Roy Hill – Heavy Haul Rail Project (WA)

The Roy Hill Project is an iron ore mining, rail and port project in the Pilbara Region, Western Australia.

Five heavy haul ore trains per day consisting of 232 ore cars with a total payload of 31,132 tonnes each will be hauled over the 344km standard gauge, single railway line to transport 55 million tonne per annum (Mtpa) of iron ore from the Roy Hill Mine to the dedicated Port stockyard facility, in the Boodarie Industrial Estate south of Port Hedland.

Approximately 7500m2 of 20mm Projex Damtec Sub Ballast Matting was used to protect more than 11 Rail Bridges and culverts against excessive vibration and from dynamic forces applied to the bridge decks, culverts and their approaches by the trains.

The benefits obtained in this project in using the Projex Damtec 20mm SBM include:

  • Dynamic and equal distribution of vibration(s) in sensitive areas;
  • Extension in the the service life of the ballast;
  • Protection of concrete substrates by reducing vibrations;
  • Improved operational track performance (TCI);
  • Reduces track geometry problems;
  • Long service life & environmentally friendly; and
  • Can handle axle loads of up to 45 tons (TAL)

The 20mm SBM was manufactured in special lengths for this project to assist with ease of installation, as the bridges were 4.5m wide.

Typical Bridge structure

Typical Bridge structure

Ballast Mat placed on bridge deck ready for installation

Ballast Mat placed on bridge deck ready for installation

Reinforced Projex SBM Tape being applied over the joints of the Sub Ballast Mats Geotextile fabric is then laid over the Sub ballast mat

Re-Inforced Ballast Mat-Tape applied over the joints of the Ballast Mats
Geotextile fabric is then laid over the ballast mat

Ballast installed directly on the 20mm Projex Damtec SBM and Geotextile membrane

Ballast installed directly on the 20mm Projex Damtec SBM and Geotextile membrane