Roll Forming Facility Support
for
BlueScope Lysaght
Long-standing partnership delivering electrical maintenance, PLC upgrades, and production line installations for Western Australia's largest roll forming operation in Forrestfield.
Overview
BlueScope Lysaght operates the largest roll forming facility of its kind in Western Australia, manufacturing Colorbond and Zincalume products from their Forrestfield site. CPR Electrical's management and senior staff have supported Lysaght for over 28 years, providing comprehensive electrical maintenance, production line installations, and control system upgrades.
This enduring partnership reflects CPR's ability to meet the exacting OHS and Quality Assurance standards required by BlueScope companies, delivering reliable electrical support that keeps critical manufacturing lines running.
Scope of Work
• Relocation of production lines from Myaree to Forrestfield complex
• Installation of new roll former production lines
• Safety guarding upgrades on brake presses and production lines
• Machine control upgrades including PLC interface programming
• Fibre optic and data network services
• Ongoing preventative maintenance and breakdown support
Challenges & Solutions
Challenge
Supporting a high-volume roll forming operation demands rapid response times and deep familiarity with complex production machinery that operates under continuous load. Any unplanned downtime on BlueScope Lysaght's roll forming lines directly impacts product output and delivery schedules across Western Australia. The Forrestfield facility's sophisticated equipment mix — including brake presses, roll formers and automated stacking systems — requires electricians with specific machine-level knowledge, not just general industrial experience.
Solution
CPR embedded dedicated senior electricians with decades of Lysaght-specific experience, ensuring rapid fault diagnosis and minimal production disruption. We implemented staged upgrade programs for safety guarding and PLC interfaces, maintaining production continuity throughout each improvement phase. This long-term embedded approach — now spanning over 28 years — provides BlueScope Lysaght with electricians who understand every machine on the floor and can respond to faults before they escalate into production stoppages.
Project Outcome
Over 28 years of continuous partnership with zero disruption to critical production schedules. Successfully relocated production lines, installed new roll former lines, upgraded safety guarding to Category 3, and delivered fibre optic and data services — all while maintaining BlueScope's strict OHS compliance standards.
Key Project Details
• Client: BlueScope Lysaght
• Location: Forrestfield, Perth, WA
• Industry: Steel Manufacturing
• Project Type: Industrial Electrical Services
• Duration: 28+ year ongoing partnership
Get a Quote or Book a Service
Contact us today to discuss your electrical project, maintenance program, or complex project works, servicing Perth, Bunbury, and all of Western Australia.
Fully Licensed & Insured
24/7 Emergency Support
Industrial & Remote Site Ready
LVR/CPR Trained & Certified
20+ Years Experience
AS45001:2018 Accredited
Perth
Bunbury
South West
Pilbara
Goldfields
Regional WA