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The overall objective of the West Cliff Coal Preparation Plant Raw Coal and Reliability Improvement Project (RC&RIP) is to replace thirty year old process elements and increase the reliability of the operating plant to meet operational demands. The project involved upgrading the existing plant through implementation of carefully planned additional structures and replacing dated process elements. This particular project involved all supply, fabrication and erection of all steelwork for the Westcliff Coal Preparation Plant to replace all the 1-47 Coal Distribution stackout conveyor trestle legs.

K&R Fabrications was the first contracting company in Australia to change a Blast Furnace Stave over the top of the bath of molten iron and coke in January 2014.  Working closely with Bluescope Steel on exchanging ideas to complete the job in the most timely but safest way possible. the scope. K&R prepared all of the new staves as well as developed and executed some of the crew training. The work was done over five one week shutdowns with eight staves changed in the first shutdown and 46 staves changed in the last. K&R Fabrication had a crew of up to 224 people on the project – whilst still crewing up for key customers outside the blast furnace project. During the August 2014 shutdown there were high winds and heavy horizontal driven rain. The normal method of using a large mobile crane to lift staves up and down could not be used. K&R successfully implemented BlueScope’s plan to use trolleys, monorails, a winch system and the personnel lift to get the staves up and down. Client representatives made the comment that they had never before seen people continue to work as our crews did in such poor weather conditions. K&R’s Furnace Top crew continued to work in the driving rain whilst soaked to the skin for their full 12 hour shift. The # 5 Blast Furnace Stave exchange project involved removing the worn out staves (water cooled copper blocks) from inside the hot furnace and replacing them with new ones above the bath of molten iron and coke. The job is unique in Australia and involves the staves being lowered in through the furnace top on winches and then being transferred to supporting wire ropes to allow them to swing close to their point of installation. The crews then use long gaffs poked through the furnace shell to capture small wire ropes attached to the staves. These ropes are pulled through the shell and allow the stave to be winched to position. Project unique characteristics include: High level concise radio communication was required as crews were in three different areas and couldn’t see each other but coordinated the lifting and positioning of the staves. Specialised training to achieve the gaffing, pushing and winching home of the staves. Extremely hot, humid and confined working space where the gaffing, gouging, bolting and welding activities take place. Subtle differences from one stave to the next which complicates the work. High quality welding is required because the 55mm thick shell of the furnace is a pressure vessel. K&R deve loped scale models for training and – together with BlueScope – set up a full scale t K&R developed several major initiatives during this project including developing scale models for training and – together with BlueScope – set up a full scale training plant which used two mobile cranes, a trial stave and a full sized segment of furnace shell. We were extremely fortunate to have a client who appreciated the significant gains from these initiatives and was happy to let us develop them. K&R assisted BlueScope with many technical changes and engineering improvements during the project. This included a strong collaborative effort to work out the best removal and installation sequences.

Omya is a global producer of calcium carbonate with 175 plants in over 50 countries. Omya Australasia operates 4 quarries and 5 mineral processing plants in Australia and New Zealand to extract, process and supply Calcium Carbonate to a wide range of applications and customers. The Moss Vale operation in the NSW Southern Highlands operates a range of mineral processing equipment to supply various construction and agriculture markets throughout NSW. The stockpile conveyor was previously used to unload raw material feed from rail operations. With the cessation of rail deliveries, and aging structure, K&R Fabrications project scope was to remove the Stockpile Conveyor from the Moss Vale Site and relocate to an unused location onsite for dismantle. The project took three weeks to complete, and involved prework, isolations, careful alignment of the Crane for removal and cleanup onsite.

K&R Fabrications was once again recognised as an industry leader at the Illawarra Regional Australian Industry Group Annual Dinner in both areas of safety and training. 2012 was the sixth year the Ai Group's Illawarra Industry Council has presented its Safety Recognition awards and K&R was a recipient for its safety performance. Companies were assessed on lag indicators, such as Lost Time and Medical Treated Injury Frequency Rates, as well as the ratio of incidents/near miss to reported injuries. Criteria also included a look at the organisation's safety systems, comprising factors such as responsibility for safety, employee engagement, hazard identification and incident investigation and management. K&R Fabrications’ high standard of training was acknowledged throughout the evening. Broden Condran, 4th year apprentice in Engineering Fabrication Trade was a finalist in the Appreciate of the Years. Broden successfully completed in the Illawarra Regional WorldSkills, and continued on to participate in the National WorldSkills, this along with his active involvement in the Surf Lifesaving Movement were also highlighted during the event. K&R Fabrications continued to be one of the only local companies to directly employee their own apprentices.

Nicole Fitzsimons was tragically taken in a motorbike accident whilst holidaying in Thailand, October 2012, with her partner Jamie Keith. The Nicole Fitzsimons Foundation has been established in her honour to continue Nicole’s legacy of helping others to fulfil their life aspirations. The Foundation is helping to raise travel safety awareness for Australians overseas and to assist passionate performing artists and sports people to achieve their full potential. K&R Fabrications has supported the Nicole Fitzsimons Foundation through the donation of a trophy for a Rugby League match between Wests Illawarra and Shellharbour Sharks in the Illawarra Coal League on 5th April at Parish Park. Jamie Keith , played for both teams previously which was why this match was selected. The Foundation sold merchandise and raffle tickets during the night, raising over $1,600. Jamie spoke about the tragedy and the Nicole Fitzsimons Foundation assisting young gifted and talented performing artists and sportspeople as well as travel safety awareness. Brett Morris and Trent Merrin drew the raffle prizes. Wests had a successful night winning all three grades: 1st Grade defeated Shellharbour 32-0, Reserve Grade won 36-12 and U 18′s won 30 – 6.

K&R Fabrications will continue to support the Bandage Bear Benefit Night on Saturday 22nd June 2013. K&R has been an inaugural supporter since 1999 and assisted in raising almost $3 million for The Disability Trust, The Children’s Hospital at Westmead, and the Southern Children’s Fund.

K&R Fabrications employee Guy Brooks has been selected as the Welding Technology Institute of Australia (WTIA) National Young Tradesperson of the Year Award winner for 2011. Guy went through a detailed two stage selection process that included writing a detailed essay and interview that highlighted his achievements. Guy's essay was based on his on the job experience in Welding High Grade Stainless Steel at the Oxygen Plant of Coregas, one of K&R clients. Guy's other achievement in 2011 was claiming a silver medal in welding at the 41st WorldSkills International Competition London, UK held from October 5 — 8 2011. Guy was presented with this award at the WTIA Annual Awards Dinner held Wednesday 9 May 2012 at Sydney Olympic Park during National Manufacturing Week, which was sponsored by Coregas Pty Ltd. Guy spoke in details of his experiences, challenges and support mechanisms he had in place during his challenges. As part of his award Guy will attend the International Institute of Welding Annual Assembly and International Conference in Denver, Colorado, USA 7 — 14 July 2012.

K&R Fabrications is proud to announce that they have received the inaugural Illawarra Coal Surface Supplier of the year. K&R received this award at the Illawarra Coal Recognition Evening held at the WIN Entertainment Centre on 24th June 2011. K&R has been being performing tasks for Illawarra Coal for over twenty five years, in particularly the West Cliff Coal Preparation Plant. K&R major role at the plant is on-site and preventive maintenance, and is regularly seen on site.

Illawarra Coal and K&R Fabrications will help local charity Kids Fund continue to support children with special needs with a joint donation of $2,000.The impetus for the donation came with K&R Fabrications being named as Illawarra Coal's Surface Supplier of the Year for 2011. As part of the annual award, Illawarra Coal provided K&R Fabrications with $1,000 to donate to a not-for-profit organisation of their choice. K&R Fabrications chose Kids Fund and decided to match Illawarra Coal's donation. Head of External Affairs John Brannon said K&R Fabrications was selected as Illawarra Coal's Surface Supplier of the Year in 2011 for its excellence in performance with the Company in areas including commitment to health and safety. "Illawarra Coal is proud that K&R's high performance in FY11 has also been able to reward and support a great local charity, and we impressed that they have decided to match the Illawarra Coal award funds," John said. "We hope that this donation will help the charity continue its instrumental role in providing support and services for local children with special needs and significant disabilities and their families." K&R Fabrications General Manager Mark Carberry said K&R has been working with Illawarra Coal for over 25 years and was delighted that the Company's employees' hard work in FY11 has been recognised. "K&R is extremely proud to be recognised by Illawarra Coal as Surface Supplier of the Year and are able to support a local charity as important as Kids Fund - K&R has seen firsthand the special work Kids Fund does and we are honoured to present this cheque to another Illawarra regional organisation," Mark said.Kids Fund is managed by The Disability Trust and aims to enhance the lives of children with special needs and significant disabilities in the Illawarra through the provision of essential aids and equipment to the ongoing health and wellbeing and quality of life of a child with special needs and their family.