The Roy Hill project is an iron ore mine, rail and port project in Western Australia’s Pilbara region. The mine itself will process 55 million ton per annum (Mtpa). The project consists of 4 packages. Package 1 includes the mine process plant, package 2 includes rail. Package 3 and 4 cover the Port Landside (stockyard) and Port Marine.

• Various scopes of work were engaged by multiple contractors on this project.
• First engaged through Laing O’Rourke, we audited the fabrication drawings supplied by other detailing contractors for package 3, Port Landside. Due to a lack of progress and the multiple errors found, Laing O’Rourke increased the scope to 3D modeling and shop detailing for a large portion of the project.
• The Port Landside (package 3) includes a twin car dumper for rail unloading and stockyard with one stacker and two reclaimers. The scope for this portion included an excess of 5,000 tons of 3D modeling and shop detailing of structural, mechanical steelwork including TFS104 Drive and Transfer Station, TFS116 Transfer Station, TFS122 Drive & Transfer, SBG004-18-01 to 04 Modules, TFS041 Transfer Station, TFS042 Transfer Station and MRT-SM2001 Sampling Monorail Support Structure.
• The Port Marine (package 4) scope came through McConnell Dowell and included a dedicated two berth facility capable of receiving, stockpiling, screening and exporting the iron ore. It has the capacity to store over 2.3 million tons. 3D modeling and shop detailing of package 4 consisted of the wharf and overland conveyors.
• Supplied design for two bulk fuel farms, rail fuel yard and the mine fuel yard and refueling facilities at the mine services area and Go Line for Decmil Australia.
• Our teams also provided input regarding model plan breakdown to assist the constructability and modularization process and was also contracted to convert a screening building model to Australian sections for fabrication by a local fabricator.
• Samsung later engaged us to consolidate all the subcontractors’ models into one overall fully intelligent Navisworks model. This model will be used for facilities management and will be the single point of truth for all drawings and data.

Highlights & Challenges

• This project scope was completed on an aggressive 8 week schedule due to schedule impacts caused by design and previous detailing errors.
• The schedule was accelerated during a 6 week period to over 40 resources and issued over 5,000 tons of steelwork.
• A global work sharing platform was utilized.
• Interim quantities and values to Laing O’Rourke to allow for progress reporting and invoicing.
• Our experience and expertise in managing and minimizing the impact of changes was vital to controlling project costs. We had the ability to resolve design issues and worked collaboratively with design and fabrication teams to minimize the impact and cost of change.
• We were able to optimize the bulk fuel containment to minimize bunding, oily water treatment and disposal requirements.

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