As part of the $10 billion Roy Hill Iron Ore project, we designed and constructed the Stanley Point Iron Ore Terminal at Port Hedland. We used substantial prefabrication and our innovative temporary works system for low-impact, high-productivity construction.

Our scope consisted 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, we delivered an abutment, drive stations, three transfer stations, and all SMPE&I works.

Our early focus on construction methodology and equipment selection resulted in the delivery of this complex project on time with minimal impact on the environment and adjacent existing infrastructure.

Our substantial pre-fabrication strategy reduced on-site construction time and cost while minimising safety risks. The two berths were prefabricated off-site in 54 m long modules to minimise site works and work over water.  They were installed using a dual heavy lift, with each module weighing up to 900 tonnes.

One of the major challenges of the project was the overland conveyor, which we constructed over mangroves, roads, and waterways in an environmentally sensitive area. We built an elevated structure, up to 17 m above ground level, and used our canti- traveler system to avoid the use of heavy equipment at ground level, thus minimising impacts on the environment. 

Our multidisciplinary capability enabled complex interfaces to be effectively and efficiently managed to deliver this project. 

Our ability to self-perform a majority of the work using our management systems resulted in effective management of project risks and outstanding safety performance. 

Further, our experience in remote project management and working with local stakeholders was also a key to our success.