Beyond the belt

At RTW, every project is an opportunity to take on new challenges and refine the way the team works.

The full belt change for the 10.5 km conveyor, running from the client’s primary crusher to their secondary crusher, was one of the company’s biggest investments yet.

After 15 years in operation, the belt had done its job well, but the time had come for a full replacement to ensure continued efficiency and reliability. This set the stage for a major effort combining technical expertise and careful planning.

The belt flaking and splicing phase was completed under a demanding 24-hour rotating shift. Nick Jokich, Works Manager, said the project brought out the best in the team.

“Lots of standout moments for the collective teams, RTW, four subcontractors and the client,” Nick said.

Like any large-scale operation, the team also faced some unexpected challenges. Nick said, despite this, their planning paid off.

“The challenges along the way were all taken in the teams’ stride with everyone 100% dedicated to achieving the target and handing over this critical asset to our client.

“We had ad hoc blast notice evacuations, multiple power outages, lightning alerts, water supply, both potable and process, that were cut off, logistical bottlenecks, last-minute transport changes with over 300 escorted trips across an arterial haul road.

“Our stakeholder relationship was rock solid. Every issue that arose was a shared problem, which gave us the confidence to solve them independently of our frontline targets.”

He said that many weeks of pre-works, along with experienced team members who had built the conveyor 15 years ago, meant the team was equipped to manage the unexpected.

“We carried extra resources into the outage knowing full well they would be allocated to the ad hoc issues. This was one of the key reasons to our success on this project, it was all in the planning,” he said.

With 21 km of belt handled across 36 reels, the scale of the job pushed operational limits. Nick said their approach was all about having the right people in the right areas.

“We engaged the right people, from engineering design to industry delivery leaders, we put focus in the right areas and planned for the unexpected,” he said.

“Unlike a traditional construction project, we ran heavy numbers with mitigation plans for resources and key assets alike. This gave RTW, and more importantly, our client, the confidence that their key asset would be back online as planned.”

He said the project had been in the pipeline for some time with RTW having started with a conversation roughly two years ago.

“At the time they were a little unsure how to approach this, specifically within the local market. The seed was planted and conversations continued as we developed the costing and proposed a plan that gave the asset owners the confidence their ageing asset could be given the birthday it desperately needed,” Nick said.

At the peak of the project, 50 RTW personnel were working across the 10.5 km conveyor.

“Even though most of the heavy lifting was done under subcontract delivery, the combined Monadelphous RTW staff were paramount from conception to completion,” he said.

“New subcontractors were set up, contracts drafted and approved, assets resourced, personnel recruited, compliance continually verified, logistics stretched to their limits.”

He said a highlight was watching the supervision team grow into their roles.

“A key moment within all the chaos was watching the supervision rise to the challenge and see them developing their contract management skills,” he said.

“They owned it, which was a proud moment. The relentless workings in the background allowed them to focus on the frontline as they should, all the way to the finish line.”

Nick said that beyond the technical achievement, the success of the project will support future growth.

“This project reinforces what RTW is capable of, strengthening partnerships and laying the groundwork for even bigger challenges ahead,” he said.