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No traffic interruptions for Super•Cor® heavy haul road arch installation.

Heavy haul road arch system at Nammuldi Mine, Australia Live rail lines keep running during construction of arches.

When Atlantic Civil Products Pty Ltd, a major AIL Australian licensee, needed to convince a client that a large, two-lane heavy haul road arch system could be constructed over an existing twin track rail line and two adjacent access roads without traffic interruption. The two compelling factors that sealed the deal were:

  • our extensive experience designing Super•Cor deep corrugated steel plate structures for use under extreme live loads, and
  • our project history building the Stockton, UK, railway arches under similar traffic constraints.
No traffic interruption  during installationof heavy haul road arch

Accelerated delivery plus some bells and whistles.

The project specified that the components be delivered and assembled according to a very tight schedule and include imbedded electronic monitoring. AIL got to work, and less than a month after the contract was awarded, the components were manufactured, test assembled and shipped from AIL’s New Brunswick plant to Australia, arriving well ahead of the planned summer construction window.

The first road tunnel went up in seven days, while the subsequent rail tunnel took 18 days and the second road tunnel only 11 days. Engineered ramping and backfilling of approximately 80,000 m3 (2,825,173 ft3) of earthworks took 38 days.  The design incorporated the installation of strain gauges, pressure plates and a data logger to the exterior of the rail tunnel.

There was no rail or road traffic interruption, and the work was completed on time, making for one very satisfied customer.

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All construction took place within a very tight schedule and without interruption to the 24-hour rail and road traffic.


Nammuldi Lens E & F
Haul Road Crossing
Brockman 2 Iron Ore Mine

Rail tunnel specifications:
Super•Cor Arch HA 68S with Ribs
Span: 13.6 m (44' 7")
Rise: 9.8 m (32' 2")
Length: 82.4 m (270' 4")

Road tunnel specifications:
Super•Cor Arch SC 54S
Span: 11.4 m (37' 6")
Rise: 7.2 m (23' 6")
Length: 80.8 m (265' 4")


Engineered Backfill Cover: 2.6 m (8' 6") / 5 m (16' 3") at a density of 27.0 kN/m3

Live weight load:
Up to GVM 390t

Design Service Life:
At least 50 years


Hamersley Iron Pty Ltd, Perth, WA

Design Consultant:
Kellogg Brown & Root, Perth, WA

Project Managers:

Integrated Project Solutions, Perth, WA

Civil Contractor:
NRW Pty Ltd, Perth, WA

Installation Contractor:
APE Erections, Perth, WA