Safety-led. Capability-driven.
Built to perform.
Safety-led. Capability-driven. Built to perform.
Light, Medium & Heavy Fabrication
Delivering high-quality, custom fabrication solutions for projects of all sizes.
Walz Group operates a large, fully equipped workshop, with 4,500m2 of fabrication space and 9,600m2 of laydown and storage area. With a full range of fabrication services, our facility supports our project and maintenance divisions and can be utilised around the clock to meet tight project timelines.
From structural steel, plate works, pipe works and other specialised items, we can meet a wide range of client requirements for any size of project. The vast workshop and laydown area offer huge benefits in the ability to work on large scale components.
The Walz Group fabrication team is proficient in custom manufacture to specification. We are experienced in complex fabrication and work closely with clients to ensure the finished product is fit for purpose.
Our fabrication facility provides around-the-clock services for fast turnaround on tight deadlines. All our workshop quality systems are independently certified to ISO9001 and meet our clients’ quality requirements.
Walz were engaged by our client to complete necessary maintenance repairs and improvements to four 22m diameter thickener tanks, as part of their periodic API inspection requirements. The scope of work involved the replacement of corroded pipework, internal feedwells, structural repairs to the strakes, and full internal blast and paint.
Coming off the back of successfully completing the installation of the new Horizontal Belt Filter BF703, we were again engaged by BMA to assist with an upgrade of an existing dewatering screen to larger dual screens. The installation of these dual screens would assist operations with rectifying a bottleneck identified in Coal Preparation Plant 1 (CPP1), resulting in increased production rates.
Continuing our ongoing relationship, we were engaged by BMA to carry out the installation of Horizontal Belt Filter BF703 at its Goonyella mine in Central Queensland. It was our first time working back at the Goonyella mine in recent years and it was a great opportunity for our team to demonstrate our capabilities working alongside a new client team.
This work involved the urgent replacement of a heavily corroded footbridge at the Hay Point Coal Terminal. The new bridge had been fabricated, but was yet to be installed, and the existing structure was quickly deteriorating after the impact of Cyclone Ului. With high structural corrosion throughout the chords and stringers, the old bridge was not capable of withstanding a significant wind or wave event.
When the existing stacker-reclaimer stockyard machines (SR1 and SR2) at the Hay Point coal terminal started to approach the end of their life, BMA commenced the process of replacing them. With an anticipated lead time of two years for the new equipment to be manufactured and shipped to Australia, the machines needed work to be kept operational until the replacements arrived.
Based on our successful track record on multiple projects at Hay Point terminal, we were engaged by BMA to deconstruct and remove the original trestle and the 17BP conveyor installed when the facility opened in 1971. The ageing 1.8km structure transported coal from the terminal to waiting bulk carriers for more than 40 years and was decommissioned late in 2016.
Cement Australia’s operations in Gladstone incorporate Australia’s largest cement kiln, capable of producing more than 1.6Mtpa of cement.
We performed the onshore works for the outloading conveyor system in the second phase of the Dalrymple Bay Coal Terminal 7X project. This expansion saw the terminal increase its capacity by around 50% to 85+Mtpa, making it the third largest terminal in the world.
Formerly owned by Wesfarmers Resources, the Curragh Coal Mine (now operated by Coronado Curragh Pty Ltd) is located in Queensland’s Bowen Basin, 30km north of Blackwater. The main product from the mine is metallurgical (coking) coal for export.
The Dalby Ethanol Plant is Australia’s first grain-to-ethanol facility. Each year the plant converts nearly 200,000 tonnes of sorghum into 76 million litres of ethanol. The product remaining after ethanol distillation — known as sillage — is separated and concentrated using centrifuge and evaporation technology to form a high energy, high protein animal feed known as wet distiller’s grain. The soluble dry matter, known as syrup, is blended with the Wet Distiller’s Grain (WDG) and sold to the local animal feed market as Wet Distiller’s Grain with Solubles (WDGS).
BHP Mitsubishi Alliance (BMA) Goonyella Riverside Mine (GRM) replaced the rejects conveyor gantries and trestles as part of the Goonyella R10M Conveyor & Trestle Replacement project. This work was part of a planned upgrade to the existing R10M Conveyor required to rectify a series of identified deficiencies during a major 6 week outage.
To facilitate the acquisition of up to 50 additional Heavy Mining Equipment (HME), the BMA Saraji Mine (SRM) engaged Walz to build an extension to the existing workshop to include 4 additional Ultra-Class (UC) bays.
Our client, Sedgman, has operated the Sonoma plant since it was constructed in 2007, and were seeking support for the detailed design, engineering, procurement, and construction of the High Cut Low Cut Brownfield Upgrade of the coal handling and preparation plant.
With stage 1 of the Wiggins Island Coal Export Terminal (WICET) completed, commissioned and fully operational in 2015, the construction barge wharf at the site was rendered redundant. After considering removal of the wharf, WICET decided it would be more beneficial to decommission and preserve the facility. This would keep the option of using it again for any further expansion works in the future.
Quality and Compliance
Quality is at the core of our fabrication services. Our processes are governed by robust quality assurance systems, documented traceability and inspection regimes to ensure structural integrity and compliance with client and industry standards. Every spool and assembly is verified for dimensional accuracy, welding integrity and specification alignment before release.
Collaborative Delivery
We work collaboratively with clients, engineers and site personnel from design review through to fabrication and handover. This integrated approach ensures clarity of requirements, consistency in execution and responsiveness to changing project needs — giving clients confidence from workshop to site.