Alcoa Kwinana Filtration Plant

Alcoa Kwinana Filtration Plant

Category: Engineering Survey – Civil Construction
Project: Alcoa Kwinana Filtration Plant
Project Value: $59.8m
Client: Sedgeman / DTMT
Location: Western Australia
Timeframe: March 2015 to October 2015

Background:

Alcoa’s decision to construct a new Filtration Plant Facility at Kwinana, once complete will lead to the production of lower moisture content bauxite residue from the refinery. This will permit ongoing residue storage within the existing storage area, deferring the need to construct new dying areas and extending the life of the residue area.

Scope:

DTMT was awarded the contract for civil construction on Alcoa’s Filtration Plant Project in Kwinana which included –

  • Bulk and detailed earthworks
  • Underground services
  • 1,500m³ of footing, pedestal and slab concrete works for plant structures including
    • Conveyors
    • Transfer stations
    • Take-up towers
    • Ring beams
    • Stackers
    • Sub-Stations
    • Switch rooms

Challenges:

  • Very tight and fast pace schedule with structural, mechanical and pipework (SMP) contractors following civil works without delay.
  • Conveyors built on dyke walls atop mud lakes which meant control had to be monitored for any movement over time as the wall settled on top of old mud lakes.
  • Due to the restricted area of the project and the fact that bulk earthworks were still being completed whilst the concrete structures were being built it made establishing useful primary control with good visibility and life span very difficult in the initial phases.

Outcomes:

BE Surveys were able to provide full survey support to DTMT and help them achieve their objective by delivering high precision setout accompanied by supporting as-constructed documentation and the timely handover to the EPC Sedgeman and SMP contractors.