A story of teamwork, ingenuity and success, as told by the project team.

Rio Tinto’s Pilbara iron ore operations map ……………………………………………………………………………………………..08 Foreword by Andrew Harding – Chief Executive, Iron Ore ……………………………………………………………………… 11 Foreword by David Joyce – Global head, Rio Tinto Projects ………………………………………………………………….. 13 Project managers’ foreword ……………………………………………………………………………………………………………………… 14

Introduction

Extraordinary growth Extraordinary times ………………………………………………………………………………………………… 18 Study phase Rigour and robust collaboration forge a firm plan …………………………………………………………………. 28 Execution strategy The path to delivery ……………………………………………………………………………………………………. 38

Implementation

Engineering and design A global effort …………………………………………………………………………………………………….. 50 Contracts and procurement Leveraging relationships, developing industry …………………………………………….. 60 Site establishment Gaining a foothold ………………………………………………………………………………………………………. 70 Dredging works Above and beyond in environmental compliance …………………………………………………………….. 82 Marine works and tug harbour Safer, more efficient construction earns high praise ……………………………….. 92 Earthworks Breaking new ground in resourcefulness ………………………………………………………………………………. 104 Civil works A solid foundation set in concrete ………………………………………………………………………………………….. 110 Structural, mechanical and piping works A modular approach …………………………………………………………….. 120 Electrical works Best practice lights the way …………………………………………………………………………………………… 128 Controls Innovation on the front line – a step change approach ………………………………………………………………. 136

Commissioning and ramp-up

Commissioning The path to operability ……………………………………………………………………………………………………. 146 Handover Operators take control ………………………………………………………………………………………………………………. 156

Post-script

Raising the bar …………………………………………………………………………………………………………………………………………. 166

Colour illusts. Signed insert : Stuart Kennedy and Anthony Radici. Very large, heavy item which will incur additional postage. SCARCE