Redesigning walls for safety and savings

You wouldn’t think there are too many risks involved in wall cladding but add in two cranes and an installation location 62 meters off the ground and we have ourselves a costly and high-risk activity. 

This is the challenge that faced Ravensworth Coal Handling and Preparation Plant’s Mark Muir, Nathan Brown and Ken Hort when tasked with replacing compromised wall cladding atop a ROM bin. Previous attempts involving cranes and man baskets incurred substantial costs and posed significant hazards, including a near-miss with a falling sheet which underlined the urgency of finding a safer solution. 

Enter Mark and his team, who introduced the concept of modular wall panels. 

"We were very much trying to find a safer way or a different way of doing the job as a priority," Mark said. 

"It all started from concepts on how we could get the panels up without doing sheet bashing. That's when we came up with a modular sort of design." 

The modular design allows for pre-fabrication in a controlled workshop environment. Once built, the panels are transported to the site, ready for installation. This approach sped up installation and drastically reduced the risks associated with working at heights. 

The results were nothing short of astonishing. Over 220 square meters of wall cladding were installed in less than two 10-hour shifts, with a whopping 1200-hour reduction in working at heights. The changes also saw over $1 million saved in cranage costs throughout the project. 

"The high cost would come mostly from the cranage because you needed two cranes sitting there to take just one sheet off at a time. Eliminating that much reliance on the cranes helped that," said Mark. 

The success story doesn't end here. Other sites have already shown interest in adopting the modular wall panel concept, recognising its potential to reduce risks and improve efficiency. With many ageing facilities needing renovation, this innovation is a timely win for the business. 

A big shout out to Mark and the Ravensworth CHPP team for their creative thinking and determination to find a better and safer way to do the everyday.