Rotary breaker & impact conveyer rebuild

Project Spotlight: Rotary Breaker and Conveyor Rebuild at Bathurst Mine

In November 2024, Kernohan Engineering successfully completed the full rebuild, strengthening, and recommissioning of critical material-handling infrastructure at Bathurst Mine—a major upgrade to the site’s rotary breaker and CV6 conveyor system.

This complex project involved mechanical, structural, and fabrication work, all delivered under tight operational timeframes and demanding site conditions.

Decommissioning and Structural Repair

The project began with the decommissioning and removal of the existing rotary breaker, along with inspection and repair of associated infrastructure. The hopper and structural steelwork, badly corroded and worn, required significant attention. Kernohan’s team rebuilt the hopper and strengthened the supporting framework, restoring stability and functionality.

Precision Rebuild and On-Site Fabrication

The rotary breaker was fully rebuilt, including the replacement of trunnion wheels with a combination of new and fabricated parts. Meanwhile, sections of the CV6 conveyor, which had collapsed due to rust and wear, were fabricated on-site and assembled to integrate seamlessly with the remaining conveyor system.

This real-time adaptability ensured minimal disruption to the surrounding plant and allowed the project to maintain momentum even with complex retrofit requirements.

Final Assembly and Flawless Start-Up

With the structure rebuilt, the team installed and aligned the trunnions, ensuring precise tracking before the newly rebuilt rotary breaker was craned into position. The final assembly involved installation of chains and carbon blocks, followed by system testing.

The result? A smooth, first-time start-up with no additional tracking or adjustments required—a testament to the accuracy and thoroughness of the rebuild process.

A Strong Outcome for a Demanding Site

This project showcases Kernohan Engineering’s ability to deliver full-scope mechanical solutions, even in high-demand industrial environments. From fabrication and precision alignment to recommissioning, the Bathurst Mine rotary breaker and conveyor rebuild stands as a great result for both site operations and long-term reliability.