To access the high grade iron ore deposits at Koolan Island, Mt Gibson Mining required the construction of a sea wall. Conventional reclamation techniques such as dump and push, or excavator placement of material were unsuitable due to unstable ground conditions. 

Cape Crushing’s concept was to modify an existing tracked crusher frame and feed hopper unit, and to retrofit a horizontal discharge conveyor. The key design criterion was that personnel and equipment were kept at least 20 meters from the discharge point, and out of the subsidence zone.

Process 26 modelled the unit using 3D modelling techniques. Our specialist structural engineering partner then designed the machine to comply with Australian Standards, including AS 4324.1 1995 Standard for Design of Bulk Materials Handling Machines. 

Process 26 fabricated, trial assembled and fully commissioned the unit in Perth prior to the unit being transported to site.

The unit was site commissioned and the design rate of 500 tph of minus 300mm quartzite was achieved. The project was completed successfully and safely with some 1.8 million BCM’s of material being deposited in the seawall.