BG&E supported the major greenfield Roy Hill Railway Bridges project from early stages through to detailed design and delivery. Located in the East Pilbara Region, the Roy Hill Mine is designed to produce 55 million tonnes of iron ore annually, featuring one of the world’s largest iron ore mines, a port facility at Boodarie Industrial Estate, and a 350 kilometre heavy haul rail line connecting the mine to the port.

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), with bridges of up to 10 spans.
• Detailed design of three rail-over-rail overpass bridges (steel through-girder), with spans of up to 45 metres.
• Stakeholder liaison to agree designs for grade separated rail-over-rail crossings, where the Roy Hill crossed over FMG, BHPBIO and BC Iron assets.
• Detailed design of one 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.
• Construction support.