Leighton – APLNG Curtis Island Workers Camp

Forming part of the six LNG trains on Curtis Island, the Australia Pacific LNG plant is Australia’s largest producer of coal seam gas (CSG). It not only supplies Queensland’s domestic gas market, but also processes CSG into liquefied natural gas to meet the demand of customers around Australia and globally. The development of the plant took some five years, shipping its first cargo in 2016.

To support the construction of the plant, Walz Group was engaged by Leighton Contractors (now known as CPB Contractors) late in 2011 to build the works accommodation camp. Our scope incorporated:

Civil Works including
- Preparation of site
- Road construction
- Building platforms
- Drainage
- Concrete works
Building installation
- 2,600 residential units
- Full commercial kitchen and dining hall to accommodate preparation of three meals a day for 2600 camp residents.
- Miscellaneous buildings including offices, gymnasiums, laundry/toilet/washroom blocks, medical facilities, lunch cribs, security huts, etc
- BBQ shelters, pavilions, walkways

Ausenco – Carborough Downs Overland Conveyor

Vale’s Carborough Downs underground mine is located in Central Queensland’s Bowen Basin, 180 kilometres southwest of Mackay. Walz Group was engaged to perform the structural, mechanical, piping, and electrical installation of the 5km overland conveyor and upgrade of the coal handling and preparation plant (CHPP). This formed part of a broader brownfields expansion. In total, we constructed almost 6km of conveyor systems (drift, stockpile, reclaim, reflect, overland and surge bin conveyors) and associated componentry.

Our works included:

Structural steel installation — trestles, conveyor gantries, transfer stations
Mechanical installation — belt weighers, scrapers, drive motors, pullies, external gravity take-up
Installation of victaulic and screwed pipework
All electrical installation

John Holland – Abbot Point X50 Expansion

We worked with John Holland Group to deliver the X50 Expansion at Abbot Point Coal Terminal. This work increased the North Queensland Bulk Ports Corporation’s annual export capacity to 50 megatonnes. The facility services the export requirements of a number of mine operators, including Newlands, Collinsville, and Sonoma mines.

Our scope incorporated a range of marine works associated with the extension of the transfer tower and construction of the additional operation berth, east of the existing Berth 1. The works included installation of piles, headstocks, and rail girders, as well as steelwork modifications, installation of new equipment, and modification of existing equipment to accommodate the expansion. Walz provided all associated marine equipment and qualified operators.

Connell Hatch – Dalrymple Bay Outloading Conveyor System

We performed the onshore works for the outloading conveyor system in the second phase of the Dalrymple Bay Coal Terminal 7X project. This expansion saw the terminal increase its capacity by around 50% to 85+Mtpa, making it the third largest terminal in the world. As the terminal operates 24×7 all work was completed in a live operating environment. It was essential to minimise disruption of operations and ensure the site remained safe and accessible for staff to continue operations in a business-as-usual manner.

Walz Group supplied all equipment and materials for the onshore construction of the new outloading system. These works delivered a third reclaiming stream and associated conveyor systems for the transfer of coal from the stockyard to a new surge bin and sample plant facility. Our scope included all mechanical, structural, civil and electrical work, as well as commissioning of new systems. The works included:

Modifications to existing conveyors including addition of new chutework
Installation of 3 x new conveyors
Installation of a new surge bin
Installation of a new sample plant
Installation of new belt feeders