In 1996-7 Beca provided key members to the client's team that planned and executed the rebuild of the first of New Zealand Steel's two melters which had been in continuous use for 12 years. The highly successful project delivered a substantially improved facility on time and under budget.
By 2002 Melter #2 had been operating for 14 years and also required a rebuild to extend its operating life.
Meticulous planning and a 'right first time' approach were essential as some parts of the melter could only be accessed once every six months. Furthermore, production needs dictated a restricted period of melter downtime.
To meet the timeframe, Beca adopted a concurrent construction technique, with up to 120 people per shift working on five to seven different levels in and above the melter.
Again the project was delivered on time and within budget, with a big 'thumbs up' from the operators in response to the improved working environment (safety and operational security) designed into the rebuild. Production capability was increased from around 280,000 to more than 330, 000 tonnes per year, with the melter breaking production records on start up.