatigue life.

We designed replacement breaker support girders with improved fatigue detailing, that also considered congested and very difficult installation along with temporary support structures.

PROJECT: Jetty Deconstruction

INTEGRAL was entrusted as a major client’s independent structural engineering reviewer for the deconstruction of a 4km long jetty structure at a major coal export terminal. The client requested us to review the structural engineering risks from the proposed method of deconstruction of the redundant outloading system. We identified potential structural issues and risks with the strength and stability of existing and temporary structures, and assisted the contractor to provide solutions.

Structural and Mechanical Audits

INTEGRAL has carried out numerous structural and mechanical audits across the Central Queensland and Bowen Basin regions. We have invested in electronic inspection and reporting tools as well as internal training to carry out inspections efficiently and effectively.

INTEGRAL works closely with clients to customise reporting of their structural and mechanical risks using our Red Dingo Risk Management process. The custom Red Dingo ® software program manages all actions from the audits and utilises the risk matrix for each site to report risk ratings. We also developed a secure website to be able to give clients access to their reports via a website login. This ensures clients have access to their up to date structural integrity information at any time.

Audits completed include:

• Structural steel

• Structural concrete

• Materials handling machines (shiploaders, stackers and reclaimers)

• Marine structures

• Reclaim tunnels

• Reinforced earth and civil structures

• Bridges and culverts

• Access/Platforms (AS1657)

• Machinery guarding (AS4024)

• Mechanical audits