From rust to robust

After four decades of dedicated service, the time has come for the Roxby Downs pebble crusher to retire and pass on the torch, with an exciting upgrade ready to take its place— a HP4 cone crusher. 

Crushers are machines that reduce the size of rocks, stones and ore. They are often utilised in aggregate production, construction material recycling, as well as mining operations. Specifically, the pebble crusher plays a crucial role in mining operations, where it processes large chunks of ore into smaller pieces, facilitating subsequent processing stages. 

Lead Project Manager Scott Lawrence said this project marks a pivotal moment in the site's infrastructure upgrade. 

"The existing pebble crusher is roughly 40 years old and is no longer fit for purpose," he said. 

"Our scope was to replace it with an HP4 cone crusher that is a similar size but has a more modern design and superior efficiency." 

The project encompassed various critical tasks, including the supply, fabrication and installation of a hydraulic annex and the provision of new power and control cables from the substation. Dismantling the outdated crusher, pre-assembling and installing the new HP4 cone crusher, while also creating new supporting platforms and guards were also integral components to be completed.  

"Stage 1 and 2 commissioning have been completed, and we're currently underway with Stage 3 commissioning," Scott said. 

Planning for the project commenced in October 2023, when Monos deployed a dedicated team comprising a superintendent, two supervisors, a project manager and two engineers to ensure its successful completion. During the six-week shutdown period, the workforce grew to include five trades on day and night shifts, with additional support from the workshop crew for component fabrication. 

"The impact of completing this project cannot be overstated," Scott said. 

“It was important to get the new crusher online so as not to impact production any further. Completing the project six days early is a massive achievement and was very well received by the Client." 

However, there were challenges along the way, particularly concerning the state of the underlying steel and concrete structure.   

"There were some unknowns as to the state of the steel and concrete structure beneath the existing pebble crusher,” Scott said.

“As it turned out there were some major unforeseen remediation works required prior to installation of the new HP4 crusher.” 

Nonetheless, the team's resilience and expertise ensured the project's timely execution. 

Reflecting on the experience, Scott highlights the camaraderie and adaptability exhibited by the team.  

"Seeing everyone come together, develop execution plans, and pivot when challenges arose was truly rewarding,” he said. 

"It sets the standard high for excellence across all our project works.” 

The state of the former pebble crusher

The state of the new HP4 cone crusher. 

Photos of the installation process