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The Roy Hill Project is a 55 million tonne per annum (Mtpa) iron ore mining, rail and port project being developed in West Australia’s Pilbara region. Situated approximately 115 kilometres north of Newman, Roy Hill is a world-class, low phosphorus, Marra Mamba iron ore deposit.
The dikes, which protect a part the iron ore mining against flooding, need to be protected against erosion and scour in case flooding occurs. The durability of the construction is important and therefor every component used in this project has to have a design life of 85 years (under marine conditions).
The original design was a traditional rock revetment with a nonwoven filter. As the project was built on a remote place, the transportation cost of the rock was very high. Also the price for quality rock was elevated. So new alternatives imposed themselves.
Bonar delivered 94,000m2 of Enka-Fix to the Roy Hill Project. Flexible concrete mats are used as an erosion control system in case of flooding. Enka-Fix combines the weight of the ballast with a filter by means of a very durable woven/ looped fabric.
Concrete blocks were cast upon Enka-Fix before installation. The loops on the fabric provide an extremely strong connection between concrete block and woven fabric. The finished panels were brought to site by truck.
A durability of 85 years in marine conditions is required. The woven fabric plays a crucial roll to maintain the stability of the structure. Bonar developed a woven fabric by adding stabilisers to the extrusion process. In this way the oxidation resistance increased. The woven was tested according to the new norm EN ISO 13438 which also defines the test procedure for a durability of 100 years.
The Roy Hill Project
Pilbara region, Australia
Reinforced Soil Structures
Soil Consolidation & Land Reclamation
Also the UV resistance is important. The product needs to withstand 200 kLy. By adding stabilisers and carbon black to the extrusion process Bonar was able to reach the required durability.
A fast and cheap solution was offered by Bonar to replace traditional rock revetment. The stability of the structure is assured by Enka-Fix and its connection to the concrete.
Preventing damage to road structures by draining edges and soil embankments to maintain the soil's strength.
Cost-effective and sustainable schemes to optimise minimal available land space when creating new infrastructure. Reduces the need for removing in-situ materials or importing new materials.
On coastal reclamation works, the finished ground profile may not settle evenly. Releasing the groundwater and reducing the pore water pressure quickly allows you to complete consolidation settlement while reclamation works and infrastructure installation are underway.
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