Sarens recently concluded a technically demanding project in Port Kembla, New South Wales, Australia, as part of BlueScope Steel’s refurbishment of the No.6 Blast Furnace (6BF), the country’s largest steel production facility.

The 6BF Reline Project, officially titled the No.6 Blast Furnace Reline – Dustcatcher Jacking, required the precise jacking of a 440-tonne dustcatcher building to allow for the installation of new lock-hopper ductwork. This effort was a vital component of BlueScope’s ongoing modernisation strategy and will enable the recommissioning of blast furnace operations for increased productivity.

The refurbishment addresses long-standing issues with dust emissions from the furnace, which posed both environmental and safety concerns. By integrating new technology, the client is taking a significant step toward more controlled and cleaner steel production.

To support this effort, Sarens was tasked with raising the dustcatcher building by 1,5 metres, an operation that demanded extreme precision and engineering excellence. With tolerances as tight as ±5mm and an operational window limited by strict weather constraints, Sarens delivered a solution that combined expertise, technical ingenuity, and proven equipment.

Selected for its technical experience and the robustness of its equipment, Sarens deployed the CS250 climbing jack system along with its custom bracing solution, the BS220. To ensure the operation could withstand Australia’s stringent design wind speeds, up to 41m/s for a 1-in-100-year event, the system was carefully engineered to meet these extreme requirements.

The jacking beams, designed and provided by the client, helped lower the starting height and improve overall system stability. The operation proceeded in two lifting phases, with intermediate installations of bracing before the structure was finally set down onto newly-installed leg extensions.

Despite the tight jobsite—confined by nearby structures and limited access routes—the Sarens team completed equipment setup in just three days and finalised the lift within a 12-hour continuous operation window.

The lift was executed with the help of 12 crew members: Five from Sarens and seven supporting riggers from the client side. Equipment was mobilised via standard trailers, with bracing sections pre-built to minimise site work. In total, Sarens spent one week on site, completing the entire operation efficiently and safely.

Sarens Project Manager Hugo Saua commended the project team, saying: “The precision and performance of the equipment were key to the success of this complex jacking operation. It was a great example of Sarens’ engineering strength and collaboration with the client to deliver an outstanding result.”

As BlueScope Steel’s blast furnace prepares for a new chapter, Sarens is proud to have played a role in supporting cleaner production processes and a stronger steel industry in Australia.