PROJECTS
Malabar Resource Mine – Precast Foundation Pads for Overland Conveyor
Client: FENNER DUNLOP AUSTRALIA
Civilcast partnered with Fenner Dunlop Australia to supply high‑precision precast components supporting the delivery of an overland conveyor system at the Malabar Resource Mine in Muswellbrook, NSW. Our team delivered 2,840 foundation pads across a 4‑month schedule, accelerating installation and reducing on‑site risk.
Project Overview
- Client: Fenner Dunlop Australia
- Location: Muswellbrook, NSW
- Scope: Supply of 2,840 precast foundation pads for overland conveyor supports
- Program: 4‑month delivery schedule with just‑in‑time site drops
This collaboration brought together Civilcast’s design, production, QA, and logistics teams to meet demanding site conditions and tight timelines while maintaining exacting tolerances for conveyor support interfaces.
The Challenge
With tight deadlines and minimal room for error, Fenner Dunlop required a high‑precision precast solution that would avoid in‑situ pours, maintain ±1 mm manufacturing tolerances, and accelerate project delivery.
Our Solution
Civilcast designed and built custom moulds and delivered a complete precast package, including:
- Conveyor support pads with high dimensional accuracy
- In‑house bolt fixing for ready installation
- Just‑in‑time delivery coordinated across an expansive site
Execution & Delivery
- Seamless logistics managed by two dedicated contractors
- Pads delivered to specific zones based on construction sequencing
- No installation delays due to the quality and accuracy of the precast product
Key Milestones
- Design completed within 10 days of order
- 12 custom moulds built in 4 weeks
- 2,840 units delivered – 2 weeks ahead of schedule
Outcomes
- Project completed ahead of time
- Reduced site labour and risk
- Accelerated conveyor installation
- High client satisfaction
Civilcast Project Team
Our Product and Design teams translated engineering requirements into practical, high‑performance precast solutions. Production manufactured each component to exacting tolerances, QA ensured every piece met stringent benchmarks, and Logistics coordinated safe, timely delivery to the remote site—keeping the project on track.