Mine Dewatering using Waterlord® in Western Australia

Rapid deployment layflat hose system for efficient high-wall dewatering operations

Power Profile

Overview:

A large open-cut mine in Western Australia required a safer and more efficient method to transfer water from deep pits to the ring main. Crusader Hose delivered a Waterlord® layflat hose system combined with the Hamersley™ Reel System, enabling faster deployment, easier handling, and improved operational safety.

Customer:

Mining Operator

Location:

Pilbara Region, WA, Australia

Industry:

Mining

Application:

High wall mine dewatering

Mining Operator

Challenge:

Dewatering deep open-cut pits presents significant operational and safety challenges, particularly when using traditional rigid pipe systems.

Key issues included:

Difficult installation on high pit walls
Heavy and cumbersome poly pipe handling
Risk of pipeline slippage, requiring anchoring systems
High labour requirements for installation and relocation
Frequent pipeline repositioning as the pit expands

These challenges increased installation time, safety risks, and operational inefficiencies.

Solution:

Crusader Hose implemented a Waterlord® layflat hose system deployed using the Hamersley™ Reel System, specifically designed for mine dewatering applications.

Key features of the solution:

Flexible layflat hose, easily deployed down high pit walls
Lightweight system, reducing handling complexity
No anchoring required, unlike rigid pipe systems
Rapid deployment using reel system, improving efficiency
Simple relocation, enabling quick repositioning as the pit evolves

The hose was deployed by:

Unwinding from the top of the pit
Pulling into position using a 4WD
Connecting quickly to the ring main for immediate pumping

Results:

The Waterlord® system delivered significant operational improvements:

Faster installation, reducing setup time compared to poly pipe
Improved safety, eliminating heavy lifting and anchoring risks
Reduced labour requirements, with fewer operators needed
Efficient relocation, enabling quick repositioning as operations evolve
Reliable high-volume pumping from deep pit environments

Operator feedback highlighted the simplicity and effectiveness of the system:

“Operators were impressed by the simplicity of the layflat system. They acknowledged how much harder and riskier it is to install a poly pipeline.”
— Francois Steverlynck, Managing Director, Crusader Hose