Sometimes the impossible can be done, a case study of the rail rectification works WICET

A150Rail rectification works at WICET (Wiggins Island Coal export terminal) delivered by GMG.

Case Study

A150Rail rectification works at WICET (Wiggins Island Coal export terminal) delivered by GMG.

Problem

GMG were approached by representatives of WICET with a problem, the 1000meter long A150 Rail sections, their newly built and commissioned Gantry Coal Stacker runs along, was cracking. As the whole WICET site was now operational and the loading of ships could not be interrupted, they were looking for a cost effective, light weight (easily mobilised and demobilised) solution to cut and secure the smaller cut sections in place to eliminate this problem.

All other suppliers considered had only offered highly expensive solutions involving major shutdown works with further costs and losses to WICET through the interruption of export ship loading.

Solution

The team at GMG had a quick round table and 2 custom built concept machines were pro-posed and support from WICET grew. GMG had a low cost, highly mobile solution that could not only deliver the rail cutting and machining relatively affordably but would impose no interruption to export and cash flow to WICET.

Rail Milling Machine
Rail Milling Machine
Rail cutting saw
Rail cutting saw

After some further consultation with engineering and the production team GMG were issued with a purchase order to build the first set of machines.

2 weeks later the machines were built and machine testing and trails were demonstrated at the GMG CQ facility to WICET representatives.

The machines that were built by GMG, were a rail cutting saw that could consistently deliver 45 degree cuts across A150 rail section at the designated positions, safely and efficiently. And a milling machine that could machine rebates in the foot of the rail to accept rail restraint blocks, all had to be able to be moved safely by 2 men inside 15 min notice as required by export activities.

Outcome

With satisfactory results demonstrated GMG was issued a supply contract through John Holland Group to roll out the rectification works.

A small team of 4 men, was deployed working online with production, and results were good but somewhat slow to start with. with further fine tuning over the next week or 2 productivity was significantly increased, WICET representatives after only a month or so were interested in a second set of machines to double the rate at which these works were completed, again within 2 weeks GMG were mobilised at site with a second set of equipment with all the lessons learned applied.

Overall a project that was expected to take 12 months was completed in only 4 with zero safety, environmental or site breaches or incidents.

WICET representatives were extremely satisfied with the results, timely and efficient delivery of full scope of work and well under budget forecasts.

Rail after Milling sequence
Rail after Milling sequence
Second Rail Milling Machine
Second Rail Milling Machine