Context
ICL’s business objective is to support the development of independent concrete batching plant operators in a wide range of markets throughout Victoria and New South Wales, with a focus on using low-carbon alternative products.
The Brief
Project Manage the delivery of a greenfield Slag Grinding Facility on a contaminated site at Yarraville in inner Melbourne.
The Project
The client purchased a Japanese (UBE) 60tph Vertical Roller Mill before engaging Ammjohn Solutions. The balance of plant required to operate the mill was procured using a process design supplied by the mill manufacturer, and a ship loading system for imported raw materials, a raw material blending plant, a mill feed system, and a final product storage and dispatch system were constructed, and the existing raw material store was repurposed.
The project value in today’s dollars is $100M.
Our Scope
Ammjohn Solutions provided the project delivery team which was responsible for:
- Devising and implementing the project management plan
- Conceptual design and management for the balance of plant
- Tender document preparation, tendering and tender evaluation
- Fabrication monitoring
- Project controls including cost and schedule reporting
- Principal contractor responsibilities controlling the site
- Construction management and site supervision
- Commissioning management
- Handover and project close-out.
Outcomes Delivered
Ammjohn Solutions’s procurement strategy balanced the client’s appetite for risk with the practical realities of delivering this type of project in Melbourne. Notwithstanding the inherent complexity of the project, including the challenge of managing a large number of contractors and suppliers, the project achieved:
- Best-in-practice plant and operations
- Safe and timely construction
- No IR issues
- Within budget financial outcomes
- Problem-free commissioning
To this day, plant availability matches industry-leading benchmarks.
Key Attributes Demonstrated
- Interface management
This was a very complex project, with over 190 separate suppliers utilised on the project. This generated many interfaces to be managed. This plant is state-of-the-art and comparable in technical difficulty to the HJP. - Managing international contractors
Many international suppliers were involved in the project. These included:
– Mill (UBE) designed and supplied from Japan
– Process design (by mill supplier) from Japan
– Bucket Elevators (Buemer) from Germany
– Hot Gas Generator (Hurll Nu-way) designed and supplied in Australia
– Main process filter (Luehr Filter) designed in Germany and manufactured in Australia
– Raw material infeed and blending (Brightwater) designed in New Zealand
– Raw material infeed and blending (Brightwater) fabricated in China
– Finished Product storage silo (Tank Connections), designed and supplied from USA
– Silo Discharge equipment (Ibau), designed and supplied from Germany.In short this was an international effort driven by Ammjohn Solutions from site. - Principal contractor
Ammjohn Solutions acted as the client’s onsite PC responsible for managing the project and site. - Managing industrial relations
The very challenging Industrial Relations landscape in Melbourne is very difficult to articulate to people who are not familiar with it. Ammjohn Solutions has considerable IR experience in Melbourne and by consultation with contractors, ensuring EBA’s were in place, maintaining a secure site, and ensuring the site was well run and a satisfying place to work, the project did not lose any time. This is very rare in inner city Melbourne.
