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.

Maintenance & Servicing Industrial Electrical Services

Long-term industrial electrical support for BlueScope Lysaght roll forming facility by CPR Electrical Perth

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.