Optimising Heat Control at BlueScope Steel Port Kembla

A Global Leader in Steel Manufacturing

With over 100 years of industry expertise, BlueScope Steel is a global leader in steel production, supplying high-quality steel products to industries such as construction, automotive, and energy.

As one of Australia’s largest and most advanced steel production sites, BlueScope Steel Port Kembla plays a vital role in delivering innovative, sustainable, and efficient steel solutions. However, recent modifications to the Metal Coating Lines introduced significant heat challenges, creating an urgent need for an effective ventilation solution.

The Challenge: Managing Increased Heat Levels

Following upgrades to the Metal Coating Lines, the facility experienced a rise in internal temperatures, with heat levels reaching over 70°C. This exceeded the recommended operating range for key equipment (<55°C), requiring an effective solution to manage thermal conditions.

The increased heat also affected critical overhead cranes, which rely on long travel laser positioning systems for operation. The heat interfered with the lasers’ accuracy, temporarily impacting crane functionality and disrupting material handling workflows.

With precise temperature regulation essential to maintaining equipment performance and operational efficiency, BlueScope needed a robust, low-maintenance ventilation system to bring temperatures back within optimal levels.

The Solution: Custom Static Ventilation for Heavy Industry

To address the heat load challenges, we designed and installed a custom static ventilation system tailored to the specific needs of BlueScope’s Metal Coating Lines. This system maximises airflow without relying on moving parts, ensuring long-term reliability and minimal maintenance.

The ventilation system featured:

• Rooftop vents to expel rising hot air efficiently.
• Fixed wall louvres to allow continuous airflow and promote better thermal balance across the facility.
• A fully passive design, providing natural ventilation without mechanical components, reducing energy consumption and ongoing maintenance.

Designed and installed within a short timeframe, this solution ensured that production remained on track while providing a lasting approach to temperature control.

The Results: Improved Thermal Management & Operational Efficiency

With the new ventilation system in place, BlueScope achieved immediate and measurable improvements:

• Temperature reduction from 70°C+ to a controlled maximum of 53°C, with an average of 32°C, well within optimal operating conditions.
• Restored crane functionality, allowing for smooth material handling and seamless workflow continuity.
• Enhanced thermal regulation, supporting equipment performance and process efficiency.
• A long-term, energy-efficient ventilation solution, reducing reliance on mechanical cooling systems.

Future-Proofing Steel Production at Port Kembla

By implementing a targeted ventilation strategy, BlueScope Steel has successfully optimised heat control, ensuring continued efficiency and equipment reliability. The passive ventilation system provides consistent, low-maintenance airflow, supporting ongoing production needs in a demanding industrial environment.

As BlueScope continues to innovate, we remain committed to delivering high-performance ventilation solutions that support Australian steel manufacturing, helping the industry stay resilient, efficient, and sustainable.