Client:
Rio Tinto
Location:
Paraburdoo, Pilbara WA
Value:
Part of a 173,000,000 AUD upgrade program
Contract:
SMP delivery within EPCM-managed upgrade
Setting:
Live operational iron ore mine
Scope:
Structural, mechanical, piping and electrical works
Rio Tinto engaged BMR to deliver multiple structural, mechanical, piping and electrical (SMP) packages as part of a major upgrade to the Paraburdoo iron ore operation. The work had to be executed while the mine remained fully operational, requiring precise integration with ongoing production, strict safety protocols, and coordinated sequencing with other contractors. The project demanded meticulous planning to ensure SMP packages could be installed without impacting the broader EPCM upgrade schedule.
The main challenge was completing SMP work packages on time while the mine continued production. Any delays could disrupt commissioning milestones and result in significant financial losses. Restricted site access, tightly controlled shutdown windows, and the need to sequence mechanical, electrical and civil works created additional complexity. The project required risk mitigation strategies that would maintain continuous operations while ensuring high standards of quality and safety.
BMR adopted an early engagement approach, prefabricating modules and skids in its Perth workshop. Detailed 3D scans and shop drawings allowed precise fit-up and minimized welding requirements on site. Daily coordination with Rio Tinto operations and the EPCM team ensured interface risks were actively managed. SMP planning and HSEQ controls were tailored to the operational mine environment. Execution highlights included: • Site-specific SMP work planning and safety controls • Controlled shutdown sequencing for tie-ins and final alignments • Continuous onsite HSEQ supervision and stop-work authority where required
BMR delivered all SMP packages in line with commissioning windows, with zero unplanned disruption to production. Modular fabrication significantly reduced onsite exposure and complexity, while careful interface management minimized rework. This execution strengthened BMR’s relationship with Rio Tinto and led to further scopes at other regional sites.
The project protected critical commissioning milestones, reduced operational risk, and streamlined onsite coordination. By providing a single accountable SMP partner, BMR simplified communication and QA oversight, which ensured consistent, traceable outcomes.
