Gudai-Darri Rail, WA

Gudai-Darri Rail, WA

Our case studies highlight significant projects successfully completed by Roundel in recent years.
Client
Rio Tinto. Civil Contractors: Acciona-Clough JV (Northern section), NRW Construction Pty. Ltd (Southern section).
Project outline
The Gudai-Darri (Koodaideri) Rail project consisted of 170 km of railway line connecting the Gudai-Darri mine to Rio Tinto’s existing rail system. The mine is located in the Pilbara, WA.
EPCM
WorleyParsons Pty Ltd
Year
2019 – 2020

Scope of works:

Our scope of work included the on-site production of 4,300 tonnes of HPL PE-coated Stilcor CSP culverts, with diameters ranging from 600mm to 2,700mm. Two pipe mills operated simultaneously on-site to service both the Northern and Southern sections of the project. Through efficient planning and execution, both sections were completed on schedule, with zero safety incidents.

The HPL PE-coated steel was selected for its exceptional durability and superior resistance to abrasion, offering a tested service life exceeding 100 years. This project also marked Roundel’s first on-site manufacture of PE-coated steel culverts. To ensure the material met the project’s performance requirements, extensive local durability testing was undertaken, confirming its suitability for the application.

To ensure the timely supply of culverts to multiple installation crews working across the project alignment, Roundel operated two on-site pipe mills simultaneously at seven different locations over a five-month period. This flexible production strategy ensured a continuous supply of culverts, enabling the project to be completed on schedule and without incident.

The HPL PE-coated culverts were manufactured in accordance with AS/NZS 2041.4 standards, while the design and manufacture of the CSP culverts and B381 bolted corrugated steel structures complied with AS/NZS 2041 standards. As the only Australian company offering both the design and manufacture of corrugated metal pipes and bolted corrugated steel structures, Roundel delivers comprehensive, nationwide solutions backed by industry-leading expertise.