A major construction milestone has been reached at Xinhai Mining's 1.5 Mtpa copper flotation project in Kazakhstan. Following the completion of key heavy equipment foundations, the project has officially entered the major equipment installation phase, marked by the successful lifting and positioning of the ball mill shell.
The milestone represents an important transition from large-scale civil works to mechanical installation. With the main processing facilities continuing to take shape, the project is progressing toward the next stages of steel structure erection, equipment installation and commissioning.
The Kazakhstan project is being delivered through Xinhai Mining's integrated Mining Full-Industry-Chain Service (EPC+M+O). The scope covers metallurgical testwork and process development, mine design, equipment manufacturing and procurement, civil construction, equipment installation and commissioning.
The plant is designed to process 1.5 Mtpa, equivalent to approximately 5,000 t/d, of copper sulfide ore averaging about 0.86% Cu, using a tailored copper flotation process.
(Xinhai integrated EPC delivery for the 1.5 Mtpa copper project in Kazakhstan)
This integrated mineral processing EPC delivery model allows engineering, equipment supply, procurement, logistics and on-site construction to be coordinated within the same project framework.
With nearly 30 years of experience in the mining industry, Xinhai Group has brought together the project's testwork, design, manufacturing and construction resources to support the development of the processing plant from early-stage technical work through to commissioning.
(Metallurgical testwork for the Kazakhstan 1.5 Mtpa copper flotation project)
One of the project's main challenges is the local construction environment. Kazakhstan's winters are long and severe, significantly restricting the conditions available for concrete works and other major civil construction activities. Summers, meanwhile, are hot and dry. As a result, the effective window for major civil works was limited to less than one year.
To maintain progress within this schedule, the project team mobilized quickly after construction commenced. Within the first 50 days, the team completed approximately:
15,000 m³ of earthwork excavation and transport
260 tonnes of reinforcement fabrication and installation
2,700 m³ of concrete pouring
(Civil construction progress)
These early works supported the successive completion of key equipment foundations and plant construction milestones.
To date, foundations for all major equipment, including ball mills, flotation machines and thickeners, have been completed. Civil works for the main production facilities—including primary crushing, secondary and tertiary crushing, screening, the main plant and concentrate dewatering—have also progressed beyond the halfway point. This has created the conditions required to advance major equipment installation and steel structure erection.
Large-scale mineral processing projects depend not only on construction speed, but also on the ability to manage changing conditions, multiple work fronts and complex interfaces.
For this project, the Xinhai team has established a structured approach to schedule management and site coordination. Technical issues, construction priorities and resource requirements are reviewed regularly to keep engineering, procurement and construction activities aligned.
(Heavy equipment installation)
When site conditions or weather create unexpected challenges, the project team works with technical specialists to assess and adjust construction arrangements as needed. Early intervention helps minimize rework, control potential schedule impacts and maintain construction quality.
Weekly management meetings are also used to coordinate overall objectives, review progress and assign tasks across different work areas. Issues are tracked through a closed-loop management process to support timely resolution and maintain coordination between departments.
On-site logistics has been another important part of the project. Warehouses have been established directly at the site, with dedicated warehouse personnel and translators supporting material management, external communication and daily logistics. This helps reduce potential delays caused by supply or communication bottlenecks and supports continuous construction across multiple work fronts.
Xinhai has mobilized a specialized team of approximately 100 personnel for the Kazakhstan project. The workforce covers project management, engineering, civil works, mechanical installation, electrical work and logistics, while skilled trades on site include carpenters, steel fixers, masons, welders, electricians and plumbers.
This workforce structure supports simultaneous and overlapping construction activities across different parts of the plant.
(Kazakhsta copper project construction team)
The project is also supported by dedicated construction equipment and material supply facilities, including an aggregate production line, concrete batching plant, concrete pump trucks and mixer trucks. These resources provide greater control over aggregate and concrete supply while reducing dependence on external suppliers. Excavators, dump trucks and wheel loaders are also deployed to support mechanized earthworks and other construction activities.
Together, these resources allow the project team to respond more flexibly to changing site requirements and maintain continuity across the construction schedule.
(Aerial view of 1.5 Mtpa copper processing plant in Kazakhstan)
From the start of earthworks in autumn 2025 to the beginning of major equipment installation in summer 2026, the Kazakhstan 1.5 Mtpa copper flotation project has progressed through several critical milestones within a tightly managed construction schedule.
The successful lifting and installation of the ball mill marks the beginning of a new phase. With civil works continuing across the main production facilities, the project will now focus increasingly on mechanical installation and steel structure erection.
Xinhai will continue coordinating engineering, equipment supply and on-site construction as the project advances toward the completion of installation, commissioning and final project delivery.
(Rendering of the 1.5 Mtpa copper processing plant in Kazakhstan)
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