CD3 renewal: big lift, big win

If you were anywhere near Port Hedland last month, you might’ve caught wind of something big, because something seriously impressive went down. The CD3 Renewal Project hit a major milestone with the successful installation of a brand-new Single Tandem Rotary cell, wrapped up in a tightly executed 46-day shutdown. 

This upgrade is a game-changer. It’s set to extend the life of Car Dumper 3 by another 20 years and support future ore types and throughput demands. Monadelphous came on board early under an ECI agreement in late 2021, working closely with BHP to rethink the original construction strategy – a plan that involved a complex jacking system and an 80-metre beam with significant execution risk, cost and safety concerns. Working closely with BHP, the team proposed a smarter, safer alternative featuring a rolling beam system paired with a groundbreaking lift strategy. 

Enter Rubino, a 1,600-tonne Tadano crane, one of the biggest in the Southern Hemisphere. Thanks to strong industry relationships, Monadelphous secured the crane straight off the production line, just in time for shutdown. It replaced the risky jacking method with a more conventional lift, reducing complexity and execution risk. 

The lift itself was no small feat. It was a technically complex operation, delivered with precision and zero incidents thanks to detailed planning and seamless coordination between Monadelphous, BHP, Tadano, and other delivery partners. A permanent crane pad was also built on site, setting the stage for faster, more cost-effective upgrades in the future. 

Innovation ran right through the project. A modular electrical substation removed 38,000 labour hours from the shutdown window, and a fully integrated schedule of over 7,000 activities kept everyone aligned. The shutdown finished 92 hours ahead of schedule, unlocking an extra 5.85 million tonnes of throughput and avoiding significant production loss. 

Importantly, the new cell design now serves as the blueprint for future upgrades at CD4 and CD6, and Rubino is here to stay, ready to support future shutdowns. The success of CD3RP has already sparked broader conversations about Monadelphous’ role in future Port works, demonstrating the strategic impact of smart planning, trusted partnerships, and bold decisions. 

To top it all off, the team was awarded the EC Teamwork Baton Award for August, a well-deserved recognition of the collaboration, commitment and capability that made this project a standout success.