BlueScope (BSL) Port Kembla is an integrated steelworks located in a coastal region of moderate climate in Port Kembla, New South Wales, Australia.
BSL Port Kembla produces flat products for downstream manufacture of its range of branded coated and building products.
BSL also supplies hot rolled coil and slabs for domestic and export clients.
The plant operates with a single blast furnace, BOF, slab casters, plate mill and hot strip mill, and produces approximately 3.1 Mt/yr.
Currently No. 5 Blast Furnace (5BF) is in operation and No. 6 Blast Furnace (6BF) is shut down. 6BF is a modern design, originally constructed in the 1990s, and is in relatively good condition. Operation commenced in 1996 and it operated successfully until shutdown in 2011.
IES has partnered with BSL in a Total Cost Estimate since February of 2024 initially removing and demolishing items in the GAS Handling, Effluent Treatment, and Off Furnace Cooling sections. This program has been undertaken over a 12 month period and was completed in February of 2025, preparing the Blast Furnace to undertake a fit out to new improved operational design .
During January to June IES continued to work on minor items within the plant, while the management team was tasks by its business partner BSL to collaboratively estimate the upcoming major works.
A new Total Cost Estimate contract was signed on June 30th 2025, which was ahead of original schedule, that comprises of 120,000 man hours to undertake major construction works. The systems that IES will solely control are on the Gas System, Off Furnace Cooling, Excess Gas Bleeder, Top Turbine Recovery System and Utilities pipework. It is estimated that IES will install approximately 6km’s of Pipework, Install 3000t of Structural Steel while installing over 200 individual mechanical devices ranging in size from sump pumps to a gas fired turbine.
IES workforce will expand to a project management team of 18 and a labour workforce estimated at 75 skilled trades.
The scope includes improvements to operational performance, reducing energy use and improving reliability.
Current planning aims for a blast furnace restart in August 2026, while 5BF continues to operate to minimise the operational security risk. The execution works are planned on a six day shift roster to minimise costs and optimise labour availability using the local contracting workforce.
