Projects

Driving change in all our projects through competence, capacity and commitment.

We provide engineering design of Process Plants and Infrastructure Facilities where we have an in-depth understanding of the project lifecycle by assissting our Clients through all stages of the projects delivery from conceptual design and feasibility studies to detail design, construction support and commissioning. Our success is founded on our ability to provide innovative and cost effective outcomes for our Clients.

ROM 3 Crushing Station

Client: Roy Hill | Location: Pilbara, WA | Services: Materials Handling, Roads & NPI
To maintain required production levels, Roy Hill required a new crushing facility 6km from the existing infrastructure. Schedule was critical to the success of the project to provide access to new ore bodies prior to depletion of existing. To cater for a diverse range of ore types, Roy Hill’s existing crushing facilities included two trains: jaw crusher for harder material and primary & secondary sizes for softer materials. BGER identified that the existing arrangement could be optimised catering for all ore types within a single gyratory crusher feed by vibrating grizzly. This arrangement allowed finer material to bypass the crusher reducing the crusher duty by 50% while maintaining required throughout. Additionally, BGER developed an innovative steel ROM wall concept that integrated the ROM wall with the bin and internal platforming removing the walls. The simplified layout allowed for all assets to be support from the ROM wall removing the need for stringent compaction criteria immediately adjacent to the walls reducing cost and construction time for the ROM walls. BGER completed all engineering for this crushing facility including civil, structural, mechanical, piping, electrical, instrumentation, controls and shop detailing.

Hydrate Storage Shed & Study

Client: Alcoa | Services: Structural & Non-Process Infrastructure | Location: Pinjarra, WA
Alcoa Aluminium required additional hydrate storage was required due to several major Calciner overhauls were approached to help mitigate any production impact by investigating feasible and cost-effective storage, export, reclaim and transport solutions that could be implemented to meet this short-term storage capacity shortfall with minimal impact to production. BGER’s investigation identified various options such as; expansion of existing sheds, inflatable storage sheds, modular prefabricated dome shelter and conventional steel sheds. The modular fabricated structure was selected as it was able to deliver the required capacity in an accelerated schedule.

Abrohlos Overpass

Client: Central Systems for FMG | Services: Rail, Civil & Structural
The project involved the construction of a concrete arch over a live rail network which provided some unique challenges and additional safety considerations. Significant planning and effort was required to safely complete the project while accommodating regular interruptions of FMG trains. Full credit is awarded to the entire team and their ability to consider, plan and deliver the project safely. The project was delivered through the COVID-19 lockdown, a significant component of the design was delivered by our team in their home offices. The increased communication between FMG, Centrals and BGER was beneficial to the design process and has been adopted by BGER moving beyond the project.

White Quartz Road Realignment

Client: Rio Tinto | Location: Tom Price, WA | Services: Public & Haul Roads
White Quartz Road (WQR) is an existing access road located approximately 55km north-west of Tom Price in the Pilbara, Western Australia. WQR is the primary access road from Tom Price to Rio Tinto’s Brockman 4, Brockman, Nammuldi and Silvergrass Mines. BGER were engaged by Rio Tinto to provide the PFS to ascertain the safest and most functional route for the realignment of WQR and provide recommendations and DD for the preferred option. The SOW included +6km of new sealed access road in total, with parts of the new alignment to be staged/deferred to suit mine sequencing to provide an optimal solution, allowance for an unsealed bypass track for future oversize loads, relocation of an existing 33kV overhead power line and removal of existing 33kV and 415kV overhead power. BGER are now providing construction phase support, including project engineering, technical support and geotechnical site support.

CB Process Water Tank

Client: FMG| Services: Mechanical & Structural
BGER was requested to provide a proposal for the design of a new 1,716m³ capacity steel tank to store process water. The new tank replaced the existing bolted panel tank of diameter 15.75m and height 8.81m. The old existing was demolished during a 5-day shutdown. The new tank was constructed adjacent to the existing tank, ±30m away, pre-shutdown and then lifted into position. The new design included all the relevant lifting beams, lugs and equipment required to lift the tank into position.

Gidhi Oxygen Injection Project

Location: Kalgoorlie, WA | Services: Detailed Design
BGER was engaged to provide detailed design for the installation of an MMS Series 100 shear reactor on two leach tanks at the Gidji Operation. The work included the installation of two slurry pumps and new VSD and drives, electrical design, pipework connecting to the shear reactor and circulating slurry from the base of the tank to an injection nozzle on the opposite sides of the tanks below the agitated zone of the lower impeller, oxygen piping and associated services relocation and installation.

Roy Hill Port

Client: Roy Hill | Services: Materials Handling, Marine Structures & Ports
As part of the $10B Roy Hill 55Mtpa Greenfields iron ore project which included a new port, mine and railway system, BG&E Resources key staff were involved from inception (feasibility study) to handover and performance testing. The port system comprised a car dumper, stockyards, out loading facilities and marine structures. The port was completed on time and under budget.

Eldo Plateau Haul Road PFS Waterways

Client: Rio Tinto | Services: Public & Haul Road
Rio Tinto Gove Operations require a haul road and a public access road to be constructed by 2022 to safeguard the mines throughput target of 13.0 Mtpa. BGER carried out PFS design for the two roads which included a waterways assessment of the crossing of the Latram River. The hydrologic analysis involved Flood Frequency Analysis and rainfall-runoff modelling to establish design flows. Hydraulic modelling was carried out to develop several options for the crossing with varying levels of service. A drainage concept for the remainder of the roads was also prepared.

Gudai Darri SMP Transportation Steel

Client: Rio Tinto | Services: Structural
BGER were engaged to undertake lifting, transportation and temporary works design of the modular steel structures. BGER worked closely with Laing O'Rourke’s transportation contractor NMT Global to optimise our design solutions while minimising risks. BGER was involved with each stage in the journey, from overseas fabrication workshops through to erection on site including; lifting on and off the ship, stability and specification of sea tie downs during sea transportation, land transportation from port to site, storage at laydown yards, lifting and combining of sub-assemblies and final lift in to permanent location. 890 modules were transported over the duration of the project, the largest module weighing in at 290 tonnes.

Parkes Terminal Facility

Client: Coleman Rail / Pacific Rail | Services: Rail Alignment, Formation & Earthworks
As lead design consultant for the brand-new freight facility with container storage, rail sidings, heavy vehicle access roads and direct interface to the first stage of ARTC’s Inland Rail. BGER partnered with Coleman Rail in a D&C contract using a preliminary design provided by Pacific National. Numerous value engineered solutions were put forward which were carried forward into the projects detailed design. BGER worked closely with Pacific National and Coleman Rail to produce a cost effective, fit for purpose design that achieved all of the functional requirements set forth within a constrained environment. The project directly interfaced with Inland Rail, with numerous rail and pavement interfaces. These were engineered in collaboration with ARTC to provide a suitable and cost-effective outcome that all parties were happy with.

Roy Hill Ultrafines Stage 2

Client: Roy Hill | Services: Greenfields & Brownfields Project
The Roy Hill Ultrafines Stage 2 Project forms part of Roy Hill’s project pipeline to identify recovery improvement and expansion projects to be able to consistently achieve the approved export capacity of 60Mtpa. BGER has completed an Engineering and Cost Study for the UF 2 Project. The project is still in progress and subject to confirmation of test data currently in progress. Project risks and opportunities are being progressively captured and the design allows for optimisation of layouts and equipment confirmation planned for the value engineering phase.

Whyalla Iron Ore Export

Location: Whyalla, SA | Client: Onesteel Whyalla Steelworks | Contractor: Kerman Contracting / Thiess Pty Ltd | Services: Design Services
Materials handling and storage facility located at the existing port in Whyalla, South Australia. The project included a 14m deep train-dump vault and inclined conveyor tunnel. The first transfer tower houses a shuttle conveyor to feed 3 separate conveyor lines. Features: Main storage sheds 170m x 72m x 26m high. Clear span trusses support in-loading ridge conveyor. Transfer towers, conveyor and trestle design.

API Hub to Mulga Downs PFS Cost Study

Client: Roy Hill | Services: Civil, Rail & Heavy Haul
BG&E Resources is currently undertaking a PFS for Roy Hill for a heavy haul rail transportation option linking the API Hub to the proposed Mulga Downs mine. The study is inclusive of a +/-30% cost estimate. Rail alignment options considered include both non-banking and banking due to challenging terrain. The alignment includes several grade separated structures at interfaces with other railways and existing roads.

RGP Rail Bridge Detailed Waterways

Client: BHP Billiton | Services: Rail, Design and Waterways
BGER was commissioned to conduct a detailed waterways analysis of 12 rail bridges as part of BHPBIO’s RGP5 rail upgrade between Newman and Port Hedland in the Pilbara region of Western Australia. The investigation included detailed hydrological and hydraulic modelling for the 12 bridge catchments to determine flood loading conditions for the structural design of each bridge. Detailed scour analysis was carried out incorporating geotechnical input.

Syama Roaster Shutdown

Client: Resolute Mining | Services: Materials Handling
BGER are assisting with the shutdown works where Resolute require structural engineering services for rigging design, development of materials movement plans and laydown areas assessment and design for a 14 tonne Primary Cyclone roof section, 20 tonne Primary Cyclone Scroll section and 21 tonne Roaster Crossover Duct section.

FMG Solomon Stockyard

Location: WA | Client: Fortescue Metals Group | Contractor: Laing O'Rourke Services: Design Services
Our team was responsible for: Design and documentation of the overland conveyor structure including foundations; Responsible for the design and documentation of all the take up and transfer structures; Verification of the lifting calculations as the majority of elements were pre-fabricated in Thailand and transported to site; Utilisation of BIM to coordinate designs with the mechanical & electrical consultants.

BHP Jimblebar NPI Buildings

Location: Pilbara, WA | Client: Kerman Contracting | Services: Design Services
Mine site infrastructure project consisting of heavy vehicle workshop, ore-handling plant workshop, HV & LV wash-down, sample-prep laboratory and minor buildings. The project was a design and build contract with Kerman Contracting for the provision of the non-process infrastructure facilities for BHP Billiton’s Jimblebar iron ore mine site in the Pilbara. The buildings format consisted of several large steel portal framed structures with in-ground concrete sumps, pits and wash-down ramps suitable for servicing the fleet of mining trucks and loaders.

MAC Minewater Tank Duplication

Client: BHP Billiton | Services: Materials & Wet Process
The key objective of this tank duplication project was to provide duplication of the current storage and pumping system to mitigate the risk to the BHP MAC plant of being reliant on a single system regarding the plant and fire water supply. BG&ER worked closely with Centrals to develop engineering solutions that minimised construction complexities. This included the use of; skid mounted pump assemblies that removed the requirement for several additional site hours; a bolted tank arrangement that reduced the need for working at heights and optimisation of the ring beam design to minimise the need for complex circular formwork. These design solutions enabled Centrals to minimise on site labour and remove scope from the critical path to reduce schedule risks.  

FMG Solomon Stockyard

Location: WA | Client: Fortescue Metals Group | Contractor: Laing O'Rourke Services: Design Services
Our team was responsible for: Design and documentation of the overland conveyor structure including foundations; Responsible for the design and documentation of all the take up and transfer structures; Verification of the lifting calculations as the majority of elements were pre-fabricated in Thailand and transported to site; Utilisation of BIM to coordinate designs with the mechanical & electrical consultants.

BHP Jimblebar NPI Buildings

Location: Pilbara, WA | Client: Kerman Contracting | Services: Design Services
Mine site infrastructure project consisting of heavy vehicle workshop, ore-handling plant workshop, HV & LV wash-down, sample-prep laboratory and minor buildings. The project was a design and build contract with Kerman Contracting for the provision of the non-process infrastructure facilities for BHP Billiton’s Jimblebar iron ore mine site in the Pilbara. The buildings format consisted of several large steel portal framed structures with in-ground concrete sumps, pits and wash-down ramps suitable for servicing the fleet of mining trucks and loaders.

Mount Morgans Primary Crusher Vibration Assesment

Client: Dacian Gold | Services: Materials Handling & Structural
Shortly after commissioning of the Mt Morgan’s Gold Mine, several failures of structural elements were identified at the crushing facility. BGER were engaged to undertake independent structural analysis and recommend remedial works required to mitigate risk of future damage. BGER worked with ALS who undertook on-site measurement to confirm high risk areas and provide Dacian Gold with a strategy to minimise risk of future damage without loss of production.

MESA A Mine Site - Heavy Vehicle Workshop

Location: Pilbara, WA | Services: Design Services
This project included an open sided workshop to service large mining trucks and located in known cyclonic areas. It featured: 550mm thick slab for jacking procedure 1200 WB portals 18m high 2 x 25 tonne overhead travelling cranes Other buildings included a welding bay, ammonium nitrate store, warehouse and wash-down areas

GNH FMG Solomon Overpass

Client: FMG | Services: Roads & Structural
BGER was engaged to provide PFS design input and technical guidance on the optioneering works required to build 5.3km of new haul road and 6km of public access road. This also involved the optioneering of a high flow culvert crossing, including assessing shutdown periods and risk to mine throughput during different rain events. Assistance with resource loading, schedule development and cost estimating was also provided to forecast FS and execution timing and costs.

Nammuldi BWT Non Process Infrastructure

Location: Pilbara, WA | Client: Rio Tinto | Services: Design Services
Three elements make up the Inflow, Primary Crushing Stations, Overland Conveying and Coarse Ore Stockpiling. The Process Plant SOW consists of both a dry and wet circuit, beginning at the COS vaults and ending at either the stockyard or tailings facilities. The train load-out forms part of the out-loading circuit which begins at the stockyard reclaimer. The role of Project Director Infrastructure, Project Director Delivery, for the entire project and Contract Superintendent encompassed all aspects of the works from engineering, procurement, contract management, construction and project management, approving authority and commissioning manager.

PT Dongi-Senoro Full Containment LNG Tank

Location: Indonesia | Client: PT Donggi-Senoro LNG | Services: Design Services
We were involved in various stages of the LNG tank development, as a specialist outer containment storage LNG tank consultant. Features: - Tender and pre-engineering design for the tank, including: Preliminary tender for outer concrete tank design. Pre-engineering dynamic analysis for site-specific earthquake conditions. Pre-engineering foundation analysis (management of geotechnical sub-consultant). Detailed design of the outer concrete tank, including: Foundation analysis and design (management of geotechnical sub-consultant). Wall design, with roof ring beam and pilasters. Base slab design. Interface with other disciplines. Highly seismic area/design for high magnitude earthquake load. Design to BS 8110 and BS 7777, including additional provisions from EN 1992-1-1 and EN 14620. Interface with TKK, designer and supplier of steel inner tank.

Roy Hill Mine Services - Heavy Vehicle Workshop Structures

Location: Roy Hill Mine, WA | Services: Design Services
The Heavy Vehicle and Boiler Maker workshops have been designed for the service and maintenance of the Roy Hill mine fleet vehicles, which includes the world’s largest haul truck capacity fleet. The Workshops structural steel superstructures house columns up to 25m high and weighing approximately 5 ton each capable of supporting the 70T overhead gantry crane loads. Pad footings were specially designed to accommodate the loads from each column ensuring minimal differential settlement with each of the workshop floor slabs being isolated from the footings and poured up 500m thick to accommodate the various jacking and operational wheel and track loads. The workshops had to be designed to house and support a vast array of lubricant and pneumatic services and equipment while still providing ample workspace to maintain and inspect the mine fleet vehicles, including the CAT 797F vehicles. Furthermore the designed used a flexible geometry and practical layout, comprising of predominately bolted connections to allow for safe and efficient construction and maintenance while also allowing for the future expansion of the site as the demands of the Roy Hill mine increase. As a result the Heavy vehicle workshop has a total floor area of approximately 1100sqm requiring 4500m3 of concrete and over 500t of steel. The Boiler workshop had a total floor area of approximately 3000sqm requiring 1500m3 of Concrete and over 200t of steel.

Pippingarra Road Upgrade

Location: WA | Client: Pilbara Minerals | Services: Roads & Civil
BGER was commissioned by Pilbara Minerals to design the upgrade of a 40-kilometre section of Pippingarra Road in the Pilbara region of Western Australia. The objective of the upgrade works was to facilitate the passage of RAV10 vehicles, allowing Pilbara Minerals to transport lithium and tantalum product from its Pilgangoora Project (approximately 120km south of Port Hedland) to Port Hedland. BGER’s design of the horizontal alignment and vertical grade lines minimised earthworks volumes, and the vertical alignment along floodways minimised cut and fill volumes.

Dampier Salt Surface Water Management Study

Client: Rio Tinto | Services: NPI, Ports & Civil
Dampier Salt engaged BGER for professional engineering consultancy to conduct a Surface Water Management Order of Magnitude Study (OoM) to identify controls to reduce risks associated with rainfall and cyclone events as much as reasonably practicable. In the study, BGER provided earthworks, hydrology and hydraulic modelling that allowed for optimization flow of stormwater during rainfall events, identification of high-level risks to operation and their corresponding risk mitigation at the Dampier, Port Hedland and Lake MacLeod sites.  

Kwinana Bulk Terminal Sustaining Capital

Client: Fremantle Port Authority | Services: Port Facility
Upgrade of the existing Kwinana Bulk Terminal KBB2 jetty conveyors. This work incorporated the replacement of the existing ship loader at end of life with a new upgraded ship loader and the replacement of the existing double back jetty conveyors with a new layout featuring an elevated single conveyor which vastly improved maintenance and spillage clean up access. The conveyor design also included a retractable tripper design to allow for the dual import and export modes that this conveyor operates in.

PPA Port Hedland - Berth 3 Replacement

Client: Pilbara Port Authority | Services: Ports & Structural
BGER were approached to conduct and independent review of the design, manufacture and supply of over 5200m2 of GRP permanent formwork at Berth 3. The panels were designed to suit the spans and shape of the existing Berth 3 deck.

Esperance Sulphur Storage Facility

Location: Esperance, WA | Client: Kerman Contracting | Services: Port, Civil & Structural
BG&E (as Carnegie Associates) were commissioned by Kerman Contracting to provide the civil and structural detailed design of the 120,000 T storage shed and associated product conveyors. BG&E also designed a stainless-steel product chute that delivered the product from the storage building’s apex conveyor to the floor without releasing a harmful dust into the atmosphere.

Nammuldi Scrubber Chute Upgrade

Client: Rio Tinto | Services: Materials & Wet Process
Tinto’s Nammuldi Below Water Table (NBWT) processing plant contains four separate conveyors fed scrubbing and screening modules. Each module includes a series of feed and discharge chute arrangements, to and from the scrubbing units. Rio Tinto required a safe, reliable and financially viable solutions to improve this existing system. The design was required to facilitate implementation in a manner which minimises plant downtime and delivers improvements to current levels of operability and maintainability.

Perdaman Destiny Project - Value Engineering

Client: SNC Lavalin | Services: Structural, Ports & Marine
BGER were engaged by SNC Lavalin to perform a value engineering exercise on the civil/structural design documentation completed by SNC’s Perth/Mumbai engineering team. BGER’s scope was to perform a high-level engineering study utilising geotechnical engineering consultancy (Golder Associates). BGER identified several areas where design improvements lead to a significant reduction in construction and capex costs.

Process Plant Ramp Up

Client: Roy Hill | Services: Materials & Wet Process
Roy Hill engaged BGER to assist with planning and implementing the ramp up of their processing plant to 55Mtpa. BGER provided detailed design services including construction documentation for the ROM bin inserts and rotable sizer structures as well as various studies for changing or improving crushing equipment geometry and functionality. In six months, BGER were able to improve process plant throughput by 25 % while remaining under budget as well as provide other significant cost savings through replacement period improvements and improved crushing circuit efficiency.

Tailings Storage Facility

Location: Pilbara, WA | Client: Roy Hill | Services: All, from project inception to comissioning & handover
The Tailings Storage Facility (TSF) is approximately 457.5 hectares in size, and formed part of the enabling works for the Roy Hill Mine. The tailings storage facility is a two-cell structure, with decant return structures and underflow drainage. The engineering works for the TSF were undertaken by engineering consultants and managed by Roy Hill. The engineering works were undertaken to accommodate use of locally won materials, which resulted in significant savings to the project. The role of Project Director Infrastructure and Contract Superintendent for the majority of the construction contracts was undertaken by our team of engineers. The role encompassed all aspects of the works from engineering, procurement, contract management, construction and project management.

Roy Hill Port Hedland

Location: Port Hedland | Services: All, from project inception through to commissioning & handover
The port component included a purpose built, world class iron ore port facility at Port Hedland capable of receiving, stockpiling, screening and exporting 55Mtpa of iron ore as lump and fines. The in-loading circuit comprised a rail loop, car dumper, apron feeders, conveyors, two ore stackers and the lump and fines product stockpiles. The out-loading circuit comprised a reclaimer, lump re-screening plant, sample station, ship loader, associated conveyors and two berth wharf. The role of Project Director Infrastructure Project Director Delivery, for the entire project and Contract Superintendent for the majority of the construction contracts was undertaken by BCEPM personnel. The role encompassed all aspects of the works from engineering, procurement, contract management, construction and project management. Other roles included Roy Hill Engineering Manager, Roy Hill Approving Authority Manager, Commissioning Manager for the Mine and Mine Process Plant Project Manager.

Trippers Detailed Design

Location: Christmas Creek | Client: FMG | Services: Materials & Design
BGER was engaged to provide detailed design for the existing Christmas Creek OPF trippers which has been experiencing material handling issues. These issues were primarily chute blockages as a result of handling problematic material with high moisture and clay contents, being anticipated as an ongoing and increasing problem. The Scope of Works included review and cross-verification of existing design drawings, update of 3D models in CAD format, undertake design reviews and develop and provision the detailed deliverables list.

Yakabindie Haul Road Creek Crossing

Client: BHP | Services: Roads, Civil & Structural
Yakabindie is located approximately 410 kilometres north of Kalgoorlie in Western Australia’s north-eastern Goldfields, with BHP Nickel West’s Mount Keith Nickel Operation (NMK) located approximately 20km to the north. The Scope of Works included providing support requirements for the combislab design including subgrade and sub-base requirements, detailed design of the Northern and Southern Creek Crossings to relevant company and Australian standards, including drainage and erosion control design for the main creek stream crossing and access ramps and development of the project specification for construction of the creek crossings.

Port Kembla Grain Terminal

Client: Kerman | Services: Ports & Materials Handling, Civil & Structural
The project involved construction of a road receival hopper, a rail receival facility, an elevated overland in-loading conveyor system and a grain storage area comprising eight fat bottom 10,000 tonne capacity silos, nine 2,000 tonne capacity elevated cone bottom silos, bucket elevators and conveyors for materials handling, ship loading conveyor and batch weighing systems, weigh bridge and control buildings.

Chadwick Site Upgrade

Client: CBH | Services: Wet Process, Mechanical & Structural
BG&E provided the civil and structural design for the Chadwick Site Upgrade and Expansion. This project entailed structural engineering design for four new 20,000T circular grain storage cells and conveying structures along with the associated civil, earthworks, drainage and road design.

Silvergrass NPI Facilities

Client: Decmil | Services: NPI, Civil & Structural
BGER were commissioned by Decmil to conduct the civil and structural detailed design for the Separable Parts 1 and 2 of the Silvergrass Project iron ore deposits. BG&E’s design considered all Client operational requirements for access and traffic flow whilst maintaining designated ‘HV and ‘LV’ zones to minimize vehicle interaction. The design of the concrete floor slab in the heavy vehicle workshop increased the speed of construction, reduced the possibility of physical injury to steel fixers and allowed steel fixers to walk.

BHP Supply Hub Warehouse

Location: Port Headland, WA | Client: BHP Billiton | Services: Design Services
Our team carried out the structural design for BHP Billiton Iron Ore’s $30.6M supply hub storage facility in Port Hedland, Western Australia. The facility comprised a 12,000m2 climate controlled warehouse, external awning structures, administration building and a vehicle washdown pad.

Port Lightning Protection Study

Client: FMG | Services: Ports
Ultrafine recovery is extremely important for incremental tonnage costs, grade quality and extending the mine lifespan. BGER provided detailed design opportunities to optimise ultrafine product recovery at the Roy Hill Processing Plant. All while remaining under budget and on schedule, BGER recognised opportunities for 30-50% reduction in concrete volume, reduction in complexity of pipe supports to improve operability, and a tilt-up solution to simplify transformer compound construction.