About
PYBAR Mining Services is a leading Australian underground mining contractor. They engaged our services when one of their rigs, critical to their mining operations, was brought to a grinding halt.
Challenge
Two guide column assemblies, the main supports used for drilling and boring operations in interconnecting tunnels, were severely damaged due to prolonged use in harsh conditions.
The support foot on each column had sheared off under excessive torque, rendering the rig unusable and costing PYBAR valuable production time.
Due to the operational downtime and financial impact, the primary challenge was to meet a fast turnaround time while maintaining a high standard.
Both columns as received
Our Solution: A Multifaceted Approach to Rapid Repair
Understanding the urgency of the situation, our team devised a comprehensive repair strategy that balanced speed with precision.
The overall objectives of this project were clear: re-manufacture the new support feet, prepare and machine the old shafts, weld the new feet to each shaft and finish-machine to its original specifications.
Our process involved several key steps:
- Sourcing High-Quality Materials: We quickly identified and procured high tensile steel forgings for the new feet.
- Precision Machining: The repair process began with rough machining of the new feet and preparation of the old shafts.
- Expert Welding: Our experienced welders carefully attached the new feet to the shafts, ensuring structural integrity.
- Quality Assurance: We engaged a third-party specialist to conduct ultrasonic testing of the welds, guaranteeing weld integrity and safety.
- Finish Machining: The repaired columns underwent finish turning in our facility.
- Collaborative Finishing: For the final milling of features requiring larger machinery, we partnered with a trusted partner, showcasing our commitment to delivering the best possible result.
Throughout the process, we maintained clear communication with PYBAR, providing regular updates on our progress and adhering strictly to the promised timeline.
Undergoing significant repairs at the A1 Metallising Services workshop
Results: Continuing Operations
We delivered the repaired guide column assemblies to PYBAR Mining within the agreed-upon timeline. Upon installation at the Carrapateena Mine, PYBAR reported that the columns fit perfectly, allowing them to resume operations without any additional adjustments or delays.
As a result, this successful repair not only minimised PYBAR’s downtime but also demonstrated our ability to handle complex, time-critical projects with precision and reliability.
The restored guide columns now continue to play their crucial role in PYBAR’s raise boring operations, supporting safe and efficient tunnel interconnection work.
Contact us today and discover how we can support your operations with our expert repair and remanufacturing services. Let’s work together to keep your machinery running at peak performance, with the wheels of industry turning, no matter the challenge.
Guided Columns repaired and ready for shipment
“A1 Metallising’s flexibility and commitment to supporting us has been outstanding. Our projects are expertly managed, ensuring every detail is considered, including our tight timelines. Their dedication to quality work and our needs ensured the project’s success”
Steve Wood, Maitenance Foreman, Pybar Mining
