McConnell Dowell was awarded the design and construction of the Stanley Point Iron Ore Terminal at Port Hedland, as part of the $10 billion Roy Hill Iron Ore project.

The Roy Hill marine project consists of a two berth iron ore load out wharf, connected with a 3600 m long elevated road and overland conveyor to the ore stockyard. In addition to the wharf and the overland conveyor, the scope of work included an abutment, drive stations, three transfer stations and all SMPE&I works.

An early focus on construction methodology and equipment resulted in the delivery of this complex project on time with minimal impact on the environment and adjacent existing infrastructure. Substantial pre fabrication reduced on-site construction time and cost while minimising safety risks.

One of the major challenges of the project was the overland conveyor, which was constructed over mangroves, road and water in an environmentally sensitive area. An elevated structure up to 17 m above ground level was built using travelers to avoid the use of heavy equipment at ground level, thus minimising impacts on the environment. 

The two berths were prefabricated off site in 54 m long modules to minimize site works and working over water.  They were installed using a dual heavy lift, with each module weighing up to 900 tonnes.

An experienced McConnell Dowell team with multidisciplinary capability enabled complex interfaces to be effectively and efficiently managed to deliver this project.  The ability to self perform a majority of the works under the McConnell Dowell management systems resulted in effective management of project risks and an outstanding safety performance.  Experience in remote project management and working with local stakeholders was a key to our success.