LafargeHolcim supports Gorgon liquefied natural gas plant development in Australia

As global population growth intensifies, so does energy consumption. The Chevron-operated liquid natural gas (LNG) Gorgon plant project, one of the world’s largest natural gas projects located in Australia, was developed to meet rising energy needs in Asia-Pacific. Through concerted efforts in customer excellence, LafargeHolcim has played a key role in the construction by supplying ready-mix concrete and services.

 

The Chevron-operated Gorgon project is the single largest resource development in Australia’s history, with a AUD 43bn budget. Located on Barrow Island, a nature reserve around 60 kilometers off the coast of Western Australia, the project included the construction of a 15.6-million-tons-per-annum liquefied natural gas (LNG) plant and a domestic gas plant with capacity to provide 300 terajoules of gas per day to Western Australia. They started operations in 2015.

A Class A Nature Reserve, Barrow Island requires rigorous adherence to quarantine procedures. Besides, Australia is no stranger to extreme weather conditions. The northwest coast saw seven cyclones alone over the course of the project. Due to the high environmental risks of its location, Chevron required a solutions provider able to fulfil strict requirements.

LafargeHolcim answers: ready-mix concrete & aggregates solutions and top-level Health & Safety performance

Our Australian teams’ involvement began eight years before product supply, providing initial support that included budget information, concrete designs, and a geological review in 2005 to investigate the suitability of Barrow Island rock deposits for concrete production. LafargeHolcim proved itself up to the challenge with a successful 2009 tender that addressed the client’s key technical, environmental and safety requirements.

We overcame these challenges by leveraging our winning customer-oriented approach and delivering the following solutions:

  • Two on-site ready-mix concrete plants, including a mobile plant. We offered a purpose designed plant with associated ice plant for temperature control of concrete  and a fleet of trucks to ensure availability and continuity of supply
  • Supply of 400,000 m3 of ready-mix concrete over four years
  • Pre-wrap of all equipment in Perth to fulfill quarantine requirement for nature reserve
  • Emphasis on safety, quarantine compliance and reliability
  • Logistics optimization: Unwilling to risk delays due to bottlenecks at the Perth and Barrow Island ports, our teams from Australia worked with Chevron to establish a cement transfer station at Dampier to maintain timely delivery. The Gorgon concrete team also carefully balanced inventory stocks to ensure the customer’s need for uninterrupted supply was met.
  • Aggregates thorough technical review involving a number of trials of admixtures and other products so as to maximize aggregate use and performance, resulting in significant cost and time savings for the client.

The successful delivery of our tailored solutions led LafargeHolcim to being named a Chevron preferred supplier. Most important of all: our excellent safety record throughout the project. Since early 2012, the team reduced both total recordable injury frequency and lost time injury frequency rates to zero.

The Gorgon project is a striking example of how close attention to environmental, logistical, social and safety issues can all feed into customer excellence and successful project completion.