Project Install Time: 44 Days
Location: Curragh Mine, Blackwater, QLD
Shelter Size: 1,897.95m²
Structure Type: Free Span Structure
Mining operations – the lifeline of productivity, in rugged terrains-are all about efficiency, durability, and adaptability. Accordingly, Coronado Global Resources, the foremost global producer of metallurgical coal, encountered a problem at the Curragh Mine site in Queensland’s Bowen Basin where it became increasingly difficult for existing workshop facilities to service modern dump trucks. The request was for an engineered shelter solution tailored to meet operational needs.
Allshelter provided an innovative Free Span Gable Shelter, designed to accommodate the latest Hitachi EH5000 dump trucks, integrate a gantry crane for streamlined maintenance, and withstand extreme environmental conditions. This case study explores how this tailored shelter solution improved Coronado Curragh’s servicing efficiency, ensuring smooth operations and enhanced productivity.
An Assessment of the Necessity of Any Upgrade
Operational since 1983, Curragh Mine is one of the premier coal mines in Australia. With an increase in the size of operations and the introduction of big heavy mining equipment, the health of the servicing infrastructure became questionable.
• Insufficient Space: The previous workshop struggled to accommodate larger dump trucks, particularly the Hitachi EH5000 models, which require substantial clearance for servicing.
• Inefficient Maintenance Setup: Without proper shelter and integrated crane systems, performing essential maintenance and replacing heavy components was time-consuming.
• Environmental Exposure: Open-air servicing left equipment and technicians vulnerable to extreme weather conditions, leading to potential downtime.
• Safety and Compliance: The site required a structure that adhered to strict engineering standards, ensuring both worker safety and operational efficiency.
To overcome these challenges, Coronado Curragh partnered with Allshelter to design a customised shelter solution tailored to their servicing requirements.
Allshelter’s Custom Shelter Solution
Understanding the specific needs of Coronado Curragh’s servicing operations, the Allshelter team developed a durable and efficient FreeSpan Gable Shelter. The key features of the solution included:
1. Large-Scale Shelter Dimensions
To provide ample space for servicing large dump trucks, the shelter was designed with the following dimensions:
Width: 25.7m
Length: 73.85m
Height: 23.835m
These dimensions ensured sufficient clearance for raised dump truck bodies, allowing maintenance teams to work efficiently.
2. Multiple Openings for Accessibility
The structure included:
Four openings on one side
One opening on the opposite side
Each opening measured 13m wide by 9m high
This design facilitated easy entry and exit, optimising workflow during servicing operations.
3. High-Quality Materials for Strength and Longevity
Given the demanding mining environment, Allshelter selected high-grade materials to ensure durability:
Structural Frame: Constructed with High-Grade Steel to withstand heavy loads and extreme conditions.
Fabric Cladding: Utilised Straatex® 9500FR High-Density Polyethylene Fire Retardant Fabric, offering superior UV protection, fire resistance, and durability.
4. Engineered for Harsh Conditions
To ensure structural integrity and compliance, the shelter was designed to meet:
Wind Region A Standards
Importance Level 2 Requirements
Terrain Category 2 Specifications
These features make the shelter resilient against high winds and environmental stresses, ensuring long-term reliability.
5. Integration of a Gantry Crane
One of the most significant upgrades was the inclusion of a gantry crane system, allowing:
Efficient removal and installation of heavy truck parts
Minimised downtime during maintenance
Improved worker safety and productivity
This features streamlined servicing operations, allowing technicians to handle large components with precision and ease.
The Impact: How the Custom Shelter Transformed Operations
Following the installation of the FreeSpan Gable Shelter, Coronado Curragh experienced immediate improvements in their servicing workflow and operational efficiency.
1. Reduced Maintenance Downtime
With better accessibility, larger working space, and the integrated gantry crane, maintenance tasks that previously took several hours were now completed faster and with greater efficiency.
2. Enhanced Safety and Worker Comfort
The covered environment provided by the shelter:
Protected workers from harsh weather conditions
Reduced exposure to dust, rain, and extreme temperatures
Improved overall workplace safety standards
This led to higher productivity and morale among the workforce.
3. Increased Equipment Lifespan
By sheltering dump trucks from direct sun exposure, rain, and dust, the structure helped prevent premature wear and corrosion, ultimately prolonging equipment lifespan.
4. Optimised Workflows and Future-Proofing
With the versatile shelter design, Coronado Curragh can now adapt to future servicing needs, ensuring the facility remains relevant and functional as equipment continues to evolve.
Why Coronado Curragh Chose Allshelter
Coronado’s decision to partner with Allshelter was based on several key factors:
1. Proven Track Record in Mining Shelters
With extensive experience in engineering custom shelters for the mining sector, Allshelter had a deep understanding of the industry’s challenges and requirements.
2. Diligent Tender Process and Industry Reputation
Allshelter’s approach to detailed tender documentation, site-specific engineering solutions, and high-quality materials set them apart as the preferred supplier.
3. Customisation and Engineering Expertise
Unlike one-size-fits-all solutions, Allshelter worked closely with Coronado Curragh to tailor every aspect of the shelter, ensuring an exact fit for their operational needs.
4. Durability and Compliance
The structure was built to last in extreme mining conditions, offering a long-term return on investment while meeting all safety and engineering standards.
The Bigger Picture: The Role of Shelters in Modern Mining
The Coronado Curragh project highlights the growing need for specialised shelters in mining and heavy industries. These structures play a crucial role in:
- Accelerating the Work-Life: Tailormade shelters optimise work processes thereby reducing downtime and exponentially increasing productivity.
- Asset Protection: Shelters shield machinery from weather-induced deterioration, thus increasing life expectancy.
- Improving Workplace Safety: Engineered to strict compliance standards, shelters create a safer work environment.
- Future-Proofing Operations: Modular, adaptable shelters ensure long-term usability as industry needs evolve.
For mining companies looking to improve their servicing infrastructure, investing in tailored shelter solutions can transform maintenance operations and contribute to sustained success.
Conclusion: A Smart Investment for Long-Term Gains
The collaboration between Coronado Curragh and Allshelter serves as a prime example of how custom-engineered shelter solutions can significantly improve mining operations. The Free Span Gable Shelter not only addressed immediate servicing challenges but also future-proofed the site’s infrastructure for continued efficiency.
With robust and high-performance shelter solutions defined by durability, cost-effectiveness, and scale, Allshelter is a true partner for custom fabric structure solutions for the mining and industrial sectors.
If you are thinking of getting some kind of custom shelter for your mining or industrial operation, reach out to Allshelter today to discuss solutions tailored for your specific requirements.
Key Takeaways
✅ Large-scale Free Span Gable Shelter improved efficiency in servicing Hitachi EH5000 dump trucks.
✅ Custom engineering ensured compliance with mining safety and durability standards.
✅ Gantry crane integration streamlined maintenance, reducing downtime.
✅ Improved worker safety and protection from extreme weather conditions.
✅ Future-proofed Coronado Curragh’s servicing facility for evolving operational needs.
