Project Location—    Pilbara, WA
Project Client—    Calibre Rail for BHPBIO
Project Contractor—    Macmahon Leighton Joint Venture


BG&E was commissioned by Calibre Rail to complete the detailed design and documentation of 10 new dual-track rail bridges over major waterways as part of BHPBIO’s RGP5 mainline rail upgrade between Newman and Port Hedland in the Pilbara Region of Western Australia. The project involved the duplication of the mainline with the existing 80m rail corridor whilst maintaining rail operations.

BG&E developed a modular steel bridge system, consisting of common steel-concrete composite deck units, steel headstocks, steel pier trestles supported on standardised concrete pilecaps and footings throughout the bridges. The use of modular off-site fabrication and standardised construction provided a cost-effective solution that streamlined the construction process and allowed for rapid and safe installation. The project included installation of 216 piles, 13,000m3 of reinforced concrete and 5,500 tonnes of structural steelwork.

The detailed design and documentation included:

  • Site investigation.
  • Detailed waterways investigation.
  • Preliminary design, value engineering and early contractor consultation.
  • Structural analysis, design and drafting of bridge substructures and superstructures.
  • Independent internal and external verification.
  • Design of scour protection works including guidebanks and rock protection.
  • Civil modelling and design of tie-ins to existing embankments, and abutment guidebanks.
  • Technical specifications.
  • Management of geotechnical and quantity surveying sub-consultants.
  • Design of temporary works to facilitate construction adjacent to existing operating railway.
  • Construction support.