Client
Location
Carrapateena Mine, SA
Duration
7 Months
Industry
Mining & Resources
Scope of Work
Our scope covered the supply, installation, and testing of steel and HDPE piping systems, spools, valves, and supports along an 8.5 km overland alignment.
Key activities included:
- Use of our in-house Pipe Bending Machine (Model PBMS/20″) to perform precise cold field bends of high-strength steel piping.
- Installation of carbon steel and UHMWPE-lined piping with flanged connections.
- On-site welding, bolting, and hydrostatic testing in accordance with Australian Standards.
- Structural installation of pipeline sleepers, supports, and anchor plinths.
- Integration with existing TSF pipeline infrastructure and completion of tie-in works.
Technology in action – The Pipe Bending Machine advantage
The D&S Pipe Bending Machine provided a safe and efficient solution for handling steel pipes up to 20″ diameter and high-strength grades (X60–X70), with wall thicknesses up to 45 mm.
Benefits included:
- Efficiency – faster installation with reduced manual handling.
- Precision – consistent bends with minimal deformation.
- Safety – advanced hydraulic controls and built-in safety systems.
- Adaptability – compatible with both coated and uncoated pipes.
Project outcome
The overland tailings pipeline was delivered in just 14 weeks under stringent quality and safety standards. The result is a durable, efficient pipeline system compliant with BHP’s rigorous SHEC standards, supporting ongoing operational performance at Carrapateena.
Skills/specialties demonstrated
- In-house cold field bending capability — the PBM (Model PBMS/20″) let D&S bend high-strength steel pipe on-site rather than relying on pre-fabricated bends or an external bending subcontractor, which is the core differentiator in this case study
- Materials handling range — comfortable working across both carbon steel and UHMWPE-lined pipe, and both coated and uncoated pipe, in the one scope
- Certified welding, bolting and testing — on-site welding and hydrostatic testing to Australian Standards
- Civil/structural pipeline works — sleepers, supports and anchor plinths, not just the pipe itself
- Brownfield integration — tying new pipeline into existing TSF infrastructure without disrupting the live system
- Safety-led equipment operation — hydraulic controls and built-in safety systems on the PBM reducing manual handling risk on a large-diameter, thick-wall pipe job