The TATA BlueScope Steel (TBSL) Downstream project got under way in 2003 with the initiation of the DPR and Pre-feasibility Study by BlueScope Steel (BSL). Hatch was retained in early 2004 to lead the project development phase and to assist with the Feasibility Report prepared by BSL. Mott MacDonald was engaged to prepare the Front End Engineering & Design Report. Currie & Brown was engaged as quantity surveyors to audit the project estimate and prepare specifications.
The year saw a number of shifts in the market focus by BSL culminating in several key outcomes:
- Butler Manufacturing USA was purchased by BSL and frame fabrication was included in its Indian market offer.
- A JV relationship with TATA Steel was established by BSL and the market offer extended to include a Midstream facility coating line (outside the Hatch scope).
In December 2004, the BSL project team was given Board approval to deliver three Downstream facilities for INR 292 crore (AUD 84.5 million) within 30 months. Thereafter, Hatch was engaged under a performance contract as the Project Lead.
The first factory, Pune, was completed in May 2006; Bhiwadi (Delhi) in October 2006; and Chennai in December 2006
BlueScope Steel Vietnam (BSV) engaged Hatch to become a member of an integrated project and construction management team to implement the Coating Project. The scope of work included preliminary engineering for early works, concept engineering and electrical design, engineering management of design work by others and review of drawings provided by the contractors, all procurement activities, cost and schedule control, site and construction management, cold commissioning and supply of engineers for hot commissioning of the facility.
While the project mainly employed conventional or proven technologies, the in-line painting section of the MCL had not yet been commercially proven in a BlueScope plant, and was under evaluation in Thailand. The new technology was commissioned successfully.
- This Project represents an excellent example of Hatch’s ability to develop greenfield sites in developing countries.
- Project staff were methodical in their approach and undertook commissioning progressively, which produced these excellent results.
- The Pune factory was the first industrial facility in India to be accredited with the India Green Certification - subsequently all facilities have also received accreditation.
- The Project was completed on budget.
- The Project was successfully completed six months ahead of schedule.
- Kirby Adams, then CEO of BlueScope Steel, Melbourne, Australia stated that the Pune facility “…is one of the most impressive facilities in the BlueScope network.”
- Project awarded 2006 ‘Well Equipped & Mechanised Project Award’ by Builders Association of India in their Well Built Structure Competition.
- Project awarded 2006 ‘Best of Best Structure Award’ by Builders Association of India in their Well Built Structure Competition.
- The project was also a recipient of the BlueScope Steel Outstanding New Business Award 2006.
Hatch’s single full-time representative and several part-time specialists successfully transferred their project controls, procurement, design management, project management, commissioning and safety skills to the Indian project team and led them through more than 4,000,000 workhours with no loss time injuries or fatalities.
