Fluor completed this complex project by using a multi-office execution approach and segregating the mega-project into five manageable segments: port, power plant, concentrator, mine, and township. Fluor also closely aligned with PTTNT as a partner to deliver this challenging project.
A major design challenge was the availability of fresh water on the island to handle the demands of the processing plant. Fluor engineers designed and tested a seawater system to ensure that all equipment used at the mine was compatible with the seawater conditions.
During construction, the workforce peaked at more than 14,000 personnel from diverse cultures and backgrounds. In addition to the economic and political unrest at the time, the logistics of feeding and housing the number of personnel and the families of expat employees on the island presented a challenge. The neighboring island of Lombok was used to provide accommodations.
Fluor and PTTNT provided extensive training to all workers, including safety orientation training in both Bahasa Indonesian and English. Training centers were set up throughout the project site and customized training sessions were provided for the duration of the project.
Fluor and PTTNT also spent more than $5 million on community development projects that included childcare centers, support of new local businesses, and a program to reduce malaria in the local villages.
Despite the many challenges and obstacles, Fluor delivered the Batu Hijau project to PTTNT one month ahead of schedule and approximately $100 million under budget. The successful project continues to exceed expectations. The success of the project was due to the commitment and partnership approach of both Fluor and PTTNT. All team members established project goals early in the schedule and worked throughout the project to ensure that the goals were achieved. The Batu Hijau project stands as one of the most successful projects in Fluor's storied 100-year history.