From Scaffold to Tailored Access Platforms: BHP’s Workshop Transformation
The Bowen Basin—an expanse of coal-rich land in Queensland, Australia, where the work is tough, the machinery is enormous, and the margins for error are non-existent. BHP, one of Australia’s and the world’s mining powerhouses, has long operated in this high-stakes environment, where efficiency and safety isn’t just important—it’s everything.
For years, the go-to solution for maintenance has been scaffolding. It has its place but is often fraught with time-consuming erection and large stocks of poles and planks. Then, only to be torn down again between workshop or plant tasks – requires resources such as, personnel, and storage space.
So, BHP decided to take action when they contacted SafeSmart Access for a scaffolding reduction audit.
Scaffolding, the Dinosaur of Workshop Maintenance
Mining is, by nature, a hazardous industry. Gigantic machines, unpredictable terrain, and the occasional explosive make it a less-than-forgiving place to work. Now, throw in scaffolding—a system that demands an army of workers to assemble and disassemble at every maintenance stop—and you get an operation that drain time and money. By no means are we advocating that scaffolding be forgone entirely; we are only demonstrating that a safer and efficient way exists through scaffolding reduction audits.
So, the challenge was clear: find a solution that was faster, safer, one that didn’t require a substantial work force just to put together.
Static to Mobile: Trailer-Mounted Access Platforms
Before the solution came the first step: a scaffolding reduction audit. BHP knew they needed to streamline their maintenance operations but didn’t have a clear roadmap. That’s where SafeSmart Access came in—conducting a thorough audit to identify pain points and create a strategy for scaffolding reduction.
Through a comprehensive site review and scaffold reduction audit, SafeSmart Access proposed introducing Trailer-Mounted Access Platforms as its workshop all-rounder.
These platforms represent a significant shift in traditional access philosophies – moving from static platforms to mobile. Constructed from high-strength, lightweight aluminium, they provide a height-adjustable solution designed for optimal mobility and operational efficiency.
The beauty of this system is its versatility. Whether you’re working on a colossal CAT 6060 excavator or an EX1200, the platform adapts. A Swiss Army knife in the range of workshop access platforms.
Making the Switch Without a Hitch
Now, transitioning from scaffolding to a new system could have been a logistical nightmare. But SafeSmart Access provided comprehensive training to ensure that the maintenance teams knew exactly how to use them.
Instead of spending 3+ hours assembling scaffolding for a single machine, mechanics can now tow a mobile platform in minutes and get straight to work. In Addition, no scaffolding crew needed—mechanics can move the platform themselves, reducing labour costs and eliminating delays.
The platforms’ height variability and a combination of common off-the-shelf parts mean that repair and maintenance for the platforms themselves are straightforward. This is particularly important in mining, where equipment lifecycles are measured in years, not months.
A Long-term System for the Long Haul
The brilliance of this solution isn’t just in its immediate benefits. SafeSmart Access continues to support BHP, ensuring these platforms remain in top condition and up to standard. Representatives in the mining height access team at SafeSmart regularly check in to ensure that the platforms are meeting the needs of workshop crews and if they have any maintenance requirements.
This kind of ongoing support is the difference between short-term sales for a product and long-term relationships that drive safety improvements and innovation ‘at the coal face’.
A Smart Move for a Tough Industry
So, what’s the takeaway from all this? Simple. Mining maintenance doesn’t have to be stuck in the past. BHP didn’t just accept scaffolding as a necessary evil. They took a hard look at their processes, identified inefficiencies, and made a smart move. By embracing mobile access platforms, they’ve cut costs, boosted efficiency, and set a new benchmark for maintenance operations in mining.
And in an industry where every second and every dollar counts, that’s the kind of thinking that keeps the big players ahead of the game.
When & Where Does Scaffolding Make Sense?
We’ve made a good case for why a mobile access platform makes all the difference in mining workshops. Scaffolding has a place in mining—just not everywhere– so when and where is it needed?
After many scaffolding audits with mining professionals, it’s clear that scaffolding is necessary—shutdowns, major plant overhauls, and capital expenditure infrastructure projects. However, scaffolding is often an unnecessary bottleneck for everyday maintenance tasks that keep mines running.
Scaffolding doesn’t make sense for your day-to-day access needs. We see a lot of scaffolding being used for really simple things like donga/portable building access, regular mechanical inspection platforms, or in and around the mobile plant in workshops. Not only do these scaffolds require time to put up, but they also need regular inspection and sign-off for safety. And if it needs work to be fixed, well, that’s more time waiting for the scaffolding crew to attend to the project.
For static inspection or access platforms around the site, having a platform that is accessible at all times, without the need for any installation or sign-off after the initial installation, is where companies like BHP see the biggest improvements in cost and labour. And the solution doesn’t need to be a custom solution, we have many off-the-shelf solutions for accessing what are essentially varying sizes of rectangular obstacles.
Where workshops are concerned, both off-the-shelf and custom solutions make a lot of sense. Furthermore, having a mobile platform that can be shifted around workshop and protects crews at heights without the requirements of ticketed scaffold staff saves an enormous amount of time for mechanics and engineers to actually get the work done.
By reviewing their scaffolding use and embracing mobile access platforms, BHP isn’t just cutting costs—they’re redefining maintenance efficiency for the mining industry.
BHP has proven that smart maintenance solutions drive real results. If you’re ready to optimise your site, reduce costs, and improve safety, start with a Scaffolding Reduction Audit today.
