Clay, concrete or cold: Going for gold through fit-for-purpose design
In mining, gold is not just a commodity; it’s a test of endurance, of climates, of constraints, of deadlines.
For Delonix Solutions, gold mining engineering projects have provided a proving ground for practical design, technical depth and reliable delivery.
Our engineering strength in gold projects has shaped our role as partner to some of Australia’s largest miners and in some of the world’s most remote locations.
Working with firms like Arccon and Primero as trusted contributors, this is the story of four gold mining engineering projects across three countries, where site constraints were solved with solutions built to last.
KCGM growth project, Kalgoorlie, Western Australia
2023 – Ongoing gold mining engineering project
Scaling throughput for Australia’s next 900,000ozpa gold mine
At KCGM’s Super Pit in Kalgoorlie, Delonix Solutions supported Northern Star Resources’ (ASX: NST) $1.5b growth project with civil, structural, mechanical and piping (CSMP) design across the dry front-end of the process plant.
When Northern Star Resources (ASX: NST) approved a $1.5b expansion of its iconic Super Pit, the aim was clear: double throughput from 13mtpa to 27mtpa and extend mine life to 2029.
Delonix Solutions was engaged under EPC contractor Primero to deliver a large portion of the dry front-end design. This included the ROM dump, primary crushing station, stockpile, reclaim tunnel and related structures.
Unlike typical projects, design and construction happened simultaneously, with Delonix Solutions founding executive director Philippe Vatin commenting on this.
“Concrete was being poured on-site before final design documents were closed out,” he said. “It demanded a deeply collaborative approach.”
To handle massive loads, Delonix designed a 30m-deep ROM vault and reclaim tunnels buried under 70m of ore.
Consequently, structures were built to be lean, durable and safe. Single large slabs resisted pressure while improving access and constructability.
From early concept to construction, the team remained embedded with Primero.
They coordinated CSMP works and interface support with electrical and instrumentation partners. In addition, they worked with offshore steel fabricators and delivered ongoing shop detailing.
The team prioritised uptime. The plant was designed for 92% availability with systems to maintain throughput and simplify maintenance.
Equipment was made interchangeable. Platforms allowed safe access and reduced working-at-height risks. Conveyor stations were coordinated to handle wood debris effectively.
Delonix Solutions didn’t just deliver engineering drawings — they engineered performance, reliability and long-term value for one of the world’s most iconic gold mining engineering projects.
Cowal gold mining engineering project, New South Wales, Australia
2018
Smart design for safe, fast execution
At Evolution Mining’s (ASX: EVN) Cowal operation in New South Wales, Delonix Solutions was engaged for the structural design of a new carbon-in-leach (CIL) tank.
It was a process upgrade to increase gold recovery by extending residence time in the plant’s leach circuit.
In order to achieve this, Delonix collaborated closely with CPC Engineering, delivering a structural and civil solution that balanced both design efficiency and constructability.
Notably, a key innovation involved preassembling a large steelwork module, more than 60m in length, at ground level. As a result, the team executed a complex lift onto the tank in a single move.
“We planned for a single-day lift to minimise working at height and reduce disruption to operations,” Mr Vatin said. “It was a precise, high-stakes manoeuvre and it worked.”
Ultimately, the upgrade was completed within budget and on schedule. Importantly, the safe installation of the CIL tank has since contributed to improved plant recovery and throughput, all without extensive downtime.
Delonix Solutions was engaged for the structural design of a new carbon-in-leach (CIL) tank at Evolution Mining’s (ASX: EVN) Cowal gold mine.
Co-O plant upgrade, Philippines
Early 2010s | International gold mining engineering project
Gold purity, simplicity and speed in the mountains of Mindanao
Co-O marked one of Delonix Solutions’ first international gold projects.
Working with Arccon Services for Medusa Mining, we faced a clear but tough challenge: upgrade and expand an operational gold plant in steep, clay-heavy terrain, under tight budget and time constraints.
Our team delivered civil, structural, concrete and platework design across the plant, from new primary crushing and emergency mill feed through to elution and carbon regeneration.
With no stockpile available, we built reliability into the system from the start.
We cut concrete volumes by designing leaner structures that still met load-bearing demands, a critical move for remote construction.
For the mill, we created a hybrid slab-and-plate foundation to support heavy liner equipment while enabling easier installation.
“The site was challenging as it was steep, difficult to retain and limited in labour skill availability,” Mr Vatin said.
“So the designs had to be as simple as they were strong.”
This project marked a milestone for Delonix Solutions. It seeded the confidence and approach we now bring to gold projects worldwide.
Golden Hills, Mongolia
Mid 2010s | Remote gold mining engineering project
Engineering in extremes
Golden Hills tested more than distance; it tested our response to harsh winter conditions.
In Mongolia’s Bayan-Arag region, Delonix Solutions delivered full civil and structural design for a compact gold plant.
This project mirrored Co-O in scope but introduced thermal challenges.
“At -30°C, standard materials behave differently,” Mr Vatin said.
“Steel becomes brittle. Concrete needs protection. Construction can’t pause just because the ground freezes.”
We solved this by designing insulated sheds for key materials and steelwork, which reduced on-site exposure and sped up installation.
Though smaller in scale, the plant demanded precise sequencing and an unrelenting focus on safety.
From Mongolia to Mindanao, Delonix Solutions has supported gold clients through the full processing journey, including the design and delivery of infrastructure that leads to moments like this – the gold pour, one of the final steps in the production process for operations.
Gold mining engineering projects built on experience
Delonix Solutions has delivered some of the most demanding gold mining engineering projects across the Asia-Pacific.
From agile solutions in tropical clay to precision engineering at Australia’s flagship pit, our story in gold reflects a team that adapts to climate, to client and to commodity, while always keeping people and plant performance at the core.
Whether the target is 150,000tpa or 27mtpa, we design for the people who run the plant, the ground they work on and the long life of the asset.
And we’ve done this across countries, contracts and climates for over a decade.
If gold’s your game, we know what it takes. Start your next chapter with Delonix Solutions — contact Contact Fil Resnik today.
