Background

The Tailings Storage Facility 6 (TSF 6) project at BHP’s Olympic Dam in South Australia required the manufacture and delivery of over 13 kilometres of HDPE pipe and approximately$1.8 million worth of fittings and assemblies. The project posed unique engineering challenges, including the design and production of large 5D radius sweep bends, eccentric reducing tees, and custom HDPE pipe supports for a new tailings storage facility. With tight timelines and strict technical requirements, DAMOS was awarded the contract in late 2021, solidifying its reputation as a trusted partner for large-scale infrastructure projects.

The Details 

DAMOS applied its advanced manufacturing capabilities and technical expertise to meet the project’s ambitious demands:

HDPE Pipe Production

• Manufactured 7,500 metres of DN400 SDR13.6 and 5,200 metres of DN315 SDR11 pipe within just 23 days.
• Delivered two double trailers of pipe daily for 35 consecutive days to meet delivery timelines.

Custom Fittings and Assemblies

• Produced 250 eccentric reducing tees (450x90mm) measuring over 5 metres in length, all hydrotested to ensure compliance with operational standards.
• Fabricated 250 launder spigot assemblies, 12 metres long, with precise drill patterns and welded elbows, stubs, and rings.

Innovative Solutions

• Developed a new HDPE pipe support system to elevate eccentric reducing tees, protecting valve and spigot assemblies.
• Established a new production area for DN450 SDR13.6 5D radius sweep bends, manufacturing over 75 bends within 16 weeks—a first for Australia

Component Sourcing

• Airfreighted 250 double-union PP ball valves from Switzerland within three weeks, ensuring timely delivery and project alignment.

Testing and Quality Assurance


• DAMOS erected an in-house hydrotesting station within its Neerabup fabrication facility to test all fabricated eccentric tees. This minimised freight movements and ensured all components met stringent quality standards.

Logistics Coordination


• Over 100 extendable trailers transported the pipes and fittings across the Nullarbor from Neerabup, WA, to Roxby Downs, SA, overcoming the logistical challenges of delivering to a remote location.    

Key Highlights

DAMOS achieved exceptional results through its commitment to innovation, precision, and operational excellence.

• ‍Hydrotesting Expertise: Successfully hydrotested all eccentric reducing tees in-house, ensuring reliability and compliance.‍
• First-in-AustraliaManufacturing: Produced DN450 SDR13.6 5D radius sweep bends locally, setting a new benchmark in HDPE manufacturing.‍
• Custom Engineering: Designed and implemented a unique HDPE pipe support system to enhance durability and performance.‍
• Efficient Sourcing and Delivery: Coordinated rapid sourcing and delivery of critical components, including PP ball valves, to meet project deadlines.

Outcome

The TSF 6 project was fully delivered within four months of receiving thepurchase order, including additional variations requested by BHP. DAMOS successfully overcame significant engineering and logistical challenges, delivering a comprehensive package of high-quality pipes, fittings, and assemblies. This project underscored DAMOS’ ability to execute complex,large-scale infrastructure projects with precision and innovation. By adhering to the highest standards of quality and performance, DAMOS reinforced its position as a leader in HDPE manufacturing and infrastructure solutions.