Mine sites need materials that can withstand heavy machinery, high traffic and corrosive materials, and that is just what DALLCON supplies.
Once the WA-based DALLCON started supplying to mining projects in 2005, it quickly established a strong reputation for its custom precast products.
Right from the start, DALLCON worked with clients to understand the site-specific challenges and requirements of mining projects. The company has continued to learn and evolve, taking the lessons of past projects while applying fresh thinking and new technologies to ensure that its products are always fit for purpose.
DALLCON offers a wide variety of standard precast products commonly used in the mining sector, including:
- precast retaining walls, footings and barriers
- concrete culverts
- stormwater pipes
- foundation slabs
- modular flooring
- cable pits
- electrical infrastructure supports.
- DALLCON has developed these standard products over the years to suit the requirement of the mining industry.
“All DALLCON standard products are fully engineer-certified, and our engineering team focuses on rigorous quality control and client-specific customisation that goes well beyond standard industry practices,” the company said.
The family-owned company has worked on some of WA’s biggest mining operations, including the Roy Hill mine and Fortescue’s Iron Bridge Magnetite Project.
Work at Roy Hill saw DALLCON supply a 95m reinforced concrete box culvert for the site’s rail bridge project in 2018, including custom blast‑resistant walls in partnership with the contracted civil engineering firm. The bespoke culvert and blast walls improved flood resilience and rail clearance consistency, minimising downtime and enhancing operational safety.
For the Iron Bridge project in 2021, DALLCON delivered more than 600 custom precast footings and pedestals, ranging in specifications and fabricated in accordance with the shop drawings, certified lift design, and project specification for concrete and relevant Australian standards.
These projects serve to provide an insight to DALLCON’s highly specialised and strategic approach to designing and manufacturing custom precast concrete solutions for mine sites, grounded in collaboration, engineering precision, and environmental resilience.
The process begins with detailed client consultations and an evaluation of the specific operational needs of the mine site, considering factors such as load-bearing requirements, corrosive soils or chemicals, climatic extremes and remote access and logistics.
The engineering team then creates detailed custom designs, optimised for structural integrity under heavy loads, ease of installation in remote or constrained environments, and compliance with relevant Australian standards.
Material selection and durability focus are critical elements of the process, and DALLCON uses high-grade concrete (typically 40 megapascals or greater), often with additives for chemical resistance, fibre reinforcement or custom rebar for added strength and waterproofing treatments for stormwater structures.
All precast components are manufactured in DALLCON’s state-of-the-art plant in Dalwallinu, about 248km from Perth in WA’s wheatbelt region.
The manufacturing process includes strict dimensional tolerances, embedded cast-in components (eg lifting anchors, steel plates, step-irons) and custom moulds for non-standard shapes or features. Each item undergoes rigorous quality control, including batch testing and curing assessments.
The next stage of the process involves the efficient transport and on-site integration of the products, which are designed from the outset for modular transport, minimising handling and reducing transport and ancillary costs.
DALLCON also understands that service extends beyond product delivery; it is not just a manufacture, but a long-term project partner.
The company offers full project documentation, engineering sign-off for compliance and council approval, and post-delivery consultation for troubleshooting or future upgrades.
With 20 years of experience under its belt, DALLCON is confident it will continue to grow and further develop its partnership with the WA mining industry.
DALLCON will be exhibiting at the WA Mining Conference and Exhibition to be held at the Perth Convention and Exhibition Centre from October 8–9.
