Giant Module Moves in Pilbara

Alongside our Pilbara Region, Heavy Vehicle Services assisted BHP in the movement of large modules along Great Northern Highway to its South Flank mine site.

The weight and dimensions illustrate the extent of the operation: the largest single combination was 100 metres in length, the equivalent of two Olympic-sized swimming pools; it was 15 metres in both height and width; and the load, alone, weighed 540 tonnes – the equivalent of 330 average-sized compact cars. 

Over an eight-month period, our Traffic Escort Wardens led more than 200 modules, all more than 5.5 metres wide, on their 350-kilometre journey from the Port Hedland Port Authority to the BHP mine site.

Larger modules, in excess of 8.5 metres wide and up to 15 metres high, were moved in accordance with an approved Transport Management Plan, ensuring prioritisation of road user safety and road infrastructure.

Large module movements saw a rolling roadblock, using advanced piloting techniques with several stages, including closing sections of Great Northern Highway during night hours. 

In January 2020, the Minister for Transport, Rita Saffioti MLA, approved Main Roads and BHP entering into a Standby Traffic Escort Services Agreement. The agreement provides four dedicated Traffic Escort Wardens to the BHP South Flank Project and gives surety Wardens will be on standby in both Perth and Port Hedland. 

One of the transported machines – a Reclaimer, for recovering bulk material such as ore from a stockpile – has a capacity to process 200,000 tonnes an hour and lays claim to being the largest in the world.

The seamless movement of the BHP modules is a great example of our work with industry, ensuring minimal impact for road users.