D. Hay & Co. Pty Ltd (HAYCO) Engineering & Fabrication Capabilities Examples
1. Sydney International Airport Upgrade
Manufacture of steel structures linking the airport terminals to the planes at the Sydney International Airport as part of the major upgrade prior to the Sydney Olympic Games.
Scope of work included supply of all steel and shop detailing from engineering drawings, fabrication, NDT (Non-Destructive Testing), part assembly, coating, delivery and installation on site.
2. Manufacture of Torch Cutting Machines for the continuous Slab Caster at BlueScope Steel.
Work consisted of supply of steel and proprietary items, fabrication to tight fabrication tolerances to maintain machine flatness, stress relieving, NDT, coating, installation of mechanical components, installation of pneumatic and hydraulic piping, fitting of components, installation of grease systems, testing and commissioning
3. Spares manufacture, storage and management.
Hayco currently manage spares for numerous departments within Bluescope Steel specifically for;
Slabmaking and Slab maintenance
Coke making and maintenance
Sinter plant and Raw materials departments
Plate mill
B.O.S. Steelmaking department
Hayco Manufactures and refurbishes a variety of operational critical components covering all facets of mechanical and structural engineering.
4. Hayco manufacture new and refurbish large Bogie frames for the B.O.S. steelmaking department at BlueScope Steel.
Refurbishments include part supply, stripping, assessment, repair and replacement of forged and heat treated wheels, shafts, casings, bearings, gears, reclamation and re-machining of bores, repair of damaged plate.
5. Hayco is a recognised RTA accredited fabricator.
Hayco is regularly called upon to manufacture items such as road expansion joints of differing designs including plate finger joints with anti slip welded surfaces and steel extrusion types allowing for insertion of rubber expansion profiles.
Other RTA work includes;
RTA road barriers
Security barriers and structures
Hand railings
Overpass safety screens
Steel formwork for civil works
Moulds for pre-cast noise barriers
Platforms and access ways
Also major works such as the manufacture of large steel girders for bridges and full railway truss bridges.
6. Hayco manufactured steel security structures for the Sydney Harbour Bridge that were installed by the site arm of the WGE group.
The structures were designed to prevent persons accessing the large steel post members of the bridge. The current security fencing was also fabricated by Hayco and installed along both sides of the entire length of the bridge.
Hayco were required to formulate a manufacturing schedule from surveyed existing hole dimensions and match all fencing components to fit on site.
7. Hayco fabricates to the most stringent of specifications.
Hayco has been responsible for the fabrication of structures for stringent, client and RTA procedures and specifications.
Work includes Large 40m long steel girders for bridge spans at Dunmore NSW, meeting all QA project requirements.
In 2011 work was completed on a 200 tonne truss railway bridge for the RTA. Again the most stringent of welding codes was applied to the project with Hayco successfully fulfilling all technical specifications and QA requirements.
Hayco have become proficient in the understanding and execution of works to welding standard AS1554.5 which is utilised for structures subject to fatigue loading.
8. Replacement Raw Materials Barrel Reclaimer - BlueScope Steel Raw Materials Department.
In 2012 Hayco will complete the manufacture of a 5m diameter 40m long barrel reclaimer for the raw materials department at BlueScope Steel. The reclaimer has also been fabricated and welded to the stringent AS1554.5 fatigue loading standard subjected to large amounts of ultrasonic and magnetic particle testing and full weld visual inspection to ensure optimum weld contour and quality.
Hayco will be responsible for the transportation of this component from our facility into the Blue Scope Steel Raw Materials Area. Hayco has established a reputation for the ability to successfully fabricate and transports extremely long, tall and wide loads in one whole single piece.
Hayco completed 12 major supply projects for the 300+ million Reline Project at the No. 5 Blast Furnace at BlueScope Steel in 2009. Major work includes the fabrication of three 60m stainless steel slag granulator stacks complete with helix wind vanes. The stack materials were completely cleaned of impurities prior to delivery using Avesta stainless steel cleaning chemicals and all welds passivated utilizing environmentally friendly electo-chemical passivating machines.
Other No.5 Blast Furnace reline work included the manufacture of three tap-hole drill machines. Work included weld procedure qualifications and welder qualifications, fabrication of heavy steel body components, submerged-arc welding, assistance with optimizing the final fabrication details, stress relieving, heavy machining, fabrication and fitting of pneumatic hard piping, painting, assembly of hydraulic motors, large slew bearings, hydraulic cylinders, hoses and drag chains, valves, manifolds. Complete assembly, testing and commissioning was carried out by Hayco.
Supply for the No. 5 BF reline also included the manufacture of three large trough cover manipulator platforms and manipulator undercarriages to facilitate the covering of the blast furnace troughs with heavy refractory lined covers.
Three water cooled tilting platforms were also manufactured along with general services pipework, varied structural components and platforms, complete overhaul of the blast furnace tap hole mud-guns, large offset ductwork to suit existing de-dusting ductwork, main trough steelwork, and heat shielding.
Other government works include:
Supply of large heavy steel bus shelters for Sydney – Liverpool to Parramatta transit way.
Hayco has also supplied in the past completed fabricated items for the Public Works department including large steel ballast pontoon structures.
Common fabrication works include:
All types of duct work and tanks utilizing varied plate materials. Hayco can execute any shape ducts from square to rounds, cylinders, square ducts, cones, complex geometries. Materials include mild steel, quench and tempered plate, hardfaced duaplate, stainless steel, boiler plate, WR350 weather resistant steel, aluminium.
Hayco manufacture and refurbish large pipe wall cooling hoods, skirts and components for the B.O.S. vessels at the steelmaking section of BlueScope Steel. The large hoods and skirts serve to cool off-gas from the steelmaking process and consist of pipe walls in the shape cylinders, square to round sections and square sections. Hoods and skirts incorporate intricate pipe flow channeling for optimum flows, header pipe work, heat shielding and refractory installation. Manufacturing processes include NDT, pressure testing, hardface cladding utilizing semi-automatic welding machines, painting with heat-resistant paint.
Ongoing work to maintain the pipework on-site includes supply of pre-fabricated pipe panels of specific sizes for site replacement of pipe sections with significantly thinned walls, manufacture of manhole doors, expansion sections, headers, inspection points, pressure explosion doors.
Hayco undertake varied types of pressure piping to various welding codes. Materials include carbon steel, stainless steel, copper to stainless. Hayco and the WGE Group were responsible for the manufacture of complete pipework and erection of the complete P.C.I. (pulverized coal injection) plant within BlueScope Steel.
Work carried out for materials transfer industries include manufacture and repair of all types of hoppers and bins, reclamation buckets, full bucket reclaimers utilizing Bradken wear plate and bucket teeth.
Other typical manufactured and refurbished works include:
Skids for mining equipment and electrical switch gear.
Other RTA work includes;
Heavy steel plate aprons.
Repair of drag chains and hose catenaries.
Manufacture of moulds for casting concrete and refractory.
Fabrication of heavy cast-in steel formwork with stud welding.
Skid pipes utilizing hardened metal spray coatings.
Repair of steel expansion joints.
Fabricated and machined gas manifolds.
Fabrication of various types of heat shielding.
Manufacture of housings for mechanical components.
Large diameter butterfly valves. Eg. Reclaiming and re-machining shaft bores, replacement of - shafts and blades, replacement of mechanical components, re-machining of flanges to ensure parallel, testing.
Impellor and fan overhauls.
Refurbishment and replacement / fitting of power transmission equipment including couplings, gears, chain, sprockets, bushes, gearboxes
Refurbishment of worm gearboxes, sprocket assemblies, vibrator assemblies.
All types of machine shop work for heavy and light industry – all types of shafts, pins, bushes, clamps, all machining work. Work involving milling, vertical and horizontal boring, turning, slotting, keying, drilling, tapping.
