Abc heavy engineering capability statement
1 like1,301 views
ABC Heavy Engineering provides heavy fabrication, machining, and engineering services from its facility in Mackay, Queensland. It has extensive equipment and capabilities for repairing and manufacturing large mining components. The company aims to assist clients in optimizing asset lifecycles through its reclamation and rebuild services.
Abc heavy engineering capability statement
- 1. Page CAPABILITY STATEMENT Corporate Office 35 Commercial Avenue Paget Mackay QLD 4740 T : 07 4952 3444 F : 07 4952 3746 E : admin@abcheavyeng.com.au ABN 15 139 918 013 Australian Bearings Corporation Pty Ltd T/as
- 2. Page 2 In this regard ABC Heavy Engineering has developed a Workplace Health and Safety Management Plan which details the following: “Safety is Our Priority” “Safety is Our Priority” Health, Safety, Environmental and Community Management Standards ABC Heavy Engineering takes responsibility for the well being of its employees, the environment and the local community, very seriously. It has in place policies and procedures that ensure we are taking all the necessary steps in providing safe and environmentally conscious worksites. Polices and Procedures Roles, Responsibilities and Accountability Risk Assessments Training and Development Inductions Incident Reporting and Investigations WHS Regulations Hazardous Substances Plant and Equipment Noise Surveys Electrical Plant and Equipment Manual Handling Emergency Planning First Aid
- 3. Page 3
- 4. Page 4 The essence of our philosophy is to provide our customers with comprehensive and integrated engineering capabilities that add significant value well beyond the repair and or manufacturing process, to reduce the total cost of ownership. ABC Heavy Engineering assist major players in the mining and allied industries, in finding solutions as they work to maximize the overall life of their assets. ABC Heavy Engineering continues to provide technologies that offer high Accordingly, the business model is based on "Reclamation & Rebuild Lifecycle Engineering”. ABC’s strategy is to proactively assist clients in optimizing asset lifecycle management to attain the greatest possible return on their assets. In the past, Australian Bearings Corporation’s operations were largely confined to repairing the part. Now, ABC Heavy Engineering assists it’s clients in all aspects of the lifecycle of the part and/or assembly - from planning through design, manufacture, operation, maintenance and monitoring systems (life-cycle), to disposal. “Safety is Our Priority” Our Approach
- 5. Page 5 valueadd while assisting clients to extend the life cycle of their assets. Through adhering to strict quality standards, ABC Heavy Engineering are continuously improving their internal structures to further develop the processes necessary to support their objectives.
- 6. Page 6 weighing up to 150 Tonne. Induction Hardening and Heat Treatment Section, Slew Bearing Section. General / Heavy Engineering Section. 10,000sqm of concrete paved lay down area. Understanding the needs of our clients, prompted the construction of an additional purpose built heavy fabrication and repair factory building. This facility is an impressive 90m long x 30m wide x 16m high and is located at the Paget property. The new building is attached to 6,000 sqm main workshop building and offers the following additional features. 2 bucket arch pits installed in the floor, 18 meters long 2.5 meters deep and 2.5 meters wide. 100t and 50t overhead cranes with 12m under hook clearance, capable of dual lifting up to 150 Tonne and is particularly suitable for large heavy structural fabrication as well as heavy equipment repair, dragline bucket and truck body manufacture and repair. “Safety is Our Priority” “Safety is Facilities ABC Heavy Engineering is located in Mackay at 35 Commercial Avenue, Paget on a four hectare heavy industrial site. The factory offers 10 000 square metres of workshop floor capacity comprising the following departments: Machine Shop with medium to large CNC machines capable of handling work up to 9 meters in diameter and
- 7. Page 7 3 x Large Sheave Rotators (capacity = 5m diameter) Using sub-arc welding process 2x Small sheave Rotators (capacity = 3m diameter) Using sub-arc welding process. 2 x Purpose built shaft rotators – Using open-arc welding process. Various rollers which may be assembled to suit job (using sub-arc welding process if required) Computer controlled gas fired oven – Capacity 6.5 x 5.5mtrs, height 2.7mtrs) for stress relieving up to 800 degree Celsius. Induction Hardening Machinery – various units, being 200,300 & 400 kw (using frequencies of between 3 & 10 kh) used to Induction Harden Sheaves, Drums, Gear teeth, Shafts, Slew Bearings and other items up to 60hrc at depths ranging from 3-15mm. Complete Insitu dragline rope drum rebuilds including weld reclamation, CNC machining and hardening are now available. 600 tonne Hydraulic Press. 1 x 100T Overhead Crane, 1 x 50 T Overhead Crane (Northern Bay) 12mtrs under hook 1 x 50 tonne crane, 1 x 20 tonne crane and 1 x12.5tonne (East Bay) crane 7mtrs under hook 1 x 50 tonne crane, 1 x 12.5tonne crane and 1 x 5 tonne crane (West Bay) 7mtrs under hook “Safety is Our Priority” “Safety is Our Priority” Specialised Equipment (machine / cranes etc) Froriep CNC Floor Borer – 10 mtr travel, Height 4.5mtrs, Bed capacity = weight 200 tonne. For turning Operations Capacity = 9 mtrs and weight capacity = 50 tonne. Berthiez CNC Vertical Borer – Capacity = 4m diameter, Table Weight = 18 tonne. Webster & Bennett CNC Vertical Borer (Twin Head) – Capacity = 3.5m diameter, Table capacity = 18 tonne. 2 x Purpose Built Drum Rotators (Incorporating heating components) using sub-arc welding process with multiple heads.
- 8. Page 8
- 9. Page 9 Operating Hours. The Commercial Avenue, Paget requirements, anytime. Additional Equipment Workshop This new facility at the Paget workshop is ideal for large Buckets and Dippers and other heavy fabrication. The building has two large arch pits and is serviced by 100 tonne and 50 tonne capacity overhead cranes. Facility Details: Building Height 16m Overhead Crane Headroom 12m Covered Floor Area 3000m2 Craneage 100 Ton Arch pits 2 Entry Width Up to 10 meters
- 10. Page 1 0 workshop has coverage 24hr, 7 days a week, 365 days a year, which means that we can cater for urgent customer Total factory size is now 10,000sqm
- 11. Page 1 1 Quality Technical Support “Safety is Our Priority” “Safety is Our Priority” ABC Heavy Engineering is committed to obtaining ISO9001 in the near future, and long term AS/NZS4801 and ISO14001. We have a Management system in place that has procedures and policies that we adhere to for all of our processes. The Management syste m is built on the foundations of International and Australian Standards. Two consulting/auditing firms have been engaged over the past twelve months to help prepare our system for accreditation. As part of our organisational structure, ABC Heavy Engineering has a Quality Coordinator who is responsible for maintaining the system. ABC Heavy Engineering also recognises the importance of gaining ISO 3834:2005 Quality requirements for fusion welding of metallic materi- als accreditation. We have appointed a welding supervisor who is under going the Welding Specialist training conducted by the Welding Insti- tute of Australia. WTIA have audited our system and we will continuing down the path of accreditation. We also conduct Individual performance reviews for each employee with Quality as one of the key elements. The ABC team is comprised of Supervisors and Team members that have decades of experience on Dragline components repairs. Their knowledge and understanding is unparalleled in the Bowen Basin. We have Product and Application Specialists that are constantly supporting our clients by visiting mine sites to provide expert technical advice and recommendations. We have comprehensive engineering support for our workshops. They have at their disposal, a network of companies and affiliations such as BMT WBM & WTIA, so we can continue to provide our clients with updated information on materials, consumables and processes. “Safety is Our Priority”“Safety is Our Priority”
- 12. Page 1 2 Mechanical Engineering & Project Management AutoCAD design and drafting Computer software including Microsoft Project Project management and quotation, including fabrication Certification of lifting equipment Certification of equipment in accordance with Main Roads specifications Site inspections, reporting and work scope preparation Site maintenance, shutdown and emergency breakdown Mechanical and structural engineering design Project and maintenance management, inspections and audits Multi-disciplinary work packages Engineering Drawing. “Safety is Our Priority” “Safety is Our Priority”
- 14. Page 14 Engineering Design & Certification ABC Heavy Engineering utilise 3D modelling software (Solidworks) to provide conceptual and workshop drawings for new and reverse engineered products that comply with AS1100 - 1992. With this software we can provide customers with CAD models in 3D accompanied with general arrangement drawings. The software also allows our qualified engineers to use Finite Element Analysis (FEA). Structural analysis using FEA is extremely beneficial to design and reverse engineered components. Designed products are optimized to ensure the most efficient materials are used. Reverse engineered products are assessed to identify areas that can be improved through design changes. Existing components are checked and modified to remove stress concentrations. “Safety is Our Priority” “Safety is Our Priority”
- 15. Page 15 “Safety is Our Priority”
- 16. Page 16 ABC Heavy Engineering Site Services
- 17. Page 17 Design Construction Fixed Plant Maintenance Mobile Plant Maintenance Maintenance Planning Draglines Electrical Labour Hire Equipment Hire ABC’s Heavy Engineering Site Division encompasses a wide range of services including breakdown, shutdown and contract maintenance.
- 18. Page 18 We pride ourselves on providing a safety conscious, timely and efficient service to our clients at all times. ABC Heavy Engineering Site Services offers the best project management skills available and can provide planning and maintenance strategies to optimise the production performance and maintenance costs of any operation. ABC Heavy Engineering— Site Services Division Include – Draglines – Breakdowns, Shutdowns, Maintenance. Shovels / Excavators - Breakdowns, Shutdowns, Maintenance. Coal Processing Plant - Shutdown, Breakdown, Relief operators. Blast Hole Drill Rigs - Breakdowns, Shutdowns, Maintenance Construction – Site Construction Teams on various projects. Shipping - On and Off Shore Repairs. Sugar Mills - Shutdowns, Breakdowns. Power Stations - Relief Operators, Breakdowns, Outage Shutdowns. Electrical, Mechanical and Construction Boom repairs to Marion 8750Dragline and Shovel Site Maintenance
- 19. Page 19 Below are details of some of ABC’s Heavy Engineering Site Division’s recent projects. Coppabella Mine – Monthly Maintenance down days, breakdowns and mini shutdowns, on dragline and shovel for the last 5 years, LTI free. BMA Peak Downs – Principal contractor for 6 week ROM shutdown, including mechanical, structural and electrical. BMA Saraji – Shovel Load Roller change out, including all jacking. BMA Saraji – All mini shutdowns on Draglines and shovels for past 3 years, LTI Free BMA Saraji – supply labour, supervision & equipment for CHPP down days and breakdowns. Bulga Coal – In Situ rebuild of Hoist and Drag Drum Isaac Plains – Monthly Maintenance down days, breakdowns and mini shutdowns, on dragline. In Situ Drum Rebuild in DraglineShovel Load Roller change out Site Maintenance
- 20. Page 20
- 21. Page 21 Site Maintenance . Marion 8050 Boom Lowering for Suspension Rope and Equalizer change out Jacked P&H 4100 Shovel for Load Roller change out and tumbler repair
- 22. Page 22 Site Maintenance - Equipment ABC Heavy Engineering can provide the following equipment as part of any project, or on a stand alone hire basis. 2 Fully equipped welding trucks, each including 2 diesel welders Fully equipped welding trailers2 Fully equipped tooling containers, including all required tooling &3 consumable items. Crib room, generators, fuel trailers, lighting towers ft Boom lift80 Low profile, 45t Forklift All equipment is fully mine site compliant “Safety is Our Priority” “Safety is Our Priority”
- 23. Page 23 Transport Capabilities 3 by 20ft Tilt-trays Prime Mover Float Trailers “Safety is Our Priority” “Safety is Our Priority”
- 24. Page 24 ABC Heavy Engineering can provide your transport requirements for moving items and equipment to and from site. Our fleet includes the following items:
- 25. Page 25 Machining of Boom Point Swivel Dragline Swing Housing Refurbishing Conveyor Pulley Fabrication & Machining Sub Arc Weld build up of Marion 8050 Rope Drum Manufacturing & Reclamation
- 26. Page 26 Over the past 28 years, the company, through its ingenuity and commitment to research and development programs, has developed into a major supplier of a wide range of services to the Mining, Sugar and Agricultural Industries, as well as the Civil Sector and Sea Ports both in Australia and overseas. P&H 9020 Revolving Frame under construction Manufactured Slew Deck Fabrication and General Engineering Workshops
- 27. Page 27 Our services include, but are not limited to, Slew Bearing Refurbishment and manufacturing, Induction Hardening, Gear Cutting, Large CNC Machining Capacity, sub-arc welding, stress relieving, haul out and transport equipment, hydraulic cylinders and associated equipment, manufacture of drill rig ground engaging components, overhaul of underground and open cut mining heavy earth moving equipment and all facets of light and heavy machining and fabrication.
- 28. Page 28 Overhauls and Repairs Track Set Refurbishment Structural Repairs to Heavy Earth Moving Equipment Gearboxes Crusher/Sizer overhauls Dragline Buckets, Dippers, Shovel Buckets Scheduled Maintenance Programs Newly Manufactured Slew Bearing Full overhaul of large gearboxes Coal Crusher Rollers manufactured & overhauled
- 29. Page 29 ABC Heavy Engineering is committed to providing value for money service. Our facilities have the capability and space to store large quantities of components. Over recent times, ABC have been increasing our stocks of dragline componentry. We have a large range of dragline drums, sheaves, walking gear, and excavator slew bearings. We have both new and refurbished items, available for outright sale or on a service exchange basis. Refurbished 1370 Deflection Sheaves New 1370 Walking Cam New 1370 Walking Frames “Safety is Our Priority” Dragline Component Stocks. “Safety is Our Priority”
- 30. Page 30
- 31. Page 31 Health, Safety, Environmental and Community Management Standards “Safety is Our Priority” “Safety is Our Priority” Daily Safe Start meetings Weekly Toolbox meeting Monthly Safety Committee meetings Measuring of LTI’s and MTI’s JHA SLAM Planed Task Observation Transparent reporting of any incident in accordance with the ABC Safety Management Plans reporting policy and complying with requirements of the client to notify the appropriate people in a timely manner, ensuring our client is well informed with regards to the rehabilitation of the injured worker, until return to work unrestricted has been achieved.
- 32. Page 32 To ensure we have Safety as a Priority, the following activities are undertaken by the workforce:
- 33. Page 33 “Safety is Our Priority” Dragline Sheaves
- 34. Page 34 “Safety is Our Priority” Dragline Rope Drums
- 35. Page 35 “Safety is Our Priority” Bogie wheel assembly
- 36. Page 36 “Safety is Our Priority” Conveyor Pulley
- 37. Page 37 “Safety is Our Priority” Thickener Drive
- 38. Page 38 “Safety is Our Priority” Gear Case Capabilities: Build Strip QA Overhaul Bore Reclamation & re- alignment
- 39. Page 39 “Safety is Our Priority” Braking Unit
- 40. Page 40 “Safety is Our Priority” Belt Reeler
- 41. Page 41 “Safety is Our Priority” Shaker Screen
- 42. DIRECTOR DIRECTOR Phone: + 61 7 49523444 Fax: + 61 7 49523746 Rick SmithMob: 0419 646 979 Paul SmithMob: 0418 712 826
- 43. Email: admin@abcheavyeng.com.au PRODUCTION MANAGER Mike Geisler Mob: 0447 760 309 ENGINEERING CO ORDINATOR Steven Boyce Mob: 0418 725 120 SENIOR SITE CO ORDINATOR Liam Flynn Mob: 0417 770 445 Web Address: uwww.abcheavyeng.com.a Postal Address: PO Box 5988 MMC Mackay Queensland 4741 Managing Director Maurie Smith Mob: 0419939300 Corporate Office & Main Workshop: 35 Commercial Avenue Paget, Mackay QLD 4740