Future-Facing Minerals

Carrapateena Mine Underground Crusher 1.0

Client

BHP (formerly OZ Minerals)

Duration

May 2019 - Apr 2020

Location

Pernatty , South Australia, Australia

Value

$17 million

PHE Group’s inaugural underground crusher delivery at Carrapateena set the pace – completing a technically complex install five weeks ahead of schedule through deep collaboration, decisive management, and a strong safety culture.

As the first underground infrastructure package, the project enabled 4.3Mtpa ore throughput via a 3 kilometre inclined conveying system to surface, significantly reducing reliance on traditional haulage methods.

Delivered within a live mine environment, the works were staged through confined tunnels and ventilation-reliant spaces with active haulage and fixed plant operations nearby. Tight access, limited laydown, and concurrent contractor activity demanded rigorous interface control, adaptive scheduling, and round-the-clock coordination. PHE was engaged to deliver the full electrical and instrumentation package, drawing on deep site familiarity and a proven record of performance in high-risk environments.

Project scope

Electrical and instrumentation (E&I) works delivered across the primary crusher, ore handling conveyors, and associated infrastructure.
Commissioning of 11kV distribution system, dewatering infrastructure, and primary ventilation systems.
Integration of all E&I works with civil and SMP teams through a collaborative delivery model.
Installation of high voltage, low voltage, communication, and instrumentation cabling underground and to surface.
Construction of a temporary 24-bed self-sufficient camp to address on-site accommodation constraints.

Innovations and solutions

Early Contractor Involvement (ECI) allowed for cost forecasting, FAT testing, and smoother site mobilisation.
A bespoke cable reeler was designed and fabricated to enable safe HV cable installation in confined underground spaces.
LED strip lighting was used to reduce power demand and accelerate temporary lighting installation.
Battery-powered tooling was deployed site-wide – reducing reliance on 240V equipment and significantly lowering electrical risk in wet conditions.
A temporary camp was designed, mobilised, and commissioned within one week to prevent schedule delays.
Underground HV/Earth cable installation in boreholes was backed by engineered calculations and hold-point methodology.

Outcomes and benefits

Delivered five weeks ahead of schedule and under budget, protecting operational timelines and unlocking early production gains.
QA admin time reduced by 25% using the PIMS system which improved traceability and streamlining energisation processes.
Zero lost-time injuries recorded across approximately 150,000 hours worked, reflecting a deeply embedded safety culture.
Strengthened PHE Group’s relationship with BHP, directly contributing to the award of the Crusher 2.0 contract.
First ore achieved two months early – despite bushfire-related delays – through disciplined planning and site coordination.
Scope growth of more than 32,000 hours absorbed without delaying commissioning, demonstrating agility under pressure.
HV terminations provided high-value training and certification opportunities for internal personnel, building capability and retention.
This first major milestone laid the foundation for long-term productivity at one of Australia’s most important copper-gold assets – a critical contributor to BHP’s future-facing investment in clean energy supply chains.

Accelerated ore production

2 months

Extra hours managed on program

32K+

Injury-free hours worked

150K+

Project Images