A reclaimed-water header for Minera Escondida's LS L2 concentrator: a 60-inch manifold (1,524 mm), its 30" discharge line and the 16" return lines to the launders, with all their special pieces.
CGK took on the project end to end: laser-scan field survey, modelling and review of the engineering drawings, full fabrication, quality control, testing and logistics all the way to site. All materials — API 5L X60 pipe and ASTM A694 F60 class 300 flanges — were imported to the project's original specifications.
The ducting was fabricated as spools (PE-100 to PE-311) with robot-assisted full-penetration welding and very little rework. Every pressure joint was certified with ultrasonic and radiographic testing, plus dye penetrant and magnetic particle testing where applicable.
The geometric challenge was solved with precision metrology: a cross-validated point cloud and alignment of the 60" header with its 30" outlets using a Laser Tracker, compensating deviations before installing the branches. The assembly was delivered two days ahead of commitment and with no lost-time accidents.
Laser Tracker
Verified to the millimetre, not by eye
Before fabricating, CGK scanned the existing ducting and connection points at the concentrator. That geometry was captured as a point cloud and cross-validated against surveys from three independent companies.
During assembly, the alignment of the 60" header with the 30" outlets was controlled with a Laser Tracker on continuous day/night shifts, compensating angular deviations before installing the branches so what was modelled fitted exactly on site.
- Laser scanner survey at the mine
- Point cloud validated by 3 companies
- Deviation analysis and compensation
60" component
Robot, certified welding and full traceability
The manifold was welded with robot-assisted full penetration — one of the technologies CGK brought in on this project alongside the magnetic crawler — achieving very low weld rework for these diameters.
Quality assurance was exhaustive: ultrasonic testing on 100% of the welded joints, radiography, dye penetrant and magnetic particle testing, under WPS/PQR/ITP procedures and third-party inspection. Every component was identified with a TAG, a QR code and a colour by area.
- Robotic full-penetration welding
- NDT: 100% UT · RT · PT / MT · quality dossier
- SSPC SP10 + epoxy system · QR traceability
Hydrostatic test
Five test circuits, five passes
Tightness was verified with large-scale hydrostatic tests: four planned circuits, transferring water between tests, which in practice added up to five tests on the 60" special pieces.
All of them came out successful. To run them, CGK purpose-built the test heads and flanges, under a test plan and procedure agreed with the client.
- Pieces PE-200 to PE-204 tested and released
- Test heads and flanges built at CGK
- Procedure validated with the client
Hydrostatic test setup · CGK hall
The manifold stood in its place before it existed
Before assembling anything, the model was taken into augmented reality with Trimble SiteVision and overlaid at 1:1 scale in the hall itself: the spools on their supports, with the blind covers fitted, exactly as they would be for the pressure test.
The same check was repeated on site, with the civil works already finished, to confirm the piece would land exactly on the existing concrete pedestals and walkway.
- Support heights and spacing between spools
- Working clearance under the overhead crane
- Fit against pedestals and walkway on site
Dispatch
From La Chimba to site, on purpose-built cradles
Every 60" spool travelled protected on transport cradles designed and built to measure (two per component, with rubber clamps), plus the frames for the 30" line.
Dispatch was coordinated with a BHP-accredited truck and oversize transport, with delivery-note traceability for every component on the route AFTA → Minera Escondida.
- 10 transport cradles + dedicated frames
- Accredited truck and drivers · 7×7 shift
- Dispatch control component by component
"The client saw what you normally don't get to see in a project — and singled out the engineering team for praise."
Closing meeting · Reclaimed Water Manifold project
Other projects
Large-diameter ducting and structures with the same demands on welding, metrology and traceability.
A large-diameter ducting project for your site?
We survey on site, model it, build it with robotic full-penetration welding, verify with a Laser Tracker, pressure-test it and take it to the mine. Start to finish.