Time and cost savings unlocked for our client via early contractor involvement and installation of piles through uncontrolled fill including 500mm diameter boulders, just a few of the key achievements from this project in remote PNG.

Photo from OK Tedi Mine PNG

The project

To facilitate the expansion of the OK Tedi copper mine, a replacement copper ore crusher was required in the mountainous terrain of the PNG Highlands. When completed it will be the biggest mining crusher erected in the Southern Hemisphere.

The challenge

The piles were designed to be installed through 10m of uncontrolled fill material, containing boulders up to 500mm diameter, in turn overlying soft sediments to 40m depth. Risks were identified with regards to removal of contaminated fill and the  reliability of concrete strength at depth using the bored pile method initially considered. 

The solution

Our early involvement with the project allowed us to confidently propose an alternative lower risk driven pile solution. With our experience in driving closed ended steel piles and the completion of a site visit, we agreed to install trial verifying the driven solution. Keller worked with the client to develop a design solution that met their construction program requirements and also trained local labour and tradespeople to further reduce costs, whilst maintaining high safety standards.

Project facts


OK Tedi Mining

Keller business unit(s)

Keller Australia

Main contractor(s)

OK Tedi Mining