Services Type: Mining Infrastructure (Form, Reo, Pour)

ROM 4 – Roy Hill Minesite

Roy Hill expanded its operations with a new Run of Mine (ROM) located to the east of Marble Bar Road in the vicinity of the Ginbata airport location, currently named ROM 4. The ROM 4 Project is a 40.5Mtpa facility which is planned to deliver first ore by January 2023 and to be in service until 2032.

FSC's Role

FSC was responsible for the complete installation of formwork, reo and concrete for the work including all foundations, footings, plinths, slabs including reinforcement steel, concrete, formwork, embedment, cast-in plates, hold down bolts and cages for Package 1 which included the following structures,

• Crushing station foundation and slab,  
• Intermediate module footings  
• Driving sump 

Scope of works

• Laying waterproof membranes if required,  
• Placement of blinding concrete,  
• Tying reinforcement,
• Set structural bolts  
• Formwork
• Pouring of structural concrete,  
• Vibrating, levelling, finishing, and curing to all concrete,  
• Stripping and removal from site of all formworks after use,  
• Finishes / patches to all surfaces if required,  
• Protection of exposed threads of holding down points, 
• All construction joints (baking rod & sealant)

Port Debottlenecking Project

The Port Debottlenecking Project was developed to expand and debottleneck BHP’s Western Australia Iron Ore’s port capacity by developing an infrastructure and operating solution which would reliably and sustainably deliver a growth pathway to iron ore production capacity of 330Mtpa. The Project is located at Nelson Point within the Port Hedland Inner Harbour. The scope of the Project includes construction and installation of a new car dumper (including associated rail and materials handling upgrades), installation of a new product stacker (including new conveyor routes) and stockyard row, construction of a new freshwater recovery plant, upgrades to existing ship loaders, upgrades to existing lump rescreening plant and construction of a new sample station.

FSC's Role

FSC provided skilled labour to deliver the SMPE&I scope of works. 

Scope of works

Our team of skilled riggers, welders, fitters, electricians and carpenters assisted with the delivery of construction and installation of a new car dumper, installation of a new product stacker and stockyard row, upgrades to existing lump rescreening plant and construction of a new sample station.

South Flank Area C

The South Flank project is a landmark development for BHP Iron Ore, aiming to transform Mining Area C into one of the world’s largest standalone iron ore processing centres. This significant project in Western Australia’s Pilbara region involves extensive civil works to support the expansion of critical infrastructure.

FSC's Role

FSC was awarded a labour supply contract with CPB, providing skilled personnel to support critical construction tasks.

Project Highlights:

• Efficient mobilisation of specialised labour resources in a remote and high-demand region
• Seamless integration with CPB’s construction team, contributing to the timely completion of key project milestones
• Demonstrated capability in supporting large-scale, high-profile mining infrastructure projects

Scope of works

Our scope included the deployment of formworkers, steelfixers, concreters, and grouters, ensuring the successful execution of complex earthworks and concrete installations under tight project timelines.

Key construction activities included:

• Earthworks and concrete works to expand and duplicate the existing rail loop and stockyard
• Development of a new ore processing plant and train load-out facilities
• Installation of underground services, including electrical and water systems, to support the above-ground works

Roy Hill Ultrafine Iron Recovery Project

The Roy Hill Ultrafine Iron Recovery Project involved significant expansion works at Roy Hill’s Wet High Intensity Magnetic Separation (WHIMS) processing plant. These upgrades were critical to enhancing the facility’s capacity for extracting additional ultrafine iron units.

FSC's Role

FSC were awarded a lumpsum contract to deliver the scavenger FRP scope of works which included,

• Scavenger feed tank
• Scavenger thickener
• Drive in sump

Scope of works

Our scope included the deployment of formworkers, steelfixers, concreters, and grouters, ensuring the successful execution of the FRP package

Key construction activities included:

• laying waterproof membranes 
• Placement of blinding concrete,  
• Tying reinforcement,
• Set structural bolts  
• Formwork
• Pouring of structural concrete,  
• All construction joints (baking rod & sealant)

Gudai-Darri (Koodaideri) Iron Ore Project

The Koodaideri Project involved the development of a new iron ore mine and the construction of rail infrastructure to connect with Rio Tinto’s existing network. This large-scale initiative encompassed complex civil works, including bridge construction, access roads, train load-out facilities, and advanced piling systems for conveyors.

FSC's Role

We were engaged as a key labour partner, providing skilled formworkers, steelfixers, and concreters. Our ability to mobilise a dedicated and experienced workforce ensured that critical milestones were met, underscoring our capacity to support major construction efforts in the Pilbara region.

Scope of works

Our scope included the deployment of formworkers, steelfixers, concreters and grouters, ensuring the successful execution of the FRP package.