Control Consoles

As part of BlueScope’s Control System Upgrade (HDCSU) project at Port Kembla Steelworks, our team was engaged to design and deliver a fully integrated control console system for the Roughing Mill, Finishing Mill, and Down Coiler pulpits. The project formed part of BlueScope’s broader modernisation program to replace end-of-life PLC, Drive, and HMI systems and ensure 20+ years of reliable operation for Australia’s only operating hot strip mill. Our scope covered the full lifecycle — from concept development, engineering and prototyping, through to production management and installation support — delivering a next-generation, fully integrated and standardised operator interface system.

Operational control, optimised ergonomics for extended duration use, and full process visibility across the manufacturing line were the primary design drivers. The pulpit layouts required operators to have uninterrupted line-of-sight oversight across all stages of the production line, ensuring complete process situational awareness. The desktop surfaces were carefully angled to reduce operator fatigue across long shifts, while maintaining optimal wrist, arm and viewing positions. A highly flexible mounting rail and knuckle system allows for fully adjustable placement of displays, control surfaces, and accessories — enabling each operator to configure their station for comfort, efficiency, and task focus. Accessory modules integrate legacy paperwork storage, telephony, lighting controls, and audio functions to fully support daily operational workflows.

The entire console system was engineered as a modular design platform, enabling configurability, expandability and future-proofing. Each console can be adapted to varying plant demands through its configurable module system — including control panels, display modules, accessory panels, and electronics bays. The custom PCB-based control modules form one key subsystem within this architecture. Designed for process control flexibility, these panels feature fully reconfigurable button layouts, tactile micro-switch assemblies, and selectively backlit indicators for critical functions. This system architecture enables BlueScope to easily reconfigure, expand or modify control functions as plant processes evolve — preserving investment while allowing long-term adaptability.

Material selection was guided by the operational demands of the industrial environment. Trespa Toplab work surfaces provide outstanding resistance to impact, wear and chemical exposure. Structural integrity is achieved through fabricated steel frames, GRP cabinet shells, and integrated TiMOTION linear actuators delivering smooth, precise desk height adjustment to suit operator needs. All cabling is fully integrated into concealed routing systems, ensuring a clean working environment, maximum serviceability, and simplified installation or upgrade pathways.

Brand identity and operator experience were integrated into the functional design. Illuminated BlueScope end caps, integrated lighting systems, and clean industrial detailing deliver a console that not only performs to the highest technical standards, but also reinforces BlueScope’s operational identity and commitment to modern manufacturing excellence. The result is a fully engineered, operator-centered control environment that enhances safety, performance, usability, and long-term operational resilience.

Learn More: Bluescope Illawarra