Proven Expertise Across the Resource Sector
At GenRock Resources, our work is more than just a service – it shows our commitment to working with clients to achieve ongoing reductions in total costs. We strive for innovation and continuous improvement, and have a proven track record of success in reducing overall costs for our clients.
Each project highlights the challenges we’ve overcome, the solutions we’ve crafted, and the results we’ve delivered for clients in the mining and resource sectors. Whether it’s precision-engineered piping, advanced fabrication, or complex logistical solutions, our projects exemplify the standard we bring to every job.
Our Process
How We Work
Our 6 Step Quality Assurance Procedures
Projects
Project 1: Tailings Sand Line Hardwall Floating Hoses
The Client / Location:
Our client’s mineral sands site in WA’s Northern Wheatbelt, where two large floating dredges extract ore from a purpose-built pond.
The Challenge:
Our client needed to extend their float line, which transports rock and clay through 425NB 8200mm floating hoses. However, their existing hoses, supplied by a previous vendor, were failing - water was seeping into the external foam flotation, causing them to sink. Additionally, the supplier’s long lead times and poor communication led to ongoing operational delays.
The Solution:
GenRock Resources engineered a smarter alternative by integrating polyethylene (poly) floats directly into the hoses instead of relying on external flotation attachments. This design offered significant key advantages:
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Superior durability and protection – Internal floats are protected from UV exposure, impact damage, and environmental wear.
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Consistent buoyancy – Eliminates weight distribution issues and prevents uneven sinking.
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Lower maintenance costs – No risk of external float detachment or frequent replacements.
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Simplified handling – Easier transport, installation, and reduced snagging risks.
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Increased safety – Reliable flotation even in rough waters and strong currents, with lower entanglement risks.
Implementation & Results:
To further extend hose lifespan, we incorporated a 25mm rubber wear liner and added lifting lugs and a flow director for easier installation. Once the GA drawings were approved, our Perth-based team maintained clear, consistent communication with the client throughout fabrication and shipping - resolving past frustrations with supplier transparency.
The hoses were delivered on schedule, meeting all quoted lead times. Since installation, our client has reported zero flotation issues, confirming the success of our design solution.
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Project 2: High-Wear Spool Redesign
The Client:
Our client’s processing plant, where high-impact slurry flow was causing excessive wear on critical piping components.
The Challenge:
A Y-piece in the client’s slurry piping system was experiencing severe wear, particularly at the confluence where slurry impact was highest. The bottom of the Y-piece, the sidewalls, and the joint were suffering from significant rubber loss, leading to performance issues and increased maintenance downtime.
The Solution:
GenRock Resources conducted a detailed Computational Fluid Dynamics (CFD) analysis to assess slurry flow patterns under two pump duty scenarios:
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Scenario 1: Pump A was running while Pump B was shut. Wear was concentrated at the confluence of the Y-piece.
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Scenario 2: Pump B was running while Pump A was shut. The high-wear zone extended further down the line and impacted the primary spool.
To mitigate these issues, we proposed a design modification:
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Increased Y-branch radius – Reducing impact velocity and redistributing wear more evenly.
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Telltale integration – Allowing early wear detection, improving maintenance efficiency.
Implementation & Results:
After implementing the design changes, further CFD analysis confirmed improved wear distribution:
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Scenario 3 (Pump A active): Wear was redirected earlier in the pipeline, reducing concentrated impact zones.
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Scenario 4 (Pump B active): Wear was now localised near Pump B instead of spreading down the line, significantly reducing overall spool degradation.
By optimising the Y-piece design and introducing a telltale for early maintenance detection, GenRock’s solution extended the spool’s lifespan, reduced material loss, and minimised downtime for our client’s operations.
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The Client/Location:
A chloride ilmenite deposit, 150 km north of Perth.
The Challenge:
Our client was facing excessive wear in the rubber lining of their DN350XDN150 T-pieces, supplied by a previous vendor. While the steel components remained intact, the deteriorating rubber lining was causing operational inefficiencies. The client needed a cost-effective repair solution that would extend the lifespan of the components while minimising downtime.
The Solution:
GenRock Resources conducted a thorough assessment of the existing rubber lining. Our process included:
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Stripping and evaluating the affected areas.
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High-pressure water blasting to prepare the spool surface.
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Applying 6mm Linatex Premium rubber for durability.
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Reinforcing the flange faces with 3mm Linatex Linard 60 to enhance longevity.
Implementation & Results:
The repair was completed in under five working days, minimising downtime and providing the client with a reliable, long-lasting solution.
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