Projects

No 6 Cement Kiln Shutdown

Project Summary

  • Client Boral
Client

Boral

Incidents
Defects

The Project was Blue Circle Southern Cement’s planned shutdown of their No 6 Cement Kiln to facilitate major remediation work through Jan / Feb 2009.

IES is a preferred service provider to Boral. Following an extensive cost estimating procedure the company was awarded three major components of the shutdown, each of which involved work at above 50 metres.

IES divided the scopes of work into manageable portions, performed due diligence, and implemented control measures to mitigate any identified risks.

Key Components

December- IES established on site with remote area workshop and storage facilities. Pre-shutdown work was performed to assist in an efficient project start date. This included hot work and drop zone area delineation, temporary supports and reduce bolting. (IES time/phase plan assigns resources and supervision for the duration of the project).

January- Schedule driven shutdown commences

IES successfully relocated the 350 tonne Kiln No 6 Firing Hood, which had been pushed out of alignment, back to its original position using hydraulic jacking and an innovative ball bearing skate technique.

IES removed and replaced the worn 80 tonne segment of tertiary air duct c/w renewal of three 2880mm diameter expansion joints. This was accomplished using a lift study and carefully co-ordinated dual 300 tonne crane lifts.

IES removed and replaced worn shell segments in the No 1 Conditioning tower at 65 metres, directly above other work groups.

Outcome

Illawarra Engineering Services carried out its entire scope of work without incident or injury and takes pride in knowing that through its Project Integration Management Plans, open communication methods and active participation in daily information sharing seminars, it successfully assisted a valued client achieve its shutdown goals and equipment reliability.

Client Testimonials

“IES was contracted by Blue Circle Southern Cement (BCSC) late in 2008 to undertake some difficult maintenance tasks during a shutdown in Early January 2009.

Four of the five jobs involved working at heights 50 metres above grade. Some of it also involved using carefully co-ordinated dual crane lifts.

They planned their work well and it went ahead without any issues. Their safety record was excellent, they integrated with the other contractors on site working in the near vicinity without issue.

The work they undertook was of high quality and they finished within the allocated time schedule despite taking on some additional work. IES were a very easy contractor to work with and BCSC would be happy to continue the working relationship.”

Ian Fulton – Engineering Manager
Blue Circle Southern

Project Summary

  • Client Boral
Client

Boral

Incidents
Defects

Similar Projects

Walking Bean Furnace Upgrade 2025

No6 Blast Furnace Upgrade 2025

MCL7 Paintline Project 2025