ABC Heavy Engineering provides heavy fabrication, machining, and engineering services from its facility in Mackay, Queensland. It has extensive equipment and capabilities for repairing and manufacturing large mining components. The company aims to assist clients in optimizing asset lifecycles through its reclamation and rebuild services.

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CAPABILITY STATEMENT
Corporate Office
35 Commercial Avenue
Paget Mackay QLD 4740
T : 07 4952 3444 F : 07 4952 3746
E : admin@abcheavyeng.com.au
ABN 15 139 918 013
Australian Bearings Corporation Pty Ltd T/as

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In this regard ABC Heavy Engineering has developed a Workplace Health and Safety Management Plan which details
the following:
“Safety is
Our Priority”
“Safety is
Our Priority”
Health, Safety, Environmental and Community Management Standards
ABC Heavy Engineering takes responsibility for the well being of its employees, the environment and the local
community, very seriously. It has in place policies and procedures that ensure we are taking all the necessary steps in
providing safe and environmentally conscious worksites.
Polices and Procedures
Roles, Responsibilities and Accountability
Risk Assessments
Training and Development
Inductions
Incident Reporting and Investigations
WHS Regulations
Hazardous Substances
Plant and Equipment
Noise Surveys
Electrical Plant and Equipment
Manual Handling
Emergency Planning
First Aid

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The essence of our philosophy is to provide our customers with comprehensive and integrated engineering capabilities
that add significant value well beyond the repair and or manufacturing process, to reduce the total cost of ownership.
ABC Heavy Engineering assist major players in the mining and allied industries, in finding solutions as they work to
maximize the overall life of their assets. ABC Heavy Engineering continues to provide technologies that offer high
Accordingly, the business model is based on "Reclamation & Rebuild Lifecycle Engineering”. ABC’s strategy is to
proactively assist clients in optimizing asset lifecycle management to attain the greatest possible return on their assets. In
the past, Australian Bearings Corporation’s operations were largely confined to repairing the part. Now, ABC Heavy
Engineering assists it’s clients in all aspects of the lifecycle of the part and/or assembly - from planning through design,
manufacture, operation, maintenance and monitoring systems (life-cycle), to disposal.
“Safety is
Our Priority”
Our Approach

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valueadd while assisting clients to extend the life cycle of their assets. Through adhering to strict quality standards, ABC
Heavy Engineering are continuously improving their internal structures to further develop the processes necessary to
support their objectives.

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weighing up to 150 Tonne.
Induction Hardening and Heat Treatment Section,
Slew Bearing Section.
General / Heavy Engineering Section.
10,000sqm of concrete paved lay down area.
Understanding the needs of our clients, prompted the construction of an additional purpose built heavy fabrication and
repair factory building. This facility is an impressive 90m long x 30m wide x 16m high and is located at the Paget
property. The new building is attached to 6,000 sqm main workshop building and offers the following additional
features.
2 bucket arch pits installed in the floor, 18 meters long 2.5 meters deep and 2.5 meters wide.
100t and 50t overhead cranes with 12m under hook clearance, capable of dual lifting up to 150 Tonne and is
particularly suitable for large heavy structural fabrication as well as heavy equipment repair, dragline bucket and
truck body manufacture and repair.
“Safety is
Our Priority”
“Safety is
Facilities
ABC Heavy Engineering is located in Mackay at 35 Commercial Avenue, Paget on a four hectare heavy industrial
site. The factory offers 10 000 square metres of workshop floor capacity comprising the following departments:
Machine Shop with medium to large CNC machines capable of handling work up to 9 meters in diameter and

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3 x Large Sheave Rotators (capacity = 5m diameter) Using sub-arc welding process
2x Small sheave Rotators (capacity = 3m diameter) Using sub-arc welding process.
2 x Purpose built shaft rotators – Using open-arc welding process.
Various rollers which may be assembled to suit job (using sub-arc welding process if required)
Computer controlled gas fired oven – Capacity 6.5 x 5.5mtrs, height 2.7mtrs) for stress relieving up to 800 degree Celsius.
Induction Hardening Machinery – various units, being 200,300 & 400 kw (using frequencies of between 3 & 10 kh) used to Induction
Harden Sheaves, Drums, Gear teeth, Shafts, Slew Bearings and other items up to 60hrc at depths ranging from 3-15mm. Complete
Insitu dragline rope drum rebuilds including weld reclamation, CNC machining and hardening are now available.
600 tonne Hydraulic Press.
1 x 100T Overhead Crane, 1 x 50 T Overhead Crane (Northern Bay) 12mtrs under hook
1 x 50 tonne crane, 1 x 20 tonne crane and 1 x12.5tonne (East Bay) crane 7mtrs under hook
1 x 50 tonne crane, 1 x 12.5tonne crane and 1 x 5 tonne crane (West Bay) 7mtrs under hook
“Safety is
Our Priority”
“Safety is
Our Priority”
Specialised Equipment (machine / cranes etc)
Froriep CNC Floor Borer – 10 mtr travel, Height 4.5mtrs, Bed capacity = weight 200 tonne. For turning Operations Capacity = 9 mtrs and
weight capacity = 50 tonne.
Berthiez CNC Vertical Borer – Capacity = 4m diameter, Table Weight = 18 tonne.
Webster & Bennett CNC Vertical Borer (Twin Head) – Capacity = 3.5m diameter, Table capacity = 18 tonne.
2 x Purpose Built Drum Rotators (Incorporating heating components) using sub-arc welding process with multiple heads.

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Operating
Hours.
The Commercial Avenue,
Paget
requirements, anytime.
Additional
Equipment Workshop
This new facility at the Paget workshop
is ideal for large Buckets and Dippers
and other heavy fabrication. The building
has two large arch pits and is serviced
by 100 tonne and 50 tonne capacity
overhead cranes.
Facility Details:
Building Height 16m
Overhead Crane Headroom 12m
Covered Floor Area 3000m2
Craneage 100 Ton
Arch pits 2
Entry Width Up to 10 meters

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0
workshop
has
coverage
24hr, 7
days a
week,
365 days
a year,
which
means
that we
can cater
for urgent
customer
Total factory size is now 10,000sqm

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1
Quality Technical Support
“Safety is
Our Priority”
“Safety is
Our Priority”
ABC Heavy Engineering is committed to obtaining ISO9001 in the near future, and long term AS/NZS4801 and ISO14001. We have a
Management system in place that has procedures and policies that we adhere to for all of our processes. The Management syste m is built
on the foundations of International and Australian Standards. Two consulting/auditing firms have been engaged over the past twelve months
to help prepare our system for accreditation. As part of our organisational structure, ABC Heavy Engineering has a Quality Coordinator who is
responsible for maintaining the system.
ABC Heavy Engineering also recognises the importance of gaining ISO 3834:2005 Quality requirements for fusion welding of metallic materi-
als accreditation. We have appointed a welding supervisor who is under going the Welding Specialist training conducted by the Welding Insti-
tute of Australia. WTIA have audited our system and we will continuing down the path of accreditation.
We also conduct Individual performance reviews for each employee with Quality as one of the key elements.
The ABC team is comprised of Supervisors and Team members that have decades of experience on Dragline components
repairs. Their knowledge and understanding is unparalleled in the Bowen Basin. We have Product and Application Specialists
that are constantly supporting our clients by visiting mine sites to provide expert technical advice and recommendations.
We have comprehensive engineering support for our workshops. They have at their disposal, a network of companies and
affiliations such as BMT WBM & WTIA, so we can continue to provide our clients with updated information on materials,
consumables and processes.
“Safety is
Our Priority”“Safety is
Our Priority”

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2
Mechanical Engineering & Project Management
AutoCAD design and drafting
Computer software including Microsoft Project
Project management and quotation, including fabrication
Certification of lifting equipment
Certification of equipment in accordance with Main Roads specifications
Site inspections, reporting and work scope preparation
Site maintenance, shutdown and emergency breakdown
Mechanical and structural engineering design
Project and maintenance management, inspections and audits
Multi-disciplinary work packages
Engineering Drawing.
“Safety is
Our Priority”
“Safety is
Our Priority”

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3
Services

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Engineering Design & Certification
ABC Heavy Engineering utilise 3D modelling software (Solidworks) to provide conceptual and workshop
drawings for new and reverse engineered products that comply with AS1100 - 1992. With this software we can
provide customers with CAD models in 3D accompanied with general arrangement drawings. The software also
allows our qualified engineers to use Finite Element Analysis (FEA).
Structural analysis using FEA is extremely beneficial to design and reverse engineered components. Designed products are optimized to
ensure the most efficient materials are used. Reverse engineered products are assessed to identify areas that can be improved through
design changes. Existing components are checked and modified to remove stress concentrations.
“Safety is
Our Priority”
“Safety is
Our Priority”

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“Safety is
Our Priority”

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ABC Heavy Engineering Site
Services

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Design
Construction
Fixed Plant Maintenance
Mobile Plant Maintenance
Maintenance Planning
Draglines
Electrical
Labour Hire
Equipment Hire
ABC’s Heavy Engineering Site Division encompasses a wide range of services including breakdown, shutdown and contract maintenance.

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We pride ourselves on providing a safety conscious, timely and efficient service to our clients at all times. ABC Heavy Engineering Site Services
offers the best project management skills available and can provide planning and maintenance strategies to optimise the production
performance and maintenance costs of any operation.
ABC Heavy Engineering— Site Services Division Include –
Draglines – Breakdowns, Shutdowns, Maintenance.
Shovels / Excavators - Breakdowns, Shutdowns, Maintenance.
Coal Processing Plant - Shutdown, Breakdown, Relief operators.
Blast Hole Drill Rigs - Breakdowns, Shutdowns, Maintenance
Construction – Site Construction Teams on various
projects.
Shipping - On and Off Shore Repairs.
Sugar Mills - Shutdowns, Breakdowns.
Power Stations - Relief Operators, Breakdowns,
Outage Shutdowns.
Electrical, Mechanical and Construction
Boom repairs to Marion 8750Dragline and Shovel
Site Maintenance

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Below are details of some of ABC’s Heavy Engineering Site Division’s recent projects.
Coppabella Mine – Monthly Maintenance down days, breakdowns and mini shutdowns, on dragline and
shovel for the last 5 years, LTI free.
BMA Peak Downs – Principal contractor for 6 week ROM shutdown, including mechanical, structural and
electrical.
BMA Saraji – Shovel Load Roller change out, including all jacking.
BMA Saraji – All mini shutdowns on Draglines and shovels for
past 3 years, LTI Free
BMA Saraji – supply labour, supervision & equipment for
CHPP down days and breakdowns.
Bulga Coal – In Situ rebuild of Hoist and Drag Drum
Isaac Plains – Monthly Maintenance down days, breakdowns
and mini shutdowns, on dragline. In Situ Drum Rebuild in DraglineShovel Load Roller change out
Site Maintenance

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Site Maintenance
.
Marion 8050 Boom Lowering for Suspension Rope and Equalizer change
out
Jacked P&H 4100 Shovel for Load Roller change out and tumbler repair

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Site Maintenance - Equipment
ABC Heavy Engineering can provide the following equipment as part of any project,
or on a stand alone hire basis.
2 Fully equipped welding trucks, each including 2 diesel welders
Fully equipped welding trailers2
Fully equipped tooling containers, including all required tooling &3
consumable items.
Crib room, generators, fuel trailers, lighting towers
ft Boom lift80
Low profile, 45t Forklift
All equipment is fully mine site compliant
“Safety is
Our Priority”
“Safety is
Our Priority”

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Transport Capabilities
3 by 20ft Tilt-trays
Prime Mover
Float
Trailers
“Safety is
Our Priority”
“Safety is
Our Priority”

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ABC Heavy Engineering can provide your transport requirements for moving items and equipment to and from site. Our fleet includes the
following items:

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Machining of Boom Point Swivel
Dragline Swing Housing Refurbishing
Conveyor Pulley Fabrication & Machining
Sub Arc Weld build up of Marion 8050 Rope Drum
Manufacturing
&
Reclamation

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Over the past 28 years, the company, through its ingenuity and commitment to research and development programs, has developed into a major supplier of a wide range
of services to the Mining, Sugar and Agricultural Industries, as well as the Civil Sector and Sea Ports both in Australia and overseas.
P&H 9020 Revolving Frame under construction Manufactured Slew Deck
Fabrication and General Engineering Workshops

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Our services include, but are not limited to, Slew Bearing Refurbishment and manufacturing, Induction Hardening, Gear Cutting, Large CNC Machining Capacity, sub-arc
welding, stress relieving, haul out and transport equipment, hydraulic cylinders and associated equipment, manufacture of drill rig ground engaging components, overhaul
of underground and open cut mining heavy earth moving equipment and all facets of light and heavy machining and fabrication.

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Overhauls and Repairs
Track Set Refurbishment
Structural Repairs to Heavy Earth Moving Equipment
Gearboxes
Crusher/Sizer overhauls
Dragline Buckets, Dippers, Shovel Buckets
Scheduled Maintenance Programs
Newly Manufactured Slew Bearing
Full overhaul of large gearboxes
Coal Crusher Rollers manufactured & overhauled

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ABC Heavy Engineering is committed to providing value for money service. Our facilities have the capability and space to store
large quantities of components. Over recent times, ABC have been increasing our stocks of dragline componentry. We have a
large range of dragline drums, sheaves, walking gear, and excavator slew bearings. We have both new and refurbished items,
available for outright sale or on a service exchange basis.
Refurbished 1370 Deflection Sheaves
New 1370 Walking Cam
New 1370 Walking Frames
“Safety is
Our Priority”
Dragline Component Stocks.
“Safety is
Our Priority”

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Health, Safety, Environmental and Community Management Standards
“Safety is
Our Priority”
“Safety is
Our Priority”
Daily Safe Start meetings
Weekly Toolbox meeting
Monthly Safety Committee meetings
Measuring of LTI’s and MTI’s
JHA
SLAM
Planed Task Observation
Transparent reporting of any incident in accordance with the ABC Safety Management Plans reporting policy and
complying with requirements of the client to notify the appropriate people in a timely manner, ensuring our client is
well informed with regards to the rehabilitation of the injured worker, until return to work unrestricted has been
achieved.

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To ensure we have Safety as a Priority, the following activities are undertaken by the workforce:

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“Safety is
Our Priority”
Dragline Sheaves

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“Safety is
Our Priority”
Dragline Rope Drums

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“Safety is
Our Priority”
Bogie wheel assembly

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“Safety is
Our Priority”
Conveyor Pulley

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“Safety is
Our Priority”
Thickener Drive

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“Safety is
Our Priority”
Gear Case
Capabilities:
Build
Strip
QA
Overhaul
Bore Reclamation & re-
alignment

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“Safety is
Our Priority”
Braking Unit

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“Safety is
Our Priority”
Belt Reeler

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“Safety is
Our Priority”
Shaker Screen

42. DIRECTOR DIRECTOR
Phone: + 61 7 49523444 Fax: + 61 7 49523746 Rick SmithMob: 0419 646 979 Paul
SmithMob: 0418 712 826

43. Email: admin@abcheavyeng.com.au
PRODUCTION MANAGER
Mike Geisler
Mob: 0447 760 309
ENGINEERING CO ORDINATOR
Steven Boyce
Mob: 0418 725 120
SENIOR SITE CO ORDINATOR
Liam Flynn
Mob: 0417 770 445
Web Address:
uwww.abcheavyeng.com.a
Postal Address:
PO Box 5988
MMC Mackay
Queensland 4741
Managing Director
Maurie Smith
Mob: 0419939300
Corporate Office & Main Workshop:
35 Commercial Avenue
Paget, Mackay QLD 4740