Previous Projects
With decades of experience in the resources industry, we've worked with names including Glencore, OK Tedi Gold, Brisbane City Council, Unitywater, METSO, Sandvik, James Hardie, Newcrest and Tarong Coal - just to name a few.
Belt Conveyors
RESCON Engineering has over many years participated in the design and construction of numerous belt conveyors, primarily for the Mining and Quarry industries. Engineering, manufacture and erection are all capabilities that can be provided to a project or plant upgrade.
Upgrade: Heavy Media Vibrating Screens and Feeders
Upgrade existing Heavy Media Installation including Design, Manufacture and Installation of Multislope Vibrating Screens and Vibrating Feeders into a heavy media plant.
A complex project to install new larger capacity equipment into 4 modules of an existing, operating installation.
The scope of work included:
- Structural and Mechanical Design of the new installation.
- Structural review of the existing structure including a full FEA analysis.
- Manufacture of new Screen and Feeder support structures.
- Manufacture of new Feeder, Screen Feed Chutes, Screen Underflow Chutes and Boil box most of which are ceramic tiled.
- Modifications to existing plant and structure.
- Integration with existing site operations.
- OH&S compliance to customer requirements.
- Project Management.
Raw Water System Upgrade
Design and Construction of an improved pump system for Raw Water Recovery.
- Incorporated;
- Pump Selection.
- System Design
- New Concrete works.
- Mechanical Works.
- Fabrication and Installation.
- Diesel Generator Selection and Installation.
TT Valve Installation
Design Layout and Structural Supports for various TT valves in Floatation Circuit.
Reagent Storage System Upgrade
Design upgrades to various reagent storage area’s including Cyanide and SX.
- Revise layout of Bunds.
- Removal of existing Tanks.
- New Civil design works.
- Repair and rectification of damaged concrete works.
- Project Documentation for Construction.
Rotary Breaker Station Structural Repairs
Investigation, remedial design and construction documentation for a Structral/Concrete/Civil repair to a Rotary Breaker Station.
- Incorporated;
- Geotech Investigation.
- Civil and Groundwater investigation and design.
- Harmonic Response Analysis of the Structure.
- Dynamic modeling of reactions.
- Design of Civil, Concrete structure repairs.
- Design Concrete cancer repairs.
- Design Structural repairs existing and New Concrete works.
- Construction Methodology and Documentation.
- Preventative Maintenance Methodology.
- Investigate Mechanical upgrades to carry and thrust roller systems.
Floatation Pump System Upgrade
Design and Construction of an improved pump system for Floatation feed duty, including
- Pump Selection and System Design.
- New Concrete works.
- Structural Mechanical and Piping Works.
- Electrical Works.
- Fabrication and Installation
Replace SAG Mill Discharge Screen
Provide services to dismantle the old installation, install the new Vibrating Screen and reinstall chutes and ancillary items for the installation.
Cone Crusher Support Structure
Design and supply Cone Crusher Structures for a large Australian Copper/Gold operation.
- The scope of work included:
- Structural and Mechanical design.
- Detail construction drawings
- Manufacture
- Protective coating
- Supply to site
Crushing and Screening
Design and Construction of a 350 MTPH Roadbase and Aggregate Plant.
Major Items of equipment includes:
- 20M/3 Feed Bin and Vibrating Feeder.
- 310Kw Cone Crusher and Structure.
- 24’*8’ Triple Deck Vibrating Screen and Structure.
- 2*220Kw Vertical Shaft Impactor.
- 2 off 20’*8 Triple Deck Vibrating Screens and Structures.
- 30m Radial Stacker.
- 3 off 18m Product Radial Stackers.
- 12 off assorted Belt Conveyors.
Ball Mill Circuit
Design and Construct Ball Mill Grinding Circuit
- Day Bin
- Trash Screen
- Conveyors
- Ball Mill
- Pumps
- Cyclones
- Belt Feeder
- Civil Structures including Piling
- Steel Structures – Predominately Hot Dip Galvanized
- Pipework
- Silo, Chutes and Fabricated Process Tanks
Crushing and Screening
METSO ES403TD, (2.4*6.0m TD) Vibrating Screen Design and Manufacture adapter assy’s for Spring bases
- Structural Modifications
- Feed Chute Modifications
- New Discharge Chute
- Bolt in AR500 Wear Liners
- Screen Access Ladder and Platform
Replace the Main product Bucket Elevator
Replace the Main Product Bucket Elevator with a New Stainless Steel Machine
Major Items and steps:
- Supply a 21m Bucket Elevator manufactured in Stainless Steel.
- Pre-Assembly of the BE in 3 major trunk sections
- Pre-Assembly of the Buckets to the drive belt.
- Removal of the old BE assembly ( in several pieces ) along with the
- discharge valves
- Alteration of foundations and Hold Down Bolts
- Installation of the lower truck and installation of bracing
- Installation of mid trunk section and bracing
- Installation of Head and Drive Assy
- Lift in the Belt/buckets string as one piece
- Design, manufacture and install a Nil-residue Rotary Diverter Valve
- to stop product contamination and chute blockages.
As this is an operating plant it was imperative the production was effected as little as possible.
The trunk, belt and Diverter Valve assemblies were pre-assembled in a laydown area on site and lifted as major assemblies into the plant to minimize installation time and disruption to production at installation.
Crusher Support Structure and Access Platforms
Details: A project to Design and Construct a new Cone Crusher Support Structure and access and maintenance platform for both the Cone Crusher and an existing VSI Crusher.
Site works included the installation of the new Cone Crusher, all structures and the modification of existing structures, Feed Chutes and Conveyors.
Cyclone Tower Repair
Details: Design, Manufacture and Install Concrete Filled Steel Shells to recover and protect Cyclone Tower Foundations from further wheel loader damage.
Step 1: Damaged Concrete is scabbled/cleaned and the New (split) Steel Protection Shells are lifted into place, bolted together and fastened to the foundations for stability when pouring the concrete.
Structural repairs to the tower base and Hold Down bolts are completed.
Step 2: Concrete is poured into the void, vibrated and finished. Baseplates have the grout repaired.
Step 3: Project Completed
Design and Manufacture Deslime Cyclone Module
Details: Design and Manufacture a Deslime Module incorporating multiple Feed, Underflow and Overflow streams.
Includes;
- Process Design.
- Structural,Mechanical and Piping Design. Cyclopack Manufacture.
- PID development.
- Detail Drawings.
Enviromental Dam Wall Replacement and Upgrade
Design and Construct a new Dam Wall and associated upgrades. Included a compacted Earth wall including RC spillway and Gabion protection.
Enviromental Monitoring and Sample requirements.
Removal of existing Spillway and Dam Wall. Dam Engineering to DERM requirement. Excavation, profiling and topping Dam Structure.
CRFS Grinding/Thickener Circuit
Design the installation of a New Thickener and the refurbishment/recommissioning of 2off Agitated Slurry Storage Tanks, an over land Slurry Pipeline and re configuration of Grinding Circuit Pumps and Pump boxes.
Includes Detail Design Drawings.
- Overall Thickener and Agitated Storage Tank Layout
- Feed Pump, HP Booster Pump, Pumpbox’s and Pipeline Arrangement
- Thickener Arrangement including access platforms and stairs.
Product Screen Module
Product Screen Module including:
- METSO CVB1845 TD Vibrating Screen Screen Structure
- Chutes – AR500 Lined
- 3*18m Product Conveyors
- 1*20.5m Product Conveyor
- Galvanized Protective Coating System
Primary Crushing Module
Design and Manufacure a Primary Crushing Module for 900tph of Iron Ore including:
- METSO C150 Jaw Crusher
- METSO VG Grizzly Scalp Screen
- Modular Design where a small number of preassembled sub-assemblies were supplied to site for easy installation.
Mobile Crushing and Screening Module
Refurbish Mobile Crushing and Screening Module including:
Replace Conveyor Drives.- Structural Modifications.
- Installation of Larger Barmac Crusher.
- General Chute repair and replacement.
- Manufacture and Installation of new walkways and handrails. Manufacture and Installation of new walkways and handrails. Blast and application of protective coating.
- Commissioning
Refurbish Gravel Crushing & Screening Plant
- Upgrade and Recommission a Wet River Gravel Crushing and Screening Plant
- Replace 2off 1.8*4.5 TD Vibrating Screens
- Replace Barmac B7150 Crusher
- Blast and Paint Structures
- Structural Repairs to all steel work Replace/Repair/Refurbish Chutes Guarding
- Platforms and Stair repair and replacement Water System Reconfiguration
New METSO Barmac B7150 Crusher
New Fine Product Screen
New Sand Screen c/w Galvanized Feed Chute
Sand Product Screen Installation
Install a New ROTEX Sand Product Screen Module
Including:
- Plant Layout and Installation Design
- Removal of an old Trommel Screen assembly
- Pre-assembly of the ROTEX Screen and Screen Structure
- Installation of the ROTEX Screen and Structure
- Supply and installation of 3 off 350 and 450mm width SANCON
- Conveyors c/w Galvanized Frames, Chutes, Dust Covers and Modular
- Support frames
- Installation and piping of a new Dust Extraction System
As this is an operating plant it was imperative the production was effected as little as possible.
The Rotex Screen, Screen Structure and Conveyor assemblies were pre- assembled in a laydown area on site and lifted as major assemblies into the plant to minimize installation time and disruption to production at installation.
Truck Loadout Facility
Design, Manufacture and Install a 50t capacity Silo and Truck loadout facility.
Including:
- Fabricated Steel Structure
- 50t Poly Silo
- HDPE Chutes
- Walkways and platforms to connect to existing plant
- Plant Air extension
- Civils and Concrete
- Stainless Steel Bucket Elevator
- Feed Conveyor – Galvanized SANCON c/w Chutes, Dust Covers and
- Modular Support Frames.
- High volume discharge to truck/tanker
As this is an operating plant it was imperative that production was effected as little as possible.
The structure, platforms and Bucket Elevator were pre-assembled in a laydown area on site to minimize installation time and disruption to production out loading.
Excavation and pouring of the foundations and truck slab were done predominately out of normal production hours to minimize plant down time during construction.
Refurbish Mobile Barmac Crushing and Screening Plant
Refurbishment of a Mobile Crushing and Screening Module.
Including the replacement/refurbishment of a BARMAC 7100 Crusher and supply of Generator Module.
This plant is designed to upgrade <22 Primary Scalps into high value aggregates.
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We're the experts in the design, construction and fabrication of complex projects, with a focus on Mineral Processing, Quarries, Materials Handling and Industrial Process Installations.