Engineering Triumph at a Queensland Mine

In a remarkable display of engineering expertise, Fenner Conveyors successfully resolved critical structural issues with a stacker conveyor system for a coal mine in the Bowen Basin.

In late 2024, Fenner Conveyors began supporting a client facing challenges caused by ground movement and instability of civil foundations beneath a critical stacker conveyor system.

Foundation movement beneath any conveyor structure presents a significant risk of failure and potential production loss. In this instance, the affected conveyor was a key piece of infrastructure, serving as the mine’s primary production conveyor.

Fenner Conveyors' brand for conveyor engineering, ACE, collaborated closely with the client to develop and implement mitigation strategies, ensuring the continued operation and stability of the system.

“We conducted various engineering and risk review processes to understand the problem's extent. With the experience of our conveyor engineering team and engineering partners, we evaluated criticality and recommended robust safety measures to protect both personnel and site infrastructure”

Engineering Manager, Mark Wilcock

The next stage involved developing and implementing temporary structural modifications, along with a robust monitoring methodology until a longer-term solution could be implemented.

Within 6 months ACE had designed, constructed, and installed a new 40-meter truss to bridge across two trestles, eliminating reliance on footings. During a 5-day, around-the-clock shutdown, the old truss was removed using a 450-tonne crane and the new truss was installed. The truss spanned over 40 meters and was transported to site in two sections, with all conveyor components installed before being joined and lifted into position.

Complete gantry pre-assembled in engineering partner’s workshop.

A key component to delivering this in the short timeframe was ACE’s ability to design, procure and assemble the new truss prior to transportation to site.

“Pre-assembly works enabled us to significantly reduce the construction time and manual handling risks on site,” explained Wilcock.

Gantry sections were pre-assembled with all conveyor equipment installed, reducing the amount of work to be carried out onsite. This included all mechanical services and devices, with key interface points identified for the existing electrical devices and services routing.

Before the shutdown, Fenner Conveyors teams interfaced with the customer’s operational requirements, carrying out pre-works to the structure to minimise downtime. This work was completed in scheduled and opportune maintenance windows. The new truss was preassembled and then transported to site.

The Site’s shutdown period was based on a longwall outage, so all preparations, resources and personnel were staged ready to go once the production outage commenced.

During the shutdown, the various teams from Fenner Conveyors’ portfolio were engaged to support the project.

ACE engineers from project and construction management teams interfaced with the client’s operational teams ensuring all aspects of the project were planned and managed in accordance with the site’s requirements.

Fenner Conveyors’ embedded field service team were then engaged to carry out critical pre-installation works, including a conveyor belt pull to facilitate the truss removal, a pulley change-out, and the removal and replacement of a 480-metre section of conveyor belt.

Half of the conveyor gantry being transported to the Bowen Basin site.

“Working with Fenner Conveyors’ service crew made job execution highly coordinated as they were established and well-known with site teams,” explained Wilcock.

“While the old belt was removed, the Fenner Conveyors team removed the existing trusses and carried out the required structural modifications. Finally, the new truss and new belt were installed.”

This tremendous team effort was a massive undertaking for both the engineering and conveyor maintenance teams.

ACE General Manager, Mark Wilcock said the success of the project is a clear demonstration of the service offering Fenner Conveyors strive to deliver.

“Our team of highly experienced technical and project management professionals are focussed on solving conveyor challenges for our clients, no matter how complex the solution may be. This close engagement between our expert teams and our client’s teams set up for a seamless transition to execution on-site.”

Fenner Conveyors’ embedded service and construction crews logged over 3,000 labour hours injury-free, completing the works under tight time constraints while maintaining the highest standards of safety and quality.

The new truss being installed on the stacker conveyor.

“This was an outstanding team effort and a testament to the strength of our people, systems, and client partnerships,” Wilcock added.

“We're proud to have supported our client with this replacement and commend the team for the safe and efficient execution.”

The new truss eliminates reliance on unstable footings and overburden, reducing the potential risk of structural failure. Overall, the project has helped the client ensure a safe working environment for all personnel and improve reliability of the conveyor system.

Engineering Triumph at a Queensland Mine

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