Telfer Headframe

The relationship between RCR Maintenance and Newcrest Mining began with a project to design, construct and install the 65 metre headframe at Telfer Western Australia’s largest - in 2003.

WA's largest
mining headframe

Standing as tall as a 15 storey building, the headframe consists of four 65 metre tubular legs of 1.8metres diameter, supporting headsheaves on two platforms at heights of 45 and 65 metres.

The legs and platform beams of the headframe were precision machined to fit with a high degree of accuracy. More than 2000 bolts were used in the assembly, with RCR’s welders facing the challenge of working 45 metres aboveground, for which specific safety training was required.

RCR carried out several studies of the lifting operations to determine the most effective and economical installation method, with the proposed solution trialled at RCR’s Welshpool facility to confirm its viability.

Three cranes were used for the installation, the largest of which was rated at 750 tonnes and transported to site on 30 road trains.

The innovative installation plan developed by RCR Maintenance was pivotal in winning the $3.5 million contract, as were our integrated engineering capabilities. This meant that all the work - including engineering, fabrication and machining was performed by a single supplier.

Despite its engineering complexity and the many logistical challenges presented by the site’s remoteness (more than 500 kilometres east of Karratha), the project was completed on-time, thanks in part to the detailed risk assessment that was conducted before site work commenced and the continuous communication between RCR and Newcrest.

The installation of the Telfer headframe was completed in December 2003.