Powering Roy Hill’s Heavy Haul Rail Operations
The Roy Hill 342 kilometre heavy haul railway in Western Australia required an enclosure solution that could stand up to some of the most extreme environmental conditions in the country. B&R was engaged by Ansaldo STS to design and supply a complete range of customised 3mm aluminium rail cabinets that would support the railway’s advanced train control and protection systems. The project demanded a durable, lightweight and corrosion-resistant enclosure system that could perform reliably in the remote Pilbara region.
B&R supplied single and double width control cabinets with full internal frames, post mount test switch boxes, post mount track disconnect boxes, and single and double width battery cabinets complete with battery interconnection cables. These enclosures formed a critical part of the infrastructure that supported satellite based train control technology, integrated electronic train orders, centralised interlocking and communications based protection for maintenance vehicles. This work drew on B&R’s proven experience supplying similar solutions for the Rio Tinto AutoHaul project and RAFA, but also required approval against a unique set of Roy Hill specifications.
The project environment presented significant engineering challenges. The railway corridor is exposed to temperatures over 50 degrees Celsius in the dry season, heavy monsoonal rain in the wet season and frequent dust storms. Vermin, windborne debris and highly abrasive dust added to the operational risks. To ensure the enclosures could perform without failure, B&R undertook extensive design analysis, prototyping and environmental testing at the company’s Brisbane headquarters. The in-house test facility allowed the engineering team to simulate structural loads, heat rise, humidity, wind forces and ingress conditions.
Thermal tests were carried out by placing a live, operational cabinet inside an environmental room. Resistive heaters were used to simulate internal heat loads from 500 to 2000 watts. The testing achieved a maximum 20K temperature rise for ambient temperatures ranging from 272.4K to 323K, confirming the design would maintain performance in harsh field conditions. Wind load testing was carried out through the application of a manual point force between 30 and 55 kilograms-force which replicated Region D, Level 4 wind exposure.
A significant advantage in the design was B&R’s expertise in aluminium fabrication. Aluminium offers better corrosion resistance, lower density and superior thermal conductivity compared with stainless steel or zinc coated steel. These characteristics reduce the risk of long-term environmental degradation and also lower freight and installation costs due to the lighter overall weight.
Throughout the project, B&R’s engineering team worked closely with Ansaldo STS personnel to refine the design and ensure that all cabinets met Roy Hill’s strict technical and environmental requirements. This collaboration continued from the earliest design stages through prototyping, testing, site integration and final commissioning. The rigorous qualification process and detailed testing program provided Ansaldo STS with complete confidence in the enclosure solution and its long-term durability.
The successful delivery of this project reflects B&R’s commitment to engineering excellence and dependable performance in remote and demanding applications. The aluminium rail cabinets continue to support the safe and reliable operation of Roy Hill’s heavy haul rail network.
