Blue Rock Quarry Upgrade
Revision Zero Completes Blue Rock Quarry Upgrade in Cedar Creek, QLD
In 2019, Revision Zero achieved a significant milestone by successfully completing the Blue Rock Quarry Upgrade, strategically located in Cedar Creek, Queensland, Australia. This project is a testament to Revision Zero’s commitment to enhancing infrastructure and meeting the growing demands of the construction industry.
Project Overview:
Blue Rock Quarry is a brownfield development of an established hard rock quarry operation. The primary objective of this project was to increase the capacity of the existing fixed crushing and screening plant. This upgrade was essential to meet the anticipated rise in demand for high-quality aggregates and roadbase products driven by regional development and infrastructure projects.
Scope of Work:
Revision Zero’s role in the Blue Rock Quarry Upgrade encompassed a range of comprehensive and technical tasks:
3D Modeling: Utilized advanced 3D modelling techniques to plan and visualise the upgrade.
Detailed Drawings: Prepared meticulous and detailed drawings to ensure precision and accuracy in the execution of the upgrade.
Santos Moomba CCS Piperack
In mid-2022, Revision Zero successfully completed a critical segment of the Moomba Carbon Capture and Storage (CCS) Project, located 800 kilometres north of Adelaide in the Strzelecki Desert of South Australia. Positioned to become one of the world's largest CCS initiatives, this project aims to safely contain 1.7 million tons of carbon dioxide, marking a significant milestone in global climate change mitigation efforts.
The Santos Moomba CCS projects, renowned for their ambitious goals and cutting-edge technology, highlight the critical role of companies like Revision Zero in advancing carbon capture and storage solutions. Revision Zero’s expertise in providing precise 3D modelling services for structural steel was pivotal to the project's success. Their meticulous drawings ensured the highest standards of precision and quality, essential for supporting the complex CO2 containment infrastructure.
In addition to 3D modelling, Revision Zero delivered comprehensive documentation, including marking plans, assembly drawings, fitting sheets, and all associated NC data required for steel fabrication, amounting to approximately 52 tons.
While pipe spooling and isometric drawings were not required for this specific project, Revision Zero continues to offer these services and is actively expanding its expertise in these areas. #revisionzero
Newcastle Distribution Centre
In the middle quarter of 2023, Revision Zero successfully completed Infrabuild’s Newcastle Distribution Centre project located on Ingall Street, Mayfield, New South Wales, Australia.
Infrabuild’s new location will simplify production flow and offer innovative space solutions. The facility's relocation will maintain a substantial amount of space for steel production and enhance convenience, accurately meeting customer needs and satisfaction.
Revision Zero played a pivotal role in this project, delivering comprehensive services in 3D modelling and shop detailing for approximately 20 tons of structural steel. A model-based information flow process was adopted as the work needed to be integrated into an existing structure. STP and DWG file formats of the existing structure were provided, enabling Revision Zero to develop the new steelwork model around it. This model workflow continued through the review and approval process, thereby accelerating the overall timeline. #revisionzero
The project scope included the following works:
South End Awning
Intermodal Door Modification
West Wall Infill Panel Support
Crane Access Stair
Door Penetration Steelworks
Modified Northern Doorway
Kurri North Switching Station
The Kurri North Switching Station Project, completed by Revision Zero in the last quarter of 2023, is a significant infrastructure development located at 1 Hart Road, Loxford, New South Wales, Australia.
Overview
As an integral part of the Hunter Power Project, also known as the Kurri Kurri Power Station, this 132-kilovolt electrical switching station is designed to contribute to New South Wales's economic growth. The switchyard equipment includes underground cables and overhead line gantries, essential for transmitting power to various associated regional infrastructures and facilities.
Project Scope by Revision Zero
Revision Zero's responsibilities for this project encompassed the Switching Room Station's 3D modelling and shop detailing, which involved approximately 10 tons of steel. The specific work package included:
Control Building Structure Steel Frame
Chequer Plate
Aircon Frame
This project underscores Revision Zero's expertise in delivering complex engineering solutions, ensuring the efficient and reliable transmission of power in New South Wales.
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Independence Day
We post this video each year at this time to appreciate the heritage and culture of the Philippines. While serving clients in North America, the UK, Australia, and New Zealand, Revision Zero's production team is based in Manila, the Philippines.
Although the Philippines Independence Day is on Wednesday, June 12th, we will be celebrating by observing the holiday on Friday, June 14th.
SP4 Production Facility Upgrade
In mid-2023, Revision Zero proudly completed the SP4 Production Facility Upgrade located in Penrith, Sydney, Australia. This project is a significant milestone in enhancing Visy Glass's capacity to recycle glass, enabling the company to recycle up to 200,000 tons of glass annually, equivalent to 150 bottles and jars.
Visy Glass, Australia's largest recycling company, collaborates with councils nationwide to manage nearly 40% of curbside recycling bins. By doing so, Visy keeps countless items out of landfills, reduces emissions, and protects natural resources. Beyond recycling, Visy offers a comprehensive range of services, including packaging supplies, point-of-sale displays, logistics, and more.
Revision Zero’s involvement in the SP4 Production Facility Upgrade was crucial. Our services included 3D modelling and the creation of workshop fabrication drawings. Key aspects of our contribution include:
Structural Steel: Approximately 211 tons.
Handrail: Around 423 linear meters.
Grating: A total of 3624 square meters.
Thanks to our expertise in model integration, we successfully interfaced with existing steel structures and significant mechanical equipment.
The upgrade project encompassed the following areas:
Forming Machine Support Steel
Feeder Floor Steel
Machine & Charge Floor
Cold End Column Removal
SP41 & SP42 Intermediate Platforms
Control Room Structures
Batch Tower
This project showcases Revision Zero's dedication to precision and expertise in structural engineering and 3D modelling. Our successful completion underscores our commitment to becoming a leading player in significant industrial expansions.
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Tritton Flotation Circuit Upgrade
In the first quarter of 2023, Revision Zero successfully completed the Tritton Flotation Circuit upgrade project, located near the towns of Nyngan and Cobar in central New South Wales, Australia.
The Tritton Mine is a long-life copper mine featuring an underground mining complex that processes 1.8 million tonnes annually through a conventional processing plant. The ore produced from the Tritton Mine is processed at the Tritton Copper Sulfide Ore Processing Plant. Copper, silver, and gold are recovered through a process of crushing, grinding, and conventional sulphide flotation to produce a copper concentrate. This copper concentrate is then exported to international customers via the Port of Newcastle.
Revision Zero's scope of work for this upgrade project included 3D modelling and shop detailing of approximately 14 tons of structural steel, around 85 linear meters of handrail, and 108 square meters of grating. This structure was integrated into an existing framework, and Revision Zero's exceptional expertise in interfacing with existing structures ensured a perfect fit on site.
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Boom Support Frames
In the last quarter of 2022, Revision Zero successfully completed the Boom Support Frames project. This innovative design, featuring top and bottom bearing frames supported by 20-foot shipping containers, ensures robust support and structural integrity. The meticulous 3D modelling and preparation of detailed drawings for approximately 28 tons of structural steel were essential for this project's success.
The project scope included:
- Boom Support Frames (4 units)
- Posts with Swivel Attachments (4 units)
- Bottom Bearing Frames (4 units)
- Handrails
Despite being a smaller project, Revision Zero maintained high-quality standards and delivered excellent results. Our commitment to precision and innovation guarantees that every project, irrespective of size, is completed to the highest standards.
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Beach Project Structural
The last quarter of 2022 marked the successful completion of the Beach Project Structural at the Otway Gas Plant, located approximately 32 to 80 kilometres from Port Campbell in Southwest Victoria.
The Otway Gas Project encompasses two offshore gas fields, Thylacine and Geographe, and an onshore gas processing facility north of Port Campbell. This facility is integral to producing raw gas, effectively separating hydrocarbon fluids into gas and liquid streams. The development features extensive offshore and onshore infrastructure, including a subsea pipeline system extending from Thylacine to the shore crossing within the Port Campbell Rifle Range and an onshore pipeline system leading from the shore crossing to the gas plant.
Revision Zero’s role in this complex project involved creating 3D models and preparing detailed drawings for structural steel and pipe supports, collectively weighing approximately 42 tons. This task required meticulous coordination with mechanical and piping models to ensure seamless integration and avoid clashes.
The scope of work for this project included:
• Slug Catcher Receiver End Platform
• Flow Meter Structure
• Slug Catcher Structure Link Platform
• Gridmesh & Cable Ladder Support
• Wellsite Meg Skid
• Otway Gas Plant Pig Receiver
• Gas Pipe Supports
Through this project, Revision Zero demonstrated its structural modelling expertise and capability to manage complex projects involving substantial infrastructure. Its successful completion underscores our commitment to precision, quality, and effective collaboration with other engineering disciplines.
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Swanson Dock West Remediation Platforms
In the latter quarter of 2022, Revision Zero was contracted as part of the comprehensive Swanson Dock West Remediation Project in Melbourne, Victoria, Australia.
Swanson Dock West is a Critical International Container Terminal, encompassing a 944-meter wharf with three container-handling berths. Extensive remediation is imperative with sections of the current wharf nearing or exceeding the standard 30-year design life. The Swanson Dock West Remediation project prioritises upgrading access platforms to ensure safe passage from land to the fenders' front, bottom, and back surfaces. This enhancement is essential for sustaining the infrastructure and operational capacity of the international container terminal, crucially supporting the Port's container handling operations.
Revision Zero spearheaded this endeavour, focusing on 3D modelling and the preparation of drawings for approximately 6 tons of structural steel. While not a large-scale undertaking, the project was profoundly rewarding.
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May the 4th be with you
Happy Star Wars Day! May the 4th be with you!
Check out this fun little animation we did a few years back, featuring our BIM model of some interfacing chutes for the Carrapateena Project. It's a great example of using technology to bring our projects to life.
#StarWarsDay #MayTheFourth #BIM #CarrapateenaProject #RevisionZero
Doonside Railway Station
Revision Zero successfully completed the Doonside Railway Station project in mid-2022. Situated along the Main Western railway line, it is 38.3km from Sydney's CBD.
Serving the suburbs of Bungarribee, Woodcroft, and Doonside, the station features two islands, forming four platforms accessible via an overhead footbridge. T1 Western trains provide service in both directions. As part of the upgrade project, four new lifts were installed, connecting the station entrances to the existing footbridge and platforms, with continuous canopy cover on both platforms. Enhancements were made to the ramps, footbridges, and stairs on Platforms 1 and 2, while new steps were added to Platforms 3 and 4. Additionally, accessible pathways throughout the station precinct were regraded for improved accessibility.
Revision Zero's contributions to this project included the creation of 3D models and the preparation of drawings for structural steel, weighing approximately 110 tons, as well as miscellaneous steels such as screens and balustrades.
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White Powersports New Warehouse & Office
In mid-2023, Revision Zero achieved a significant milestone with the successful completion of the White Powersports New Warehouse & Office, strategically situated at 142 Kohia Drive, Burbush, Hamilton, New Zealand.
The White Powersports New Warehouse and Office project stands as a pinnacle of modernity, boasting state-of-the-art warehousing facilities, meticulously designed offices, and captivating showrooms. Spanning an impressive 5,700 square meters, the warehouse features towering 14-meter-high racking, complemented by an adjacent 800 square meters of thoughtfully crafted office space. Additionally, the site includes essential infrastructure such as a BTrain ring road for streamlined logistics and ample staff car parking. This visionary facility is poised to not only accommodate the company's expansion initiatives but also foster the continued success of the prestigious brands it represents across Australia and New Zealand.
Revision Zero's integral role in this endeavour encompassed comprehensive 3D modelling and meticulous shop detailing for approximately 250 tons of structural steel. Their unwavering commitment to precision and excellence ensured the seamless realisation of this landmark project.
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Bulga ROM Bin Access Stairs
Projects at Revision Zero encompass a broad spectrum, ranging from small-scale endeavours to expansive undertakings spanning thousands of tonnes. Despite the variance in size, each project is approached with equal measures of respect and diligence. Such was the case with the Bulga ROM Bin Access Stair project, completed by Revision Zero in mid-2023. Situated 15 kilometres southwest of Singleton, near the villages of Broke in Bulga within New South Wales Upper Hunter Valley, this project exemplifies our commitment to precision and excellence.
The Bulga ROM Bin Access Stair formed a component of the Bulga ROM Feeder Size Upgrade, an integral part of the Bulga Coal Complex. This complex is a significant producer of semi-soft coking coal and thermal coal, transported via rail to the Port of Newcastle for export to China and Japan, where they are predominantly utilised in steel production and energy generation. Comprising a Coal Handling and Preparation Plant (CHPP) and a rail loading facility, the complex supports both open-cut and underground operations.
Revision Zero's involvement in the Bulga ROM Bin Access Stair project primarily entailed providing 3D modelling services and developing workshop fabrication drawings. This encompassed the detailing of structural steel components totalling approximately 18 tons, along with the specification of around 125 linear meters of the handrail and 36 square meters of the grating.
#revisionzero
Hunter Power Station
Revision Zero successfully concluded the Hunter Power Station project in the final quarter of 2023. Situated within the confines of the former Kurri Kurri aluminium smelter site in Loxford, north of Kurri Kurri, the project spans approximately 35 kilometres west of Newcastle and 125 kilometres north of Sydney, within the Cessnock City Council local government area.
The Hunter Power Project is a monumental endeavour, comprising a 660MW open-cycle gas-fired power plant. This cutting-edge facility features two heavy-duty, open-cycle gas turbines (OCGT), representing the pinnacle of efficiency and innovation from premier global manufacturers. The project entails the construction and operation of a power station, an electrical switchyard, as well as the requisite fuel gas and diesel supply infrastructure. Notably, this initiative is poised to enable an estimated 1.5 to 2GW of renewable energy capacity, akin to approximately 160,000 household solar installations.
Under the stewardship of Revision Zero, the project achieved remarkable milestones. Comprehensive 3D modelling services were executed alongside the production of structural steel drawings amounting to approximately 390 tons, 334 square meters of grating, and 1185 linear meters of the handrail.
The project's scope encompasses various critical components, including but not limited to:
Exhaust Stack Stair Towers (Zone 1 & 2)
Mitsubishi Substation and Control Room (Zone 1 & 2)
Gas Turbine Generator Rotor Supports (Zone 1 & 2)
Transformer System Breaker Structures, Platforms, and Stairs (Zone 1 & 2)
Lube Oil Building Access Platforms (Zone 1 & 2)
GT Access Stairs (Zone 1 & 2)
Generation Plant System (Zone 1 & 2)
High Voltage Gantry (Zone 1 & 2, Sitewide)
Step-Up Transformer Stairs (Zone 1 & 2)
Revision Zero takes great pride in its involvement in environmentally conscious initiatives such as the Hunter Power Station project. As a company committed to sustainability and innovation, we continually seek opportunitie
Bengalla Mine Tailings Upgrade
Revision Zero successfully completed the Bengalla Mine Tailings Upgrade project in the first quarter of 2023. Located in the Upper Hunter Valley of New South Wales, approximately 130 km northwest of Newcastle and four kilometres southwest of Muswellbrook, the mine supplies international markets with around 7Mt/year of thermal coal.
Bengalla Mine operates as an open pit mine, extracting coal at a depth of approximately 270 meters using a dragline, trucks, and shovels. The site infrastructure includes a Coal Handling and Preparation Plant (CHPP), administration and bathhouse facilities, rail loop, and loading facilities. The tailings upgrades at Bengalla Mine involved dewatering, single-stage Dense Medium Cyclone (DMC) and spirals, as well as a two-stage DMC conversion and CHPP upgrade aimed at enhancing stacking capacity and product quality.
Revision Zero managed BIM for this project, providing comprehensive 3D modelling services and creating structural steel drawings for approximately 178 tons of structural steel, along with 890 square meters of grating and 433 linear meters of handrails.
The scope of the upgraded project includes:
• Collector CL702 Adaptor Plate
• TK710 Oversize Collection Modifications
• TK730 Belt Press Filter Feed Tank
• BX730 Oversize Protection Box
• Belt Press Filter Underpans
• Belt Press Filter Discharge Chute
• SM703 Filtrate Collection Sump
• PP735 Support Steel & Perforated Plate
• CV731 Discharge Chute Skirting & Guards
• BFF Discharge Chute Deflector Plates
• LCS Frame
• Pipe Supports
• Filtrate Line Cross-over Stairs
• Density Gauge Access Platform
• Pipe Bridge
• Personnel Bridge
• BPF Building Primary Structure
• BPF Conditioning Tank Support Frame
• BPF Guards
• BPF LCS Frames and Slewing Monorail
• TK730 Access Platforms
• PP735 Slewing Cable Tray Support
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Cadia East T1-T2 Regrind Gravity Concentrator
Over the past eight years, Revision Zero has been extensively involved in construction modelling for a substantial portion of the Cadia development. In 2023, the successful completion of the Cadia East T1-T2 Regrind Gravity Concentrator project marked another milestone.
This project is located approximately 25 kilometers from the city of Orange in central west New South Wales, about 250 kilometers west of Sydney.
Part of the Cadia Valley Operations, the Cadia East panel cave mine ranks among the world's largest gold and copper deposits. Its development began in 2012, and commercial production commenced in 2013. Currently, it holds the distinction of being the largest underground mining operation adjacent to the Cadia Hill pit.
The Cadia East project involves upgrading the low-grade concentrator, introducing a new ball mill circuit, screening building, upgraded crushing circuit, new High-Pressure Grinding Rolls, and Flotation Circuit. A newly installed gravity concentrator in the cyclone feed stream of regrind mill ML-2006 is designed to capture gravity-recoverable gold, optimising overall gold recovery from Concentrator 1.
Revision Zero was pivotal in this project, providing essential 3D Modeling services and creating workshop fabrication drawings for approximately 35 tons of structural steel, including handrails and gratings.
The project's scope of work encompasses the following key components:
• Circuit Feed Screen
• Concentrate Hopper
• Concentrator Building IC Bund Support Frame
• Grating
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Prominent Hill Refrigeration Plant
Revision Zero successfully completed the delivery of Construction Modelling, Fabrication and Erection Drawings for Prominent Hill in early 2022, strategically positioned 650km north of Adelaide and 130km northwest of Olympic Dam within the Gawler Craton of South Australia. The site is conveniently accessible via a robust gravel all-weather road network and air transport services.
Prominent Hill is an underground copper, gold, and silver mine that contributes to South Australia's mineral resources. Presently, it is a key player in the global copper market, producing high-grade copper concentrate and maintaining a competitive position in the lower half of the copper cost curve. The mining process involves conventional crushing, grinding, and flotation processing.
The ongoing Prominent Hill Expansion Project aims to enhance the existing infrastructure, introducing vital components such as underground truck loading chutes, an underground primary crushing station, a skip loading station, a production hoisting system, and surface materials handling infrastructure.
Revision Zero played a crucial role in this expansion by executing essential steelwork for the Refrigeration area. This involved comprehensive 3D modelling services and the creation of structural steel drawings totalling approximately 100 tons. Additionally, about 330 linear meters of handrails and 245 sq.m of grating were meticulously fabricated.
The scope of work for this expansion project encompasses:
Condenser Structure
Condenser Support Steel
Condenser Support Handrails
Condenser Support Grating/Floorplate
Pipe Bridge
Pipe Bridge Steel
Pipe Bridge Handrails
Pipe Bridge Grating/Floorplate
The successful completion of these steelwork components by Revision Zero contributes to the overall efficiency and sustainability of the Prominent Hill Expansion Project.
Santos Area 1069 Tirrawarra andArea 1083 Moomba North
Revision Zero successfully completed the Santos Area 1069 Tirrawarra and Area 1083 Moomba North project in the 1st quarter of 2023.
This project is located in the Southwestern portion of the Permian–Triassic Cooper Basin in central Australia. The Tirrawarra oil and gas field, the largest discovered in the basin, is approximately 50 km north of the Moomba processing facility.
Tirrawarra, a conventional gas field, commenced production in 1985, recovering an impressive 92.18% of its whole recoverable reserves. In contrast, Moomba North, an unconventional gas field, achieved its peak production in 2002, recovering 94.17% of its total recoverable reserves.
An associated expansion project, the Tirrawarra Development project, focuses on concept development for facilities and infrastructure related to CO2 capture, compression, separation, and delivery to the injection well.
Revision Zero's engagement encompassed 3D Modeling services, including the creation of workshop fabrication drawings. This involved structural steel weighing approximately 16 tons, around 86 linear meters of handrail, and a total of 35 square meters of grating.
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RTA Hopper Platform
In the last quarter of 2022, Revision Zero successfully completed the RTA Hopper Platform, situated at Rio Tinto's Yarwun Alumina refinery in Gladstone, Queensland, Australia.
Currently, Rio Tinto's Yarwun Alumina Refinery is executing a capital project in the calciner area aimed at enhancing the existing hydrate stockpile. This initiative is designed to safeguard the quality of hydrate and bolster the reliability of the facility's infrastructure. The project encompasses the construction of a new stockpile pad, shed, conveyors, and associated infrastructure, as well as the incorporation of additional equipment to optimize the storage and reclamation of hydrate.
Revision Zero secured the contract for the RTA Reclaim Conveyor 480CV10100 Tail Modifications & Feeder Platform. Their involvement extended to providing 3D Modeling services and generating workshop fabrication drawings for approximately 5 tons of structural steel. Additionally, Revision Zero contributed around 47 linear meters of handrail and a total of 56 square meters of grating to the project.
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