Newcastle Trough Replacement – Calderys at ArcelorMittal Newcastle
In a critical infrastructure upgrade at ArcelorMittal Newcastle, our team was engaged by Calderys to execute the full removal and replacement of the trough system. The goal: increase the reliability, safety, and cooling efficiency of the molten metal transport system within the plant.
This project represented a seamless collaboration between Calderys, a global leader in high-temperature solutions, and our field-execution team, recognized for our precision in industrial metalwork and high-performance installations.
Scope of Work
The project was completed in several stages, each involving close coordination and detailed execution:
- Removal of Old Trough
The aging trough system was carefully dismantled and removed, ensuring surrounding systems and structural elements remained intact. Removal required precision cutting, rigging, and safe disposal of heavy refractory and metal components. - Supply, Fabrication, and Installation of New Air-Cooled Trough
A custom air-cooled trough system was fabricated offsite, designed for enhanced durability and thermal management. Once completed, the new unit and associated runners were transported to the facility and installed on-site using Overhead crane assistance and a team of skilled riggers and welders. Air cooling channels were integrated to maximize operational lifespan and reduce thermal stress. - Installation of New Runners
In conjunction with the trough replacement, all runners were fabricated to match the updated system specs, ensuring smooth and efficient flow of molten material through the new infrastructure. - Pressure Testing
To ensure the integrity of the new air-cooled system, pressure testing was conducted. This included visual inspections leak detection under controlled conditions. The system passed all operational benchmarks and was cleared for full load capacity.
Challenges and Solutions
Space Constraints:
Working within a Reline Shutdown and co-ordinating with a lot of other contractors working in the same area. We worked hand in hand with other contractors and strict planning that allowed minimal disruption to ongoing operations while still meeting tight project deadlines.
Safety Protocols:
With hot works and heavy equipment operating side-by-side, safety was paramount. Daily toolbox talks, full PPE compliance, and continuous supervision were enforced to maintain a zero-incident record throughout the project.
Outcome
The completed installation resulted in:
- Increased reliability of the molten metal transport system
- Improved cooling efficiency and reduced thermal fatigue
- Streamlined maintenance and better access for inspections
- Zero safety incidents during execution
The Newcastle trough replacement stands as a successful example of targeted industrial intervention—where precise planning, expert fabrication, and trusted partnerships come together to deliver sustainable operational improvements.
