The Roy Hill Mine includes one of the biggest iron ore mines in the world, it includes a port facility at Boodarie Industrial Estate and 350 kilometres of heavy haul rail line which connect the mine and rail line. The mine, rail line and port facilities were designed to produce 55 million tonnes per annum of Hematite iron ore.

The mine is located approximately 277 kilometres South of Port Headland and is at the eastern end of the Chichester Range in the East Pilbara region of Western Australia (WA).

BG&E provided bridge design, civil and structural engineering services and hydrological analyses for the Roy Hill Mine and associated infrastructure to the port.

The scope of works included the following key elements:

• waterways analysis including hydrological analysis, hydraulic analysis, scour estimation, and design of scour protection for major river crossings in the Pilbara Region;
• detailed design of eight rail-over-water bridges (steel-concrete composite) and three railover-rail overpass bridges (steel through-girder), and independent internal verification;
• detailed design of road-over-rail bridge over the port rail loop;
• civil roadworks design of Great Northern Highway intersection, level crossing, port access road and intersection, and rail construction yard, including the earthworks;
• management of geotechnical investigation including fieldwork, testing, interpretive reporting and design for bridges;
• design of pavement and surfacing for access roads and Great Northern Highway;
• safety and constructability reviews and workshops;
• liaison with stakeholders;
• technical specifications to comply with Roy Hill and Main Roads WA requirements; and
• construction support.