Rio tinto case study

Precision and Safety in Super Structure Cell Repairs.

Background

Rio Tinto is a global mining and materials company known for producing essential resources including aluminium, copper, and iron ore. In New Zealand, it operates the Tiwai Point aluminium smelter — a key site producing high-purity aluminium for international markets.

To improve the efficiency, consistency, and safety of super structure cell repairs, Rio Tinto partnered with Autoa Robot Welding to upgrade an existing robotic cell at their Tiwai Point site. The result was a robotic welding aluminium smelter solution purpose-built to meet the demands of repairing large steel assemblies within the smelter’s rodding process.

Project Overview

Customer: Rio Tinto
Product: Super Structure Cell Repair System
Country: Tiwai Point, New Zealand
Installed: 2018
Industry: Aluminium Smelting
Solution: Custom Robotic Welding Cell
Featured Equipment: Yaskawa GP280 Robots, YRC1000 Controller, OTC Daihen P500L Power Source, OTC Daihen Manual Welding with Auto Handover, Milling Systems, Cutting Lubricant Systems, 2D Laser Scanning, Tip Cleaning Station, Integrated Safety Componentry and Access using RFID tags.

The Solution

Autoa partnered with Rio Tinto to replace an existing robotic welding system with a fully customised welding cell designed specifically for super structure cell repairs. These large steel components, used to support the smelter’s anode assemblies, require precise, repeatable welding over multiple heavy-duty joints. Installed in 2018, the system was integrated seamlessly into existing operations, delivering immediate improvements in safety, consistency, and workflow.

The robotic welding aluminium smelter system features dual Yaskawa GP280 robots with OTC Daihen P500L power sources, capable of performing high-quality, repeatable multi-pass welds. Integrated 2D laser scanning ensures accurate seam detection and positioning, while custom-built milling and lubrication systems prepare surfaces for optimal weld conditions.

To support flexibility and operator ease, the system includes auto handover between manual and robotic welding, along with a tailored HMI for intuitive control. Safety is reinforced through an RFID-enabled access system, and an automated tip cleaning station extends consumable life and minimises manual maintenance.

The Results

Since the installation of the robotic welding aluminium smelter system, Rio Tinto has seen clear improvements in safety, reliability, and throughput for super structure cell repairs. By eliminating manual welding and the need to handle heavy components in confined workspaces, the system has removed key safety risks such as exposure to hot zones, pinch points, and repetitive strain — creating a safer working environment for operators.

Weld quality has also improved through consistent, multi-pass execution with full penetration, reducing the need for rework and minimising wear on downstream components. Intelligent seam detection and automated setup have shortened cycle times, enabling more efficient and predictable repair schedules.

The addition of automated tip cleaning, seam detection, and precise gas/wire control has extended consumable life and reduced unscheduled downtime. These results have contributed to more predictable scheduling and higher confidence in the structural performance of every repaired super structure — highlighting the long-term value of Rio Tinto’s robotic welding aluminium smelter upgrade.

“It’s about keeping people away from the load. People and safety first,” says Paul Cavanagh, long-serving crew leader at the Tiwai Point smelter.

The IMPACT ON Rio tinto

This project focused specifically on improving the repair process for super structure cells — a critical component in the Tiwai Point smelter’s operation. The previous system, while functional, lacked the precision, safety systems, and flexibility needed to keep pace with production and maintenance targets.

The upgraded cell introduced refined welding processes, purpose-built operator controls, and integrated safety features, tailored to the super structure task. These upgrades allowed for repeatable, high-quality welds across large components while reducing the physical strain on the employees at Rio Tinto.

Rio Tinto’s Tiwai Point site has always been about its people. According to long-serving staff member Paul Cavanagh, that focus was central to the decision to upgrade and double the site’s robotic welding equipment. The investment reflects a long-term commitment to keeping people safe, improving working conditions, and ensuring the super structure cell remains a reliable and efficient part of smelter operations.

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