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Conventional Formwork used on Roy Hill Iron Ore Mine

Article Details

  • SYSTEM Formwork
  • PRODUCT alshor-plus-aluminium-shoring-system
  • STRUCTURE TYPE Bridges, Dams, Industrial, Mining, Rail, Tunnels, Utilities, Viaducts, Water Works
  • REGION Australia & New Zealand

RMD Perth won the supply of the Roy Hill Rom (Run of Mine) Wall section of the project with Whittens Group. Focus was on delivering a simple and quick formwork solution providing a high quality finish. This was achieved by using RMD’s Super Slim Soldiers and Alform Beam wales which enabled large formwork shutters to be constructed.


Conventional Formwork used on Roy Hill Iron Ore Mine

Roy Hill is an iron ore mining project in the Chichester Range in the Pilbara region of Western Australia, located 115 kilometres north of Newman. With indicated reserves of more than 2.4 billion tonnes, it is set to become one of the largest mining projects in Australia. Mining operations will produce 55 million tones of iron ore per annum with an operating life of more than 20 years.

Gina Rinehart’s Hancock Prospecting is the majority stakeholder in the project with a 70% interest. Capital costs to develop the project are estimated to be at least A$7 billion, and the first shipments from the mine are expected in 2015.

RMD Perth were supporting the Whittens Group
RMD Perth won the supply of the Roy Hill Rom (Run of Mine) Wall section of the project with Whittens Group. As the previous contractor had gone into liquidation the time frame to construct this aspect of the project was extremely tight, so attention was focused on delivering a simple and quick formwork solution providing a high quality finish. This was achieved by using RMD’s Super Slim Soldiers and Alform Beam wales which enabled large formwork shutters to be constructed.

The ROM walls are each over 90m long and 15.8m high at the highest point. Due to the height of the walls they had to be constructed in two lifts, the conventional forms were jumped using anchor screws.

RMD delivered in a tight situation
The initial requested concept was changed just prior to its commencement and on a number of occasions after that, but RMD was able to deliver against an extremely tight program both on the design side and equipment procurement, particularly when the schedule was changed to deliver two walls simultaneously.

A supreme effort was provided by the RMD design team and in particular the yard staff to deliver high quality, serviced equipment to the site against this revised schedule.

Also supplied formwork and shoring for the Car Dumper on Package 3
Also on the Roy Hill Project, RMD Perth supplied formwork and shoring for the Car Dumper on Package 3, Port Landside, again with the Whittens Group. The same scenario evolved as they took over from the previous contractor who had gone into liquidation.

Alshor Plus Shoring system was used for supporting the slabs
This was a complex structure constructed with a number of different pours over several levels with 2 thick slabs up to 2600mm in depth. It also had a tunnel 92m long and Super Slim Soldier and Alform Beam shutters were used for the walls of both structures. The RMD Alshor Plus shoring system was used for supporting the slabs formed with Ply, Albeam and Alform Beam tables lifted into position after the erection of the shoring. The Alshor Plus shoring system is an innovative system, with integrated safety and productivity features.

The original idea was to roll the tables out on the Alshor Plus castor units after the first slab pour and lift them into position for the second slab pour, however, this was not possible due to the late inclusion of a myriad of plinths and pedestals on the base slab.

A late change to the design concrete density for the main Car Dumper slabs led to a complete re-design of the formwork system. This was completed successfully within a very short time frame.

This project ran from April 2014 to May 2015.

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