Aurizon on-track jacking system

On-track jacking system

Fraser-Lever designed, supplied and commissioned a purpose-built on-track jacking system for Aurizon, enabling coupled freight wagons to be safely lifted during on-train repair activities. The integrated system combines a rail-mounted hydraulic scissor lift, lateral side-shift capability, electrical controls and a dedicated hydraulic power pack and trailer.

Capabilities demonstrated

Sectors

Rail & transport

Delivery Approach

End-to-end project delivery (EPCM)

Service Types

Mechanical engineering
Project management
Design verification & certification
Electrical & controls engineering

Asset Types

Rail maintenance equipment

Project overview

Aurizon required a purpose-designed system to support on-track freight wagon repairs by safely lifting coupled wagons and allowing controlled lateral alignment of the wagon wheels with the rails during lowering.

Fraser-Lever developed a complete 35 tonne working load limit jacking system, incorporating the scissor lift structure, hydraulic lifting and side-shift functions, electrical controls, mechanical secondary locking, transport and handling features and a dedicated hydraulic power pack trailer.

Fraser-Lever’s role

Fraser-Lever provided an integrated engineering, build, testing and commissioning service, coordinating the mechanical, structural, hydraulic, electrical and controls elements of the system from functional design through to site commissioning.

The scope included:

Functional and detailed design
3D modelling and engineering drawings
Structural and mechanical calculations
Finite element and fatigue analysis
Hydraulic system design
Electrical and controls engineering
Safety-in-design and specification compliance reviews
RPEQ design review and independent third-party RPEQ audit
Fabrication and build support
Dedicated test-rig design
Type and production load testing
Commissioning and site trials
Operator training
Installation, operation and maintenance documentation

Fraser-Lever maintained engineering oversight through fabrication and testing, coordinating the interfaces between the structure, hydraulics, controls and transport module through to commissioning.

The engineering challenge

The system needed to safely lift a 35 tonne working load within a compact rail envelope while operating on both standard and narrow-gauge track.

The four-cylinder lifting arrangement introduced complex load-sharing conditions, while wagon mass imbalance, lateral loads, wind, fatigue, buckling and pin behaviour all needed to be considered in the design. The system also required 200 mm lateral movement in either direction to allow wagon wheels to be accurately realigned with the rails during lowering.

Beyond the structural requirements, the equipment needed to provide fail-safe recovery, practical handling and maintenance, outdoor storage capability and multiple operating modes while remaining straightforward for operators to use in a rail maintenance environment.

Engineering in practice

Fraser-Lever combined detailed 3D design, hand calculations and Strand7 finite element analysis to assess the system in both raised and lowered configurations. Structural models incorporated cylinder relief loads and uneven load sharing between the four hydraulic cylinders.

High-strength platework, engineered pins and bushes, wide load-transfer wheels and a compact base were integrated with hydraulic overload protection and independent load-holding valves to provide a robust lifting arrangement.

Practical operation and safety were considered throughout the design. Key features included automated mechanical locking arms, four independent counterbalance load-holding valves, pressure-relief overload protection, lateral side shift, positive locators for standard and narrow-gauge track and hydraulic connections designed to reduce the risk of incorrect hose connection.

Forklift pockets, lifting and lashing points and maintenance-free bushes improved handling and maintainability, while radio, tethered and manual controls provided flexibility in how the system could be operated.

Project outcomes

Fraser-Lever delivered the designed and fabricated jacking system, hydraulic power pack and trailer together with the engineering verification and compliance documentation required to support its operation.

A dedicated test rig was developed to enable load testing prior to dispatch, followed by site trials, commissioning support and operator training. Installation, operation and maintenance documentation was also provided as part of the completed system.

By retaining engineering oversight from design through fabrication, testing and commissioning, Fraser-Lever was able to integrate structural, mechanical, hydraulic and controls requirements into a single engineered solution. Practical handling, maintenance, recovery and safety features were incorporated throughout, with Australian-available components used where practicable to support ongoing operation and maintenance.

Need a practical solution to a complex rail engineering challenge?

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Appin mine vent shaft 7 & 8 main substation

Fraser-Lever delivered the coordinated multidisciplinary design for the main 66/11 kV substation supporting the Appin Mine Vent Shaft 7 & 8 project. The new substation provides power distribution for critical ventilation, underground mine equipment and surface infrastructure, integrating high-voltage supply with protection, controls, communications and supporting civil and structural works.

Capabilities demonstrated

Sectors

Mining & resources

Delivery Approach

Existing operations & brownfield upgrades

Service Types

Structural engineering
Civil engineering
Design verification & certification
Electrical & controls engineering

Asset Types

Mine infrastructure areas (MIA)
Industrial structures & balance-of-plant-assets
Power & substations
Utilities & services infrastructure

Project overview

The Appin Mine Vent Shaft 7 & 8 project required additional ventilation, power and communications infrastructure to support safe and efficient underground mining operations as mine workings progressed further from existing entries.

The new main substation incorporates a 66 kV switchyard, two redundant 66/11 kV transformers, an 11 kV switchroom and equipment room, low-voltage protection and control facilities, 415 V general and essential services, backup generation, power factor correction, earthing and communications infrastructure.

Fraser-Lever’s role

Fraser-Lever provided integrated electrical, civil and structural engineering across the substation package, coordinating the physical layout, equipment interfaces and supporting infrastructure required for construction and commissioning.

The scope included:

Electrical system studies and protection design
66 kV and 11 kV single-line diagrams, schematics and termination drawings
PLC, SCADA, communications and inter-tripping documentation
Substation layout and 3D model coordination
Earthworks and substation pad design
Cable trenching and conduits
Earth-grid design
Concrete foundations
Fencing and associated construction specifications
Construction and commissioning design updates

The team also integrated the incoming utility connection with the mine’s electrical systems, completed fault, protection and arc-flash studies and maintained coordinated civil, structural, electrical and controls documentation throughout delivery.

The engineering challenge

The substation brought together a high-voltage utility connection, critical mine ventilation loads, underground power distribution and surface services within a single safety-critical facility.

The design required close coordination between the 66 kV switchyard, transformers, modular switchrooms, underground borehole feeds, cable routes, earth grid, foundations, fencing and future mine-access infrastructure.

These physical interfaces also had to integrate with Endeavour Energy requirements and the mine’s broader safety inter-tripping philosophy, while allowing the engineering to be updated through construction and commissioning.

Engineering in practice

Fraser-Lever developed a coordinated substation arrangement that separated the incoming isolator, 66 kV switchyard, transformer bays, 11 kV switchroom, low-voltage protection and control facilities, power factor correction equipment and backup generation while maintaining the required electrical, cable and operational interfaces.

Civil and structural design was developed around the electrical arrangement, coordinating the substation pad, trenches, conduits, earth grid, foundations and fencing with equipment locations and cable routes. Electrical studies were undertaken to validate fault levels, protection coordination, CT and VT application and arc-flash requirements.

Reliability and safe operation were incorporated through two 66/11 kV transformers providing N-1 redundancy, independent 11 kV underground feeds, backup supply for critical services, remote high-voltage switching and integrated safety inter-tripping. Coordinated 3D model-based set-out helped manage civil and electrical interfaces and support constructability.

Project outcomes

Fraser-Lever completed the multidisciplinary design packages for the Appin Vent Shaft 7 & 8 main substation, including detailed civil, structural, electrical and controls documentation.

Deliverables included detailed drawings and specifications, coordinated engineering models, power-system and protection studies, functional and system design documentation and commissioning-related revisions. An as-built functional requirements specification was also prepared following commissioning.

The integrated approach reduced interface gaps between the electrical plant and supporting civil and structural works, supported clearer construction packages and improved constructability. The resulting design provides redundant power distribution for critical ventilation, underground and surface loads while accommodating future mine-access interfaces.

Planning an upgrade to critical mine infrastructure?

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PHOX Skyshaft relocation

Fraser-Lever provided the temporary works engineering and structural verification required to enable a substantially completed Skyshaft structure to be assembled away from the shaft collar and relocated to its permanent position using Self-Propelled Modular Transporters (SPMTs).

Capabilities demonstrated

Sectors

Mining & resources

Delivery Approach

Existing operations & brownfield upgrades

Service Types

Structural engineering
Civil engineering
Project management
Design verification & certification

Asset Types

Mine infrastructure areas (MIA)
Bulk materials handling systems
Industrial structures & balance-of-plant-assets

Project overview

The project developed the temporary works and structural verification required to support the off-shaft assembly and relocation of a 616.8-tonne Skyshaft structure at Prominent Hill Mine.

The Skyshaft was designed to be pre-assembled on temporary foundations in a dedicated laydown area approximately 400–500 metres from its final location, before being transported to the Wira Shaft using SPMTs.

Fraser-Lever’s engineering covered the temporary assembly foundations, steel transport frame and connections, assessment of the loaded SPMT travel across the existing shaft collar, temporary propping beneath the collar slab and reinstatement of modified permanent steelwork following removal of the transport frame.

Fraser-Lever’s role

Fraser-Lever provided structural and civil engineering, temporary works design and engineering verification across the Skyshaft relocation methodology. The scope included:

Independent mass and centre-of-gravity verification
Temporary concrete assembly footing design
Temporary steel transport frame design
Connections between the transport frame and Skyshaft columns
Structural assessment of the existing shaft collar under SPMT loading
Temporary propping assessment and design input
Structural analysis and finite-element assessment
Column repair and reinstatement details following removal of temporary steelwork
Civil foundation drawings and design reporting
Review and coordination of shop details
RPEQ design certification and sign-off

Fraser-Lever integrated client, vendor, geotechnical and SPMT information into a coordinated temporary works design basis, supported by structural modelling, first-principles connection checks and constructability review.

The engineering challenge

Relocating a structure of this scale required the temporary works, transport system and existing shaft infrastructure to be considered as a single engineering problem.

The design needed to accommodate the 616.8-tonne transport mass, the height and geometry of the Skyshaft, centre-of-gravity accuracy, temporary wind exposure and acceleration and braking loads generated during SPMT transport.

The transport route introduced further constraints, including strict grade limits and limited manoeuvring tolerance as the loaded transporters crossed the existing shaft collar. Ground and concrete bearing, shear and punching shear, local connection forces and modifications to the permanent columns also needed to be assessed.

The engineering required close coordination between M2P Engineering, the site and delivery teams, heavy-lift specialists, fabricators, detailers and other engineering consultants.

Engineering in practice

Fraser-Lever developed an integrated three-part structural solution comprising temporary reinforced-concrete assembly footings, a modular steel transport frame connected adjacent to the Skyshaft columns, and structural verification of the existing shaft collar for the loaded SPMTs.

The team independently checked the structure’s mass and centre of gravity, modelled temporary and transport load combinations, assessed footing bearing, shear and reinforcement requirements, extracted transport-frame actions and verified critical connections through structural analysis and hand calculations.

A key practical decision was the introduction of snug-tight temporary propping beneath the suspended collar roof slab along the SPMT travel path. While the structural assessment did not identify a general requirement for propping, its inclusion provided additional robustness where transporter positioning and manoeuvring tolerances could move loads further into the slab span.

Repair plates were also incorporated to reinstate column capacity following removal of the temporary transport connections.

Project outcomes

Fraser-Lever delivered the temporary works engineering basis, calculations and drawings required to support the proposed Skyshaft assembly and relocation methodology. The engineering package included:

Temporary assembly foundations
Transport frame design for the 616.8-tonne move
Assessment of the existing shaft collar under SPMT loading
Temporary propping requirements
Permanent steelwork reinstatement details
Design calculations and engineering documentation
RPEQ certification and sign-off

The coordinated approach allowed the temporary foundations, transport steelwork and shaft-collar interfaces to be assessed as one engineering system, reducing uncertainty at critical interfaces and supporting constructability, fabrication, methodology and risk reviews.

Planning a complex brownfield installation?

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Aurukun bauxite project

The Aurukun Bauxite Project proposed a greenfield open-cut bauxite mine near Aurukun in western Cape York. Fraser-Lever undertook multidisciplinary feasibility engineering for the project’s Central Zone, integrating the beneficiation plant, mine infrastructure, product haulage facilities, utilities and water infrastructure to support project definition and investment decision-making.

Capabilities demonstrated

Sectors

Mining & resources

Delivery Approach

Feasibility & early-stage engineering

Service Types

Mechanical engineering
Structural engineering
Civil engineering
Process engineering
Project management
Electrical & controls engineering
Feasibility & study services

Asset Types

Mine infrastructure areas (MIA)
Bulk materials handling systems
Industrial structures & balance-of-plant-assets
Minerals processing plants
Utilities & services infrastructure

Project overview

The proposed development included an open-cut bauxite mine and on-site beneficiation plant, with processed product transported by triple road trains to a coastal loading facility for offshore transhipment.

Fraser-Lever’s study focused on the Central Zone, bringing together the beneficiation plant, mine infrastructure area, product haulage infrastructure, process-water systems and raw-water supply from Tapplebang Dam. The work advanced the engineering to feasibility level and supported development of a project cost estimate with a target accuracy of ±15%.

Fraser-Lever’s role

Fraser-Lever provided multidisciplinary feasibility engineering and project coordination across the Central Zone, bringing together process, mechanical, structural, civil, electrical, instrumentation and controls engineering with project management, architectural and estimating capability.

The scope included:

Central Zone site layout and multidisciplinary coordination
Beneficiation plant flowsheets, layout and equipment selection
Heavy and light mobile equipment facilities
Mine infrastructure buildings and operational support facilities
Power and utilities
Fire, potable water, sewage and compressed-air systems
Process-water infrastructure
Tapplebang raw-water pumping and 13 km transfer pipeline
Cost estimating and scheduling
Project execution planning and construction methodology

The team also coordinated interfaces with mining, ROM, fines containment and access-road requirements while developing the models, drawings, schedules, material take-offs and vendor enquiries required to support the feasibility study.

The engineering challenge

Developing an integrated feasibility design for a remote greenfield operation required multiple infrastructure systems and operational requirements to be considered together from an early stage.

The site is located in a remote area of western Cape York, near an Indigenous community and within a tropical cyclone region. The engineering needed to coordinate the beneficiation plant, mine infrastructure, product haulage and the movement of people and vehicles while integrating with fixed interfaces being designed by others.

The study also needed to address a 13 km uphill raw-water pipeline and provide practical infrastructure for operating and maintaining a large mobile-equipment fleet in a remote environment.

Engineering in practice

Fraser-Lever used coordinated layouts and a 3D Navisworks model to review multidisciplinary interfaces and constructability across the Central Zone.

Structured RAMBO reviews considered reliability, accessibility, maintainability, buildability and operability throughout the design. Detailed drawings, engineering models, equipment schedules, material take-offs and vendor budget pricing were then used to develop a bottom-up feasibility estimate.

The study also identified opportunities to simplify infrastructure and reduce project footprint and cost. Office, control, muster, crib and emergency response functions were consolidated, wash facilities were combined and workshop functions were integrated where practical.

Modular buildings, container-mounted shelters and off-site prefabrication were incorporated where appropriate, while spare generator connections provided flexibility for future expansion. Targeted optimisation studies were also undertaken to address specific process issues as the design developed.

Project outcomes

Fraser-Lever completed the Central Zone feasibility report and Basis of Estimate, providing Glencore Bauxite Resources with a coordinated engineering and estimating basis for further project evaluation and decision-making.

Key deliverables included:

Coordinated feasibility engineering for the beneficiation plant and mine infrastructure
3D engineering models and drawings
Equipment, material, valve and cable schedules
Material take-offs
AACE Class 3 target estimate
Construction schedule
Project execution strategy
Construction methodology

The integrated study improved coordination across plant, mine infrastructure, utilities and product-haulage interfaces while identifying design and delivery risks and embedding maintainability and operability into the developing design. Practical modular and consolidated facility solutions were also developed to suit the project’s remote operating environment.

Planning a new mining development?

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Newmont Tanami airport upgrade

The Tanami Airport Upgrade involved the brownfield upgrade of The Granites Airport supporting Newmont’s remote Tanami operations. Fraser-Lever provided multidisciplinary engineering design and construction support across the runway, taxiway, apron, airfield ground lighting and associated aviation infrastructure.

Capabilities demonstrated

Sectors

Mining & resources

Delivery Approach

Existing operations & brownfield upgrades

Service Types

Civil engineering
Electrical & controls engineering

Asset Types

Mine infrastructure areas (MIA)
Airport & aviation infrastructure
Power & substations
Utilities & services infrastructure
Water & services

Project overview

The project involved upgrading the existing airport to provide safe, reliable and compliant air access for Newmont’s remote Tanami operation and support ongoing Embraer 190 aircraft operations.

Works included resealing the existing runway, reconstruction and extension of the taxiway and apron, redesign of the airfield ground lighting and associated electrical infrastructure, weather-station upgrades and development of aerodrome fire-protection infrastructure.

Fraser-Lever’s role

Fraser-Lever provided multidisciplinary engineering design and construction support across the airport upgrade, working with Newmont, contractors and aviation stakeholders throughout delivery.

The scope included:

Runway pavement investigation, analysis and design
Runway reseal design
Taxiway and apron reconstruction
Apron extension
Airfield ground lighting and associated electrical design
Weather-station upgrades
Fire-water storage, pumping, hydrant and foam-system development
Tender and contractor support
CASA liaison
Site supervision and technical support during construction

Fraser-Lever developed the civil and electrical design packages and coordinated interfaces between pavement, lighting, power, controls, underground services and fire-protection infrastructure.

The engineering challenge

Upgrading an operating airport in a remote desert environment required the engineering to respond to tight construction windows, variable pavement conditions and the operational constraints of a critical mine-site asset.

Pavement testing identified significant variability across the runway, with CBR results ranging from 9 to 110 across nearby test locations. Construction methodology was also constrained to a single stabilising layer undertaken during day shift, while high desert temperatures created additional challenges for the application of the bitumen pavement.

The design therefore needed to accommodate materially different ground conditions while remaining practical to construct within the available methodology and operational constraints.

Engineering in practice

Fraser-Lever designed the pavement for 1,000 annual aircraft movements over a 20-year design life, using the Embraer 190 as the design aircraft.

Rather than applying a uniform pavement treatment across the runway, the team developed a practical, risk-based approach using the available CBR data. Sections with CBR values below 50 were designed with a 250mm stabilised layer, while stronger sections used 200 mm. Binder trials determined that 2% lime provided the most consistent UCS response and greatest improvement in the weakest material.

The airfield ground lighting was coordinated with the revised runway, taxiway and apron geometry, including power and control interfaces, underground conduit routing, equipment and pole interfaces and aerodrome documentation.

Fraser-Lever also developed the fire-protection arrangement for the fuel-storage bund, aircraft refuelling and tanker unloading areas. The design incorporated hydrant and foam coverage, dual fire-water storage, dual diesel duty pumps and a jacking pump arrangement, while maintaining practical equipment access and separation of critical infrastructure.

Project outcomes

Fraser-Lever delivered an integrated airport upgrade design and construction-support package covering runway pavement works, taxiway and apron upgrades, airfield ground lighting, electrical infrastructure, weather-station upgrades and fire-protection infrastructure.

The coordinated approach converted variable site conditions and construction constraints into practical pavement treatments and integrated service layouts, helping reduce interface, constructability and delivery risk for a critical remote-site asset. Fraser-Lever also supported tendering, contractor coordination, CASA liaison and construction through site supervision and technical support.

Planning an upgrade to critical operational infrastructure?

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Olive Downs complex

The Olive Downs Complex is a large-scale greenfield mining development designed to support modern autonomous mining operations. Fraser-Lever delivered integrated engineering services across multiple disciplines, coordinating the design of critical infrastructure including the Coal Handling and Preparation Plant (CHPP), mine infrastructure, haul roads, water services, high-voltage power distribution and specialist mechanical equipment.

Capabilities demonstrated

Sectors

Mining & resources

Delivery Approach

Greenfield infrastructure & facility delivery

Service Types

Mechanical engineering
Civil engineering
Project management
Electrical & controls engineering

Asset Types

Mine infrastructure areas (MIA)
Materials handling systems
Water infrastructure
Coal handling & preparation plants (CHPP)
Conveyors & transfer systems

Project overview

The Olive Downs Complex is a Tier 1 steelmaking (coking) coal development located in Queensland’s Bowen Basin. Developed by Pembroke Resources, the project incorporates a Coal Handling & Preparation Plant (CHPP), Mine Infrastructure Area (MIA), haul roads, high-voltage electrical infrastructure, water services and extensive supporting surface infrastructure required to enable autonomous mining operations.

Fraser-Lever delivered multidisciplinary engineering and specialist mechanical fabrication across several major work packages during project delivery. Working alongside multiple contractors and engineering design organisations, our team provided practical engineering solutions across mechanical, civil and electrical disciplines while helping coordinate complex interfaces across critical project infrastructure.

Fraser-Lever’s role

Fraser-Lever provided multidisciplinary engineering design and specialist mechanical fabrication across several major work packages, including:

Mechanical equipment design, fabrication, supply and commissioning support
Surface and non-process infrastructure design
Mine infrastructure area (MIA) detailed design
High-voltage reticulation and kiosk substation design
Site-wide water services distribution and pumping
Haul roads, light vehicle roads, earthworks and drainage
Electrical protection studies and integration, including support for the Ergon connection agreement
Interface coordination across multiple contractors and engineering design teams

The breadth of Fraser-Lever’s involvement enabled engineering decisions to be considered across disciplines rather than in isolation, resulting in practical, coordinated and constructable engineering outcomes.

The engineering challenge

Delivering a major greenfield mining development requires hundreds of interconnected infrastructure systems to function as a single operation.

At Olive Downs, Fraser-Lever worked across multiple engineering packages interfacing with the Coal Handling & Preparation Plant (CHPP), Mine Infrastructure Area, water infrastructure, tailings facilities, substations and supporting surface infrastructure. Engineering teams were required to continually define battery limits, coordinate overlapping scopes and maintain alignment between multiple contractors and engineering organisations.

At the same time, infrastructure needed to support staged construction while remaining capable of meeting the long-term operational requirements of an autonomous mining operation. Delivering practical, buildable solutions across mechanical, civil and electrical disciplines required continual collaboration, engineering judgement and interface management throughout the project.

Engineering in practice

One of the defining aspects of the project was balancing immediate construction requirements with the long-term needs of the operation.

Within the Mine Infrastructure Area, Fraser-Lever designed both temporary and permanent facilities that supported staged mine development. Temporary infrastructure included heavy vehicle workshops, storage facilities, tyre change areas and supporting services that enabled early mining operations. Permanent infrastructure was subsequently developed to integrate with and replace these facilities as the operation matured, including purpose-built heavy vehicle workshops, high-voltage refuelling facilities, HV and LV wash pads, explosive reload facilities, pit dewatering infrastructure, lighting, drainage and sections of the autonomous haul road.

Engineering judgement also played a significant role in coordinating electrical protection schemes between Ergon, Yurika, the CHPP and the Mine Infrastructure Area while managing complex interfaces across multiple infrastructure packages.

Throughout the project, Fraser-Lever’s multidisciplinary approach ensured engineering solutions remained practical, safe, constructable and adaptable as project requirements evolved.

Project outcomes

Fraser-Lever successfully delivered multidisciplinary engineering packages supporting the construction and commissioning of the Olive Downs Complex. Key outcomes included:

Delivery of integrated mechanical, civil and electrical engineering packages across multiple infrastructure work scopes
Design, fabrication and supply of the CHPP Rejects Gate for the Coal Handling & Preparation Plant
Detailed engineering of the Mine Infrastructure Area supporting both staged construction and long-term mining operations
Integrated design of site-wide infrastructure including roads, drainage, water services and high-voltage reticulation
Successful coordination of complex engineering interfaces across multiple contractors and engineering organisations
Continued engagement supporting Stage 2 studies and sustaining capital works

The project demonstrates Fraser-Lever’s ability to deliver practical multidisciplinary engineering across large-scale mining developments while maintaining a strong focus on constructability, operational performance and long-term asset value.

Planning a similar mining development?

Whether you’re delivering a greenfield mining project, expanding an existing operation or upgrading critical infrastructure, Fraser-Lever brings practical multidisciplinary engineering experience across every stage of the asset lifecycle.