The BHP Iron Ore (BHPBIO) operates an integrated system of four processing hubs and five mines which are connected by more than 1,000 kilometres of rail infrastructure and port facilities in the Pilbara region of Western Australia.

BG&E provided the detailed design and documentation for 10 new dual-track rail bridges over major waterways, as part of BHPBIO’s RGP5 Mainline Rail Upgrade, between Newman and Port Hedland.

Our team developed a modular steel bridge system, consisting of common steel-concrete composite deck units, steel headstocks, steel pier trestles supported on standardised concrete pile caps and footings throughout the bridges. The use of modular, offsite fabrication and standardised construction provided a cost-effective solution, which streamlined the construction process and allowed for rapid and safe installation.

The project included installation of 216 piles, 13,000 cubic metres of reinforced concrete and 5,500 tonnes of structural steelwork.