Safety-led. Capability-driven.
Built to perform.
Safety-led. Capability-driven. Built to perform.
Site installation & Erection
Site Installation and Erection (SMP)
Integrated SMP construction solutions delivered safely, efficiently, and to the highest standards.
Walz Group specialises in the construction of structural, mechanical and piping (SMP) installations for processing plants and materials handling infrastructure. We deliver comprehensive multidisciplinary engineering construction for brown and greenfield projects.
From intricate, bespoke modifications, through to large scale plant upgrades, Walz Group has both the size and the agility to handle projects of any magnitude . We support structural, mechanical and piping (SMP) installation that is delivered safely, on time, and within budget.
Walz Group takes an integrated, multidisciplinary approach to carrying out SMP work in a multitude of service areas, including greenfield and brownfield mining infrastructure, LNG and CSG upstream and downstream facilities, onshore and offshore port infrastructure, petrochemical plants, and utilities infrastructure. Our experienced teams simplify the interface between structural, mechanical, and piping disciplines, ensuring a streamlined project execution process.
Our SMP services are supported by our own specialist fabrication and protective coating facilities.
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.
Rio Tinto’s Alcan Gove operations are located on the Gove Peninsular in northeast Arnhem Land in the Northern Territory. Our client identified that the plant was experiencing product loss and dust emissions at a juncture of two conveyors transporting ore to the harbour. The dust emission issues were due to inefficiencies within the transfer station. Walz Group was engaged to upgrade the export conveyor system and transfer station to achieve a targeted reduction in visible dust generation of 85%.
Vale’s Carborough Downs underground mine is located in Central Queensland’s Bowen Basin, 180 kilometres southwest of Mackay. Walz Group was engaged to perform the structural, mechanical, piping, and electrical installation of the 5km overland conveyor and upgrade of the coal handling and preparation plant (CHPP). This formed part of a broader brownfields expansion.
We were proud to support our client, Bechtel, to deliver one of six LNG trains on Curtis Island as part of the largest concentration of private capital investment in Australian history. This historical program of work resulted in three plants that yield roughly 8% of the world’s total LNG production.
As BMA’s Broadmeadow longwall mine operations advanced, a need was identified to install new conveyer infrastructure to replace shuttle cars and diesel ram cars to transport coal from the face. Walz Group was engaged by BMA to complete the structural, mechanical and pipework installation of two new conveyers — Maingate 10 (MG10) and Maingate 11 (MG11).
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.
Hay Point Coal Terminal is one of the largest coal export ports in the world. Walz Group had previously worked directly for the owner-operator, BMA, to urgently replace a footbridge . We were subsequently engaged to support BMA to deliver the third major expansion of the facility.
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.
The Scope incorporates the fabrication and installation of new carbon steel pipelines (Bauxite Slurry line, Caustic line, CGW line) from the wharf to South Trees Island and from STI to the mainland via the causeway.
After working together successfully on previous projects, Wesfarmers Curragh Pty Ltd (WCPL) engaged Walz Group to support the installation of a new tailings retreat circuit to the Coal Preparation Plant 1 (CPP1) at its Blackwater mine in Queensland. We’ve worked at Curragh before and have gained a solid understanding of the mine’s operational requirements.
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).
The Rio Tinto Alcan Yarwun Refinery (RTAY) is undertaking a CAPEX project to upgrade the existing Hydrate Stockpile infrastructure in an effort to reduce contamination of the Hydrate Stockpile.
Australian Gas Infrastructure Group (AGIG) are developing the Hydrogen Park Gladstone project, for the small scale production of hydrogen and injection into the natural gas distribution network as a 10% blended mix. A 175kW NEL electrolyser is the primary hydrogen generation equipment installed, with supporting infrastructure to facilitate the generation and injection of the gas into the distribution grid.
Fitzroy Coal Management are currently constructing a new underground coal mine, Ironbark No1, located 50km northeast of Moranbah Queensland Walz Group were engaged to complete full Structural, Mechanical and Piping Installation as well as managing an electrical subcontractor to complete the E&I installation works.
We worked with John Holland Group to deliver the X50 Expansion at Abbot Point Coal Terminal. This work increased the North Queensland Bulk Ports Corporation’s annual export capacity to 50 megatonnes. The facility services the export requirements of a number of mine operators, including Newlands, Collinsville, and Sonoma mines.
Walz were engaged to complete the Structural, Mechanical and Piping construction scope for the main kiln bag filter replacement project, at Cement Australia’s Gladstone plant.
Forming part of the six LNG trains on Curtis Island, the Australia Pacific LNG plant is Australia’s largest producer of coal seam gas (CSG). It not only supplies Queensland’s domestic gas market, but also processes CSG into liquefied natural gas to meet the demand of customers around Australia and globally. The development of the plant took some five years, shipping its first cargo in 2016.
Peak Downs Mine (PDM) identified the Coal Thickener Bridge was at its end of life and required replacing. It supports a range of services including mechanical drives, hydraulics, electrical and control services, flocculent dosing system, compressed air and coal slurry and water pipes. It also provides the suspension of the feed well and thickener raking system.
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.
Sedgman was engaged to design and construct a sands beneficiation plant, port stockpile expansion, and other associated infrastructure at BHP Billiton’s GEMCO facility. The plant aimed to increase the capacity of the existing concentrator plant by reprocessing ore from tailings stockpiles.
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.
Sinosteel engaged Walz Group to carry out the structural, mechanical and piping works for the greenfield installation of a new 3Mtpa copper processing plant at their Rocklands mine, approximately 17km west of Cloncurry, in northwest Queensland.
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.