Pilgangoora Processing Facility P1000 Expansion

Location

Marble Bar, WA

Value

$(10 – 20)M

Client

Pilbara Minerals

Completion Year

2025 (ongoing)
Project Overview

Westforce was engaged by Pilbara Minerals to deliver the Bulk Earthworks package for the P1000 Expansion Project at the Pilgangoora Processing Facility. Following the successful start of works, our team was awarded additional scopes covering brownfields concrete, ROM backfill and gas infrastructure, reflecting client confidence in our on-ground delivery.

The P1000 Expansion is a strategic upgrade that will boost Pilbara Minerals’ lithium spodumene concentrate production capacity by 47 percent, taking the nameplate output to one million tonnes per year. Westforce is supporting this uplift by preparing key areas for structural and process infrastructure, while managing services and road access across a busy and expanding operational site.

Our work spans both greenfield and brownfield zones, with careful coordination across active plant interfaces. From producing material at borrow pits to trenching and pressure-testing gas lines, Westforce is providing integrated delivery in step with the client’s expansion milestones.

Westforce is delivering a broad mix of earthworks, concrete, HDPE piping and trenching across greenfield and brownfield areas. The scope is structured across three workstreams: Bulk Earthworks, Brownfields Concrete and the Gas Main Package.

Bulk Earthworks Package

  • Topsoil stripping, clearing and grubbing
  • Bulk earthworks over
  • Foundation preparation and pad formation
  • Borrow pit development and material production
  • Pavement and road construction
  • Construction of 4 metre high rock berms
  • Installation of two turkey nests with HDPE liner, including DN400 and DN800 PN12.5 pipework
  • Full pipe welding, bolting and pressure testing
  • Installation of culverts, headwalls and stabilised sand backfill
  • Development of Traffic Management Plans and road diversions
  • Underground service location and relocation

Brownfields Concrete and Primary Crusher Packages

  • Detailed and bulk earthworks
  • In-situ concrete works for footings, plinths, slabs and pedestals
  • Construction of ROM bump stops and crusher slabs

Brownfields Gas Main Package

  • Trenching and HDPE pipe installation
  • 1,000m of 50mm diameter HDPE and 600m of 250mm diameter HDPE
  • Isolation, tie-ins and commissioning

Topsoil Stripping, Clearing and Grubbing: 100,000m²~
Foundation Preparation: 140,000m²~
Bulk Earthworks: 203,000m³~
Borrow Pit Material Development: 30,000m³~
Pavements and Pads: 77,000m²~
Concrete Volume: 1,000m³~
Rock Berm Construction: 9,000m³~
Turkey Nest Area with HDPE Liner: 19,000m²~

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