Hydro engaged CMA Contracting (a Delta Group company) as the lead contractor for a staged decommissioning and deconstruction of the 2,000 hectare Kurri Kurri Aluminium Smelter in the Hunter Valley region of NSW.

The scope of works for Stage One included:

  • Site preparation, including amenities, materials hoist, gantries and full/partial height perimeter scaffold and hoardings.
  • Demolition of Potlines 1-3 superstructures to ground level, including aluminium risers and busbar removal works.
  • Asbestos and hazardous waste removal.
  • Transport logistics, including traffic management and supervision.
  • Emissions, noise and vibration controls.
  • Recycling of waste materials.

In completing the mechanical deconstruction of 2.2km of Potline buildings, we achieved:

  • 21,000 total man hours.
  • Compliance with Hydro HSEQ audits – six (out of ten) audits achieved 100% compliance.
  • Removal of all ferrous ‘add-on’ materials and fixtures to prepare anode busbars, including stockpiling and transport of the busbars and associated steelwork in designated laydown areas.
  • Thermal lancing to deconstruct and downsize aluminium busbar and risers.
  • Oxy cutting and manual de-dressing ferrous components from aluminium sections.
  • More than 4,000 crane lifts using a combination of overhead gantry and mobile cranes, with lifts ranging between 1-10t.
  • Processing and load out of 4,050 tonne of scrap steel using a 20t excavator.
  • Management and storage of 3,600 of tonnes of varying size aluminium sections.
  • More than 6,200km of forklift transport for recyclable scrap commodities (to lay down areas).
  • Recycling of more than 7,650t of mild steel and aluminium.