The project involved the construction of a new wellhead transfer station and the installation of approximately 34.5 km of duplicated HDPE raw water pipeline, tying into the existing Carrapateena processing plant raw water dam. This infrastructure forms a vital component of the site’s water supply network and future production growth.
Scope of work
D&S Resources’ scope encompassed the end-to-end delivery of pipeline and associated infrastructure works, including design coordination, construction, testing, and integration with existing assets.
Key activities included:
- Fast-fusion welded HDPE pipeline installation across a ~34.5 km alignment
- Multiple road, creek, and pastoral crossings
- Installation of scour pits and air relief valve tie-ins to maintain consistent flow rates
- Pigging operations, tie-ins, and full hydrostatic testing
- Integration with existing Carrapateena processing plant infrastructure
Project delivery
Executed in a remote and environmentally sensitive location, the project required detailed planning, disciplined safety and quality management, and close coordination with stakeholders to maintain continuity of site operations.
Leveraging D&S Resources’ strong fleet of specialised in-house equipment and experienced project teams, the works were delivered efficiently and cost-effectively while meeting stringent performance requirements.
Safety & performance
The project was completed with an outstanding safety outcome, recording zero Lost Time Injuries (LTIs) across nearly 27,000 man-hours. This result reflects D&S Resources’ strong safety culture and commitment to quality execution on high-risk, high-value mining infrastructure projects.
Project outcome
The Northern Borefields Stage 4 Project provides BHP with a robust and reliable raw water supply solution, supporting ongoing and future operations at Carrapateena. D&S Resources is proud to support BHP in delivering critical water infrastructure that underpins sustainable mining operations.
Skills/services demonstrated
- Long-distance pipeline construction — ~34.5km of fast-fusion welded HDPE pipeline delivered across a single alignment
- Complex crossing management — multiple road, creek and pastoral crossings navigated within the one build
- Flow assurance infrastructure — scour pits and air relief valve tie-ins installed to maintain consistent flow rates
- Rigorous testing and integrity assurance — pigging operations and full hydrostatic testing across the line
- Brownfield integration — new infrastructure tied into the existing Carrapateena processing plant and raw water dam without disrupting site operations
- In-house specialised fleet capability — leveraging D&S’s own equipment rather than third-party hire, supporting cost and schedule efficiency
- Remote, environmentally sensitive site delivery — detailed planning and stakeholder coordination to work within sensitive terrain
- Safety leadership on high-risk infrastructure — zero LTIs across nearly 27,000 man-hours, demonstrating a mature safety culture on high-value mining infrastructure