Case Study

Hazelwood Mine Rehabilitation Project

  • ClientENGIE
  • StartMay 2017
  • Value$100m+
  • CompleteOngoing

Major project to rehabilitate the Hazelwood power station and mine in the Latrobe Valley, including transforming the mine pit into a lake.

Doing 'it' better

All work delivered within required timeframes, preventing impacts to subsequent activities

FSC ScopeExpand+

  • Bulk earthworks
  • Surcharges and benches
  • 3km water pipeline to fill pit
  • Fire safety water-sourcing pipelines
  • Mine security gatehouse
  • Extensive drainage and batter stability works
  • Landfill capping design and delivery
  • Re-engineering a former ash pond into an asbestos containment area
  • Eastern overburden dump site investigation
  • Developing an EPA-compliant investigation program to inform the site’s environmental water model

ChallengesExpand+

  • Coordinating work across the 4000-hectare site
  • Strict construction deadline to start filling the former mine pit with water
  • Numerous unrecorded services
  • Lean budgets, large production targets and complex interfaces
  • A geological profile that often conflicted with actual conditions
  • Seasonal weather patterns limiting bulk earthworks to dry months, adding to schedule pressure

SmartsExpand+

  • Collaborating with the client to proactively understand site conditions and avoid hidden surprises
  • Supporting ENGIE to change their systems to those needed for overseeing a massive project with numerous disciplines
  • Providing the client with excellent visibility of project performance, forecast cost and completion dates
  • Initiation and development of resource levelled integrated program delivery schedule to effectively manage multiple, concurrent projects and interfaces
  • Implementation of processes to mitigate against significant scope creep being experienced
  • Utilisation of drone surveys providing real-time progress metrics across the large geographic spread of works

AchievementsExpand+

  • Working with the client, designers and EPA on an alternative landfill capping design, saving the client 35% of their initial project budget
  • Improved bulk material haul efficiencies resulting in a $2m reduction in costs
  • Challenged technical specifications to increase utilisation of in-situ material, further reducing costs by c. $1m
  • Saving the client $250,000 by reusing 500m of 750mm diameter steel pipe
  • Reducing the extent of in situ pipe welds needed for the Eastern Ring Main Pipeline, saving around $20,000
  • Optimising the placement of isolation and scour valves

PerformanceExpand+

  • Safety: Zero Lost Time Injuries to date
  • Cost: Improved efficiencies preventing the client from realising a forecast $5M overspend
  • Program: All work delivered within required timeframes, preventing impacts to subsequent activities

FSC StaffExpand+

  • Lachlan Smith – Senior Consultant 
  • David Courtot – Construction Manager
  • David Gill – Project Manager
  • John Massie – Design Manager
  • Stuart Twelftree – Design and Estimating Consultant/Environmental Compliance Manager
  • Alex Malesevic – Senior Project Engineer
  • Andrew Hines – Senior Project Engineer
  • Rory Lamont – Senior Site Engineer
  • Dalton Burton – Site Engineer
  • James Rodgers – Project Engineer
  • Mitch Thomas – Project and Quality Assurance Engineer
  • Samuel Wilkinson – Site Engineer
  • Matt Powers – Site Engineer 
  • Tom O’Sullivan – Project Controls Engineer
  • Amanda Fontaine – Mine Stability Technician

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