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Publication date: October 2013

Cover and inside cover images courtesy of Laing O’Rourke

Austrade gratefully acknowledges the assistance of Martin Baggott in the preparation of this report.

2 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL Image courtesy of Meridian Image courtesy

INNOVATIVE AND PROVEN SOLUTIONS DELIVERING SUCCESS

HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 3 INTRODUCTION World-leading rail infrastructure and operations have INDUSTRY OVERVIEW long underpinned Australia’s success in the resources and freight logistics industries, allowing the sector to operate INDUSTRY STRENGTHS efficiently and reliably as a major global competitor.

COMPANIES AND Established partnerships between Australian This industry capability statement gives you an CAPABILITIES resources and rail companies support the overview of Australian capability in the heavy delivery and long-term sustainability of haul, intermodal and freight rail industries, resources projects, which are often critical for including examples of some of the many FURTHER national economic development and growth. Australian companies with specialist expertise. Australia has the heaviest and longest heavy INFORMATION Talk to your local Austrade representative haul trains in the world and is pioneering for more tailored advice and information several world firsts, including remotely about connecting and partnering with the located train control centres and automated, Australian heavy haul, intermodal and freight driverless heavy haul trains. rail industries. Australia can deliver state-of-the-art solutions across every step in a heavy haul or freight rail project – from planning, design, construction, equipment, operation, safety and maintenance through to training and research and development (R&D).

4 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL Image courtesy of Laing O’Rourke Image courtesy

Australia can deliver state-of-the-art solutions at each stage of a heavy haul or freight rail project

HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 5 Australian heavy haul, intermodal Australian companies and research rail infrastructure are also essential for INTRODUCTION and freight rail expertise is broad centres have a strong record of the viability of resources projects and and diverse. It encompasses not innovation and R&D across all aspects Australia has considerable expertise to INDUSTRY OVERVIEW only ‘below-rail’ capabilities such as of freight and heavy haul rail. This offer in all these areas. planning and design, infrastructure allows the industry to be flexible, Australian capabilities in leading- construction, facilities, infrastructure efficient and resourceful and provides INDUSTRY STRENGTHS edge design, planning, operation and systems and technologies, but also tailored solutions to challenging and maintenance can minimise downtime ‘above-rail’ capabilities like rail system sometimes unique problems. and interruptions in the operation of COMPANIES AND operation, maintenance, rolling stock A harsh climate, huge distances to resources projects over their lifetime, and related technologies, and training CAPABILITIES cover and remote mining locations which can significantly reduce costs (including management-level training, are some of the challenges that the and improve efficiency. safety and environmental training and Australian industry has met with FURTHER technical training for operations and innovative and proven solutions to maintenance). INFORMATION transport resources successfully by rail Australia runs the world’s the heaviest from ‘pit to port’. Similarly challenging and longest heavy haul trains, with axle conditions exist in regions such as loads of 40 tonnes and train lengths the Middle East, Mongolia, South of 2.5 km or more. It is implementing America, North Africa and South Asia world firsts for heavy haul rail, including – and Australia has the capacity to train control centres located more deliver heavy haul and freight solutions than 1800km from the train networks, worldwide. driverless trains which operate 24 Training, safety and the reliable hours a day, every day, and fully continuous operation of pit-to-port automated maintenance facilities.

6 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL Image courtesy of Rail Skills Australasia Image courtesy

HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 7 PIT-TO-PORT AND EDUCATION AND A framework of education pathways INTRODUCTION has been pioneered by the INTERMODAL FREIGHT TRAINING Australasian Railway Association so INDUSTRY OVERVIEW SERVICES For any rail operation to run smoothly, that employees can progress their safely and reliably, a skilled and careers through continuous learning. Australia’s heavy haul capabilities are well-trained workforce is essential. Areas of learning with formalised INDUSTRY STRENGTHS closely linked to its position as a major Australia is a world leader in many accredited courses are: resources producer and exporter. fields of education and training, and The resources industry has led to the • rail infrastructure and rollingstock COMPANIES AND the rail freight and heavy haul sectors development of capabilities in long design are no different, providing training CAPABILITIES haul freight and innovative solutions • rail infrastructure construction and education for everything from to harsh conditions and remote capacity building for government • rail infrastructure maintenance FURTHER locations. Australian expertise in officials through to management, • rollingstock maintenance minerals transport also encompasses INFORMATION operational, technical and trades- the design and delivery of mine site • operations employee training related requirements. loading, port unloading and materials including drivers, train controllers handling facilities throughout Australia As well as engineering degree courses and freight handlers and overseas. provided by a number of Australian • signalling design and maintenance universities, Australia delivers a The logistics chain is very dependent • rail communications and networks wide range of vocational education on its longest arm – the railway. This • rail operations management and training options, some via the has meant that a number of systems including business continuity and Technical and Further Education have been developed in Australia RAMS (TAFE) system, relevant to the rail to schedule operations and permit freight sector. • track maintenance transparency of operations to all the • rail logistics and supply chain elements of the chain. Many of the management strengths Australia’s intermodal and freight rail sectors possess have been • rail safety management. developed from Australia’s heavy haul Further information can be found at rail capabilities. training.gov.au

8 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL ITTD delivers the right people Case study: training behalf of Transnet Freight Rail, the largest freight haulage company in In heavy haul and freight operations, Africa. ITTD worked with Transnet skilled personnel are as vital as state- in other areas, including advice and of-the-art equipment. Australian firm guidance on staff recruitment and International Transport Training and retention, organisational development Development (ITTD) has earned an and carrier paths, and continuing international reputation providing development of its training programs. experienced personnel and training services to the transport industry. • conducting an independent audit on training and competence, developing Since being established in 1996, ITTD has a competence matrix for drivers, expanded to open offices in the Middle and developing and delivering an East, the UK, South Africa and Dubai. advanced course for trainers on behalf Recent projects include: of RapidKL in Malaysia • measuring and evaluating skill sets of • specialist advice to Bovis Lend Lease revenue protection officers (Authorised Dubai on all facets of operations and Officers) for Yarra Trams in operator management for its Dubai to ensure they met the competency Metro project. This included a full requirements for a new government training needs analysis, investigating qualification and sourcing overseas development options and developing and delivering • providing engineering input for in-house, tailor-made training courses. maintenance documentation supplied for the Citadis tram operated by Yarra • delivering an international training Trams in Melbourne. program for freight rail drivers and on-job trainers, conducted in Melbourne and South Africa, on

Image courtesy of CERT

HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 9 TTG delivers savings all around the world Case study: fuel minimisation Energymiser® works by advising drivers technology how to achieve an efficient use of energy (fuel or electricity) based on a An in-cabin Driver Advisory System given location and specific arrival time. (DAS) developed in Australia is helping international rail operators save energy The system uses a control strategy and costs. based on algorithms developed by the Signalling and Control Group at The Energymiser® System, produced by the University of . It TTG Transportation Technology, provides automatically adjusts control and speed real-time driver advice and web-based profiles so that the train arrives at the reports that has typically achieved up to next target location at the specified 10 per cent savings for heavy haul trains arrival time, not just at the earliest in Australia, the UK and Africa (coal or time, while also minimising energy iron ore trains); to 10 per cent or more consumption. for freight trains in Australia, the UK and India; and 10 per cent to 20 per cent or Other benefits include improvements more for passenger trains in UK. Results in on-time arrivals of about 10 per depend on variables such as the terrain cent, reduction in braking reductions over which trains travel and the extent to of up to 30 per cent, which reduces which individual drivers comply with the maintenance costs, and smoother train real-time advice. handling due to increased coasting and reduced powering. The system is attracting growing industry attention. The UK rail operator First Group received an innovation award in 2012 for implementing Energymiser® on its high-speed train fleet.

Image courtesy of TTG

10 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL TECHNOLOGY AND The world’s first automated heavy haul INTRODUCTION network, incorporating driverless trains, INNOVATION is due to be launched in the Pilbara INDUSTRY OVERVIEW In response to the challenging region of Western Australia in 2014 demands of the environments and and 2015 by mining company Rio INDUSTRY STRENGTHS markets in which they operate, Tinto, which currently runs a 1 500km Australian firms produce a broad rail network to service its mining COMPANIES AND range of technologies to help increase activities. efficiency, reduce costs and assist Other Australian companies provide CAPABILITIES with asset management and resource software packages to optimise mine- optimisation, particularly for pit-to-port to-port logistics, including transport FURTHER infrastructure in remote locations. scheduling solutions. INFORMATION Driver assistance IT systems enable Innovations developed by Australian freight trains to reduce fuel use while companies and implemented maintaining schedules by processing throughout the world include: data including train type, weight, speed, fuel consumption, track • multi-array ultrasonic inspection conditions, GPS location and driving • rail grinding profile measurement techniques, then providing instructions • fuel optimisation that allow the driver to optimise power. • multi-factor railway alignment In-motion wagon weighing technology optimisation reduces stoppages and improves • weld parameter technology for efficiency by allowing trains of 300 stress relief in rail welds wagons or more to be weighed with • signal display and switching legal-for-trade accuracy at speeds of up to 100 km/hr. • longitudinal train dynamics simulation.

HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 11 RESEARCH AND Rail Innovation Australia, which was The Institute of Railway Technology INTRODUCTION created from the former Cooperative (IRT) at Monash University, Melbourne, DEVELOPMENT Research Centre for Railway is working on a number of projects INDUSTRY OVERVIEW Australian rail industry bodies Engineering and Technologies (Rail with heavy haul applications, such as: CRC), commercialises technologies and research centres are actively • increasing axle load capacity involved in developing products and and intellectual properties developed INDUSTRY STRENGTHS • improving vehicle components to technologies to enhance all aspects of by rail companies as well as increase service life and decrease rail transport, including the heavy haul Australian universities and institutes of costs COMPANIES AND and freight sector. technology. Its current projects include: • increasing rail life through better CAPABILITIES • Train Health Advisory System The Cooperative Research Centre understanding of wheel-rail (THAS), a low cost on-board train (CRC) for Rail Innovation links interaction FURTHER participants from major rail industry monitoring system for multiple • optimising ore train dumper companies throughout Australia and wagon use INFORMATION operations to reduce component New Zealand with several leading • Rail Noise and Wear Assessment damage and energy use. Australian universities. Its areas System, software for an on-board of research include climate and noise monitoring system that eng.monash.edu.au/railway environment, performance, safety and can identify areas of track in bad security, workforce development, smart conditions requiring attention technology and urban rail access. • D-Track – a computer-based model Current projects range from exploration that allows track engineers to model of future power technologies and track design, track modification and human factors analysis to building the effects of additional or worn best practice models for safety rollingstock on track. culture management, to development railinnovation.com.au of new steels for rail wheels, track stability management and life cycle management of bridges. railcrc.net.au

12 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 13 Image courtesy of Laing O’Rourke Image courtesy

14 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL The Centre for Railway Engineering The Commonwealth Scientific and INTRODUCTION (CRE), based at CQUniversity in Industrial Research Organisation Queensland, is applying a number of (CSIRO) is applying statistical, INDUSTRY OVERVIEW engineering disciplines to rail research. optimisation and simulation expertise Some of its current projects are: to assist the transport and logistics sector, including heavy haul, improve INDUSTRY STRENGTHS • Intelligent Train Monitor (ITM), an safety, and simulate and streamline in-cabin device that provides the processes to reduce costs. Recent train driver with information that can COMPANIES AND projects include: potentially save up to 15 per cent on CAPABILITIES energy consumption and improve • optimisation modelling for a coal rolling stock life producer that helped identify FURTHER • Train Health Advisory System capacity requirements and cost INFORMATION (THAS), a monitoring technology effective capacity improvement with the capability to detect flat initiatives, as well as software that wheels, hunting, abnormal wagon assists operators to create optimal behaviours, derailment and track rail schedules. irregularities • innovative simulation and • a prediction model to improve optimisation models for bulk materials management of track buckling risks like coal, minerals or agricultural and speed restriction settings commodities that can improve the efficiency of use of yard machines, • integrated wear-fatigue-lubrication observe constraints on the use of the models and economic models facilities, allow for maintenance and for assessment of rail-wheel streamline rail schedules. degradation and operational risks csiro.au/Outcomes/ICT-and- • design and testing of new insulated Services/TTL.aspx rail joints. cqu.edu.au/research/research- organisations/institutes/resource- industries-and-sustainability/ centres2/centre-for-railway- engineering

HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 15 TOUGH CONDITIONS, INNOVATIVE SOLUTIONS

Pit-to-port (P2P) Remote, harsh conditions (50°C) Need for reliability Heavy axle loads 27 mines Rail asset management Multiple operators Automated operations Narrow-gauge system and maintenance 5 ports, 220 million tonnes Remote train control PILBARA MINING REGION QUEENSLAND MINES AND PORTS

TRANSCONTINENTAL RAIL LINK

NSW MINES AND PORTS

3000km supply chain Multiple operators Remote condition monitoring Fuel minimisation Communications and data Coal and mixed operation Train control 200 million tonnes port Large intermodal terminals Simulation

16 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL AUSTRALIAN CAPABILITIES ARE IN GLOBAL DEMAND

Pit-to-port (P2P) Simulation Fuel minimisation Pit-to-port (P2P)

Pit-to-port (P2P) Simulation Simulation Remote, harsh conditions (50°C) Rail asset management

Pit-to-port (P2P)

Pit-to-port (P2P) Rail asset management

Narrow-gauge system

HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 17 INTRODUCTION PLANNING AND DESIGN SAFETY AND SECURITY With its long history of rail transport, Australian intermodal and heavy haul INDUSTRY OVERVIEW Australia has substantial experience in rail freight capabilities include products the planning and design of heavy haul and solutions to many aspects of and all types of rail infrastructure as well safety and security, as well as training INDUSTRY STRENGTHS as the rehabilitation and maintenance of and management. existing routes. In heavy haul railways, Trespassing and road vehicle incursions operations costs have been minimised COMPANIES AND are significant safety and security using grade and curve optimisation, CAPABILITIES problems that have been addressed while in intermodal tasks the need with the use of remote CCTV monitoring. for improved transit times has led to This has become more important with FURTHER innovation in curve design and structure increasing automation of systems. to permit higher speeds. INFORMATION Remote radiofrequency identification Specific engineering capabilities include: (RFI) tagging has substantially improved consignment tracking. • alignment design • environmental planning Other areas of innovation and expertise are: • construction and track laying • tunnelling and bridges • fire detection and response • rail management in welding, grinding • remote monitoring and detection and inspection for tunnels, railyards, tracks and unattended or secure locations • geotechnical analysis • video surveillance and analysis • simulation and modelling • train schedule monitoring • remote asset protection and • track maintenance and detection of monitoring damage or obstructions Australian companies are designing • railway crossing management and and delivering rail infrastructure and detection of objects on the line engineering services for freight and • detection and recognition of heavy haul rail all over the world, overspeeding including recent projects in Africa, Middle East, Asia and South America. • detection of objects protruding from moving freight trains.

18 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL Aurizon leads the way Case study: heavy haul and As well as coal, Aurizon is Australia’s intermodal complex network largest haulier of iron ore outside the capability Pilbara region and is an integral supply chain partner, with customers exporting Australian company Aurizon is a leader through three major ports on the west in bulk freight, logistics and infrastructure coast. solutions. Every day, Aurizon moves thousands of tonnes of coal, iron ore With a national rail network covering all and other minerals as well as agricultural major states and with 40 distribution and general freight around the country, centres across Australia, Aurizon’s including more than 500000 tonnes of intermodal business provides vertically coal each day bound for international integrated rail and road solutions. It also markets such as Japan, China, India, has a network of regional maintenance South Korea and Taiwan. It is one of depots and heavy maintenance the world’s largest rail transporters of workshops to deliver all aspects of metallurgical coal from mines to ports for rollingstock maintenance. export markets. Aurizon operates and manages the Central Queensland Coal Network, the largest export coal rail network in Australia, comprised of 2670 km of heavy haul rail infrastructure. The system schedules scores of train movements daily in a logistics process that transports coal from the loaders at the mines to the conveyor systems for ship loading at major export ports.

Image courtesy of Aurizon

HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 19 Trimble has the plan for project success Case study: alignment agency, stakeholder and community planning software needs and concerns. Where a benchmark alignment is available, Identifying the best corridor and Quantm has also enabled government ultimately the right alignment for planning departments, engineering transport projects can make a big consultants and civil contractors alike to difference to their cost and overall identify significant capital construction viability. Software developed in Australia cost savings and reduce long term is helping planners and engineers operating costs. find optimised alignments quickly and economically while addressing social in Western and environmental considerations. Australia used Quantm to minimise environmental impacts and maintenance Created in the 1980s by the Australian costs for a 280 km open-access, heavy- Government as a CSIRO research haulage railway, completing the project project and commercialised in 2000, in just nine months. The Trimble® Quantm® alignment planning system was quickly adopted Quantm has been chosen by many by governments and private companies governments and private companies for around the world. In 2006 Quantm was planning major infrastructure projects, purchased by navigation and positioning including high-speed rail, regional technology specialists Trimble, who rail and freight rail, in Australia, New established the Melbourne-based Zealand, the US, Canada, Mexico, Trimble Planning Solutions Pty Ltd. India, China, Portugal, Brazil, Malaysia, Indonesia, Mongolia and Russia. The The result of a unique mathematical technology has also been used on algorithm, Quantm enables the project a broad range of road and highway team to analyse alignment options projects, including mine haul roads. efficiently while also considering client,

Image courtesy of Trimble

20 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL ENGINEERING Methods used to improve project INTRODUCTION timelines, functional outcomes and Short project timelines have seen environmental targets are: INDUSTRY OVERVIEW the Australian engineering sector implement modern methods of survey • LIDAR (Laser) survey for 2mm and drafting that work together with accuracy INDUSTRY STRENGTHS contractors who may be appointed • GIS (Geographic Information at the same time or in cooperation System) for information layering COMPANIES AND with the engineering organisations. • BIM (Building Information CAPABILITIES Engineering, Procurement and Management) for 3-D representation Construction Management (EPCM) of structures and interface of railway FURTHER combines the two activities. with loading/unloading facilities Delivering projects to timelines and • on-site testing and commissioning INFORMATION accuracy of engineering requires with GPR (Ground Penetrating layering of activities and high levels of Radar) and on-site validation tools communication between engineers, • engineering software permitting drafters, contractors, material interactive ‘mark-up’ facilities suppliers and clients. • use of global resources placed in other countries permitting same day turnaround.

HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 21 PROJECT RISK Australian engineering and INTRODUCTION construction companies have MANAGEMENT developed new and unique methods INDUSTRY OVERVIEW Resource and intermodal projects and expertise in the implementation of need fast response times in order contractual engagement by using: INDUSTRY STRENGTHS to meet financial targets. For this • EPCM (Engineering, Procurement reason, commercial projects may be and Construction Management) required to meet faster implementation • ECI (Early Contractor Involvement) COMPANIES AND timelines than similar-sized CAPABILITIES government social projects. • Double ECI (Competitive Tender ECI) • PPP (Public Private Partnership) The boom in Australian resource FURTHER development has stimulated miners, • Equity Participation INFORMATION engineering and construction • BOOT (Build Own Operate Transfer) companies to look for new ways to These methods provide opportunities improve the delivery timeframes without to distribute risk and rewards fairly incurring additional costs or risk. throughout the partnership and has led to many examples where all parties have been able to benefit from expedited project delivery.

22 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL Track IQ technology keeps ore trains on the move Case study: wayside monitoring • RailSQAD (Railway Squeal Acoustic technology Detection System), an acoustic array system that measures wheel Australian firm Trackside Intelligence speed and direction and wagon Pty Ltd (Track IQ) is building a global identification AEI tags, uses advanced reputation as a specialist manufacturer signal processing techniques to and supplier of wayside detection follow individual wheelsets of a train equipment to the railway industry. and records and analyses the noise Reliability is vital in remote mining emitted by wheel/rail interaction operations, and in the Pilbara district, • PhotoTag, a wayside high-speed all major mining companies rely on a camera that captures vehicle technology developed by Track IQ for identification during pass by without acoustic monitoring of railway wheel the need for RFID vehicle tagging. bearings, the Railway Bearing Acoustic Track IQ also works with other industry Monitor (RailBAM). RailBAM can detect specialists to integrate a wide range and monitor bearing faults in heavy of wayside sensors (such as bogie haul wagons at speeds of 25-160 km/hr, geometry, wheel profile and brake minimising expensive delays associated wear sensors) into asset monitoring with vehicle setouts when bearing ‘Supersites’ where sensor data is failures are detected by traditional integrated into the Track IQ-developed thermal monitoring systems. FleetONE database, allowing the system Other Track IQ sensor systems include: owner to perform scheduled condition monitoring reporting, fleet analysis and • Wheel Condition Monitor (WCM), repair scheduling. a trackside system that can detect wheel spalls, shelling, surface Currently Track IQ has over 120 systems roughness and long period defects installed worldwide.

Image courtesy of Track IQ

HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 23 SMEC builds success in Bangladesh Case study: infrastructure and embankment and construction of new engineering embankment for bridge approaches alongside the existing operating main With over 30 years of experience line. The new embankment of more in railway engineering consultancy than 2 million cubic metres is intended services, Australian company SMEC has to accommodate future broad gauge undertaken a range of projects from the (BG) tracks. Geotechnical investigations design of new routes for urban, main undertaken identified unstable line and provincial railway networks to foundation conditions over 20 km of the rehabilitation and maintenance of the length requiring specific soft ground existing routes. treatment including PVD and sand piles SMEC focuses on the practical to be undertaken during embankment application of advanced technologies construction. to provide innovative, cost-effective and SMEC provided the Project Manager appropriate solutions. The company (Engineer) as well as specialists in also has significant experience in the railway design, bridge design and delivery of large infrastructure projects construction, geotechnical matters using Design and Construct, Private (including review of the contractor’s Public Partnerships and Alliance delivery geotechnical investigations and soft models. ground treatment designs), track and In late 2011, SMEC was the lead signalling works. consultant and engineer for the Tongi- With 5000 employees worldwide, SMEC Bhairab Bazar Double Line Project operates from an established network in Bangladesh, which involved the of more than 70 offices in Australia, Asia, construction of 64 km of main line and the Middle East, Africa and North and 22 km of loops and sidings, widening of South America.

Image courtesy of SMEC

24 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL CONSTRUCTION AND The Australian construction industry INTRODUCTION now utilises: CONSTRUCTION • LIDAR (Laser) aerial surveying for INDUSTRY OVERVIEW MANAGEMENT accurate knowledge and control of Influenced by the vast number of cut and fill requirements INDUSTRY STRENGTHS resource based projects, railway • alignment designs capable of taking construction in Australia has modified into account available materials for COMPANIES AND its approach in many ways to improve construction CAPABILITIES environmental outcomes, reduce • mobile crushing plants and materials cost, reduce risk and implement handling projects faster. The techniques now • prefabricated solutions for structures FURTHER used to balance these goals are global best practice. • Procurement and Construction INFORMATION Management (PCM) and other ‘fast Construction starts with design, implementation’ contract techniques but also includes the correct use • ‘best for project’ fly-in fly-out of machinery and making the best workforces possible use of materials at hand. • cooperative and flexible partnering approaches based on relative strengths and capabilities.

HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 25 ENVIRONMENTAL Design and construction principles • positioning of precasting and INTRODUCTION have been shaped by the awareness manufacturing locations to reduce SUSTAINABILITY that 30 to 50 years of operation transport footprint INDUSTRY OVERVIEW Australia is justifiably proud of its will follow the construction, so that • containment provisions for record on environmental sustainability the effect of the operation on the chemicals and other polluting INDUSTRY STRENGTHS when it comes to project management environment is likely to be higher than materials that of construction alone. and railway development. • zero spillage, zero overfill fuel COMPANIES AND The sustainability equation starts at Australian companies have used management and transfer systems the beginning of a project and carries design, construction and operation • ‘off-set’ creation for instances of last CAPABILITIES through design, construction and principles such as: resort FURTHER operation. • alignment optimisation for • end of lifecycle planning, including Australian railway construction minimisation of corridor footprint on restoration INFORMATION companies have now achieved environmentally sensitive areas • waste minimisation, energy and close to zero impact on the • alignment optimisation for water saving technologies and landform footprint with the use of minimisation of fuel in balance with practices in rail network operations material recycling and reprocessing, other potential ‘pollutants’ and maintenance. construction of fauna natural habitat • waterway design to promote natural and water management. flow through greater use of culverts Design plays a major role in the and ‘wet areas’ achievement of these goals: not only • use of all available materials by the the design of the finished product, addition of ‘enhancers’ where usually but also for temporary works during understrength construction and use of materials.

26 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL IRT reduces the burden of track maintenance Case study: remote monitoring instrumentation and data collection systems, which can be integrated A novel approach to track condition into ore trains running on the regular assessment developed by Monash schedule. Track condition data is University’s Institute of Railway recorded continuously while the vehicles Technology (IRT) is reducing downtime are in operation and transmitted back for heavy haul operators in Australia to a central base at the IRT facilities at and internationally. Monash University’s Clayton campus Conventional assessment involves using for processing and reporting once the a dedicated track recording vehicle vehicles are in mobile phone range. to travel along the line, which means Having engineered the IOC for operation assessments must be fitted in to busy in remote and harsh environments, rail schedules and around the availability solving challenges such as power supply of recording vehicles. It also requires and the need to withstand loading additional processing of results to take and unloading movements, the IRT is into account the different effects of a now supplying its technology around comparatively light recording vehicle the world. There are now 70 IOCs in and a fully loaded heavy haul train operation, including three in Brazil which travelling at speed on the same track. are used by iron ore miner Vale on the Developed in 2002, the IRT’s major Estrada Ferro Carajás and Vitória Instrumented Ore Car (IOC) overcomes a Minas railroads. many of these limitations. It is a standard track car, fitted with custom-designed

Image courtesy of IRT

HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 27 CSIRO is helping haul transport into the future Case study: planning and simulation stockyard expansions, rail duplications, inloader/outloader upgrades. CSIRO research is helping mining and freight companies plan for the future CSIRO research into rollingstock and as well as optimising their current materials handling design has produced operations. innovative physical simulation platforms that account for particles, fluid flow The Infrastructure Futures Analysis and free surfaces. These have been Platform (IFAP), a GIS-based freight applied to coal hopper wagon designs transport network optimisation tool to evaluate unloading times and identify co-developed by CSIRO and the optimal rail wagon designs vehicle Queensland government, uniquely designs based on discharge time and combines layers of maps with a transient stress loading of the wagon mathematical optimiser and allows walls. Discharge time depends on coal planners to determine the infrastructure flowability, which is a complex function needed to ensure efficient, cost-effective of particle size and shape distributions, transport from mines to port and material properties and cohesive forces processors up to 25 years ahead. in wet coal. Other CSIRO freight planning platforms The same technologies have been include long-term capacity planning applied to material handling equipment modules. These are used by the Hunter that is integral to bulk rail infrastructure Valley Coal Chain Coordinator (HVCCC) such as conveyors, chutes, hoppers, to select future assets. They also drive reclaimers, dump stations and silos. simulation studies of whole-of-chain future performance, with options for modelling inland coal terminals,

Image courtesy of CSIRO

28 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL ABOVE-RAIL SYSTEMS a number of innovative methods INTRODUCTION and products to support its asset Most resources and railway logistics management principles and the INDUSTRY OVERVIEW chains in Australia have been operation of above-rail assets such as: developed in remote regions where there is little access to maintenance • driver support fuel optimisation INDUSTRY STRENGTHS and repair services. As a result, the software workshop repair facilities created in • CBCT (Communications Based Train COMPANIES AND these locations have had to be highly Control) for freight train application CAPABILITIES self-sufficient and they rely on highly • lightweight heavy axle load ore cars reliable and maintainable equipment. (40 tonne axle load) design FURTHER Australia is a world leader in the • driver relay methods, reducing train management of its above-rail assets, stop requirements INFORMATION locomotives, wagons and asset • aerodynamic ore car design protection (bearing, wheel, dragging • ECP (Electronic Controller Brake) equipment and flood detection) implementation equipment. • robotic and automated wheel, axle Management of above-rail systems and wagon repair is highly dependent on the asset • combined ‘hot bearing’, ‘hot wheel’, management methods used and also ‘flat wheel’, ‘angle of attack’ and on innovation in areas like condition ‘sonic signature’ technology monitoring and repair equipment. • network scheduling optimisation. Australian companies have developed

HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 29 OPERATIONS AND • driver related human factors analysis • wagon weighing technologies, INTRODUCTION and implementation including drug including high speed in-motion MAINTENANCE and alcohol and fatigue avoidance systems INDUSTRY OVERVIEW Australian companies offer solutions for • information systems for customers • highly accurate, zero spillage fuel all aspects of heavy haul rail operations including operations control management and transfer systems INDUSTRY STRENGTHS and maintenance, plus innovative transparency in multi-operator with flow rates of up to 1000 litres technologies for extending the life of rail environments per minute COMPANIES AND lines, rolling stock and equipment. • signalling systems design and • wheel and wheel bearing condition In operations, Australian companies manufacturing monitoring systems CAPABILITIES have optimised fuel consumption, • railway workshop equipment, • wayside sensor systems that can improved reliability in supply chains such as lathes, wheel and bearing measure the operating condition of FURTHER and reduced maintenance costs in presses, drop tables, and test rail vehicles INFORMATION harsh and remote environments to equipment • innovative track monitoring and improve cost competitiveness. • workshop automation enabling high inspection systems and solutions Some examples of Australian expertise productivity and improved safety using ultrasound, eddy currents, in this area are: • rail welding, repair and profiling thermal imaging, video-optical, equipment and training mechanical and electronic • operations simulation, network technologies. scheduling and capacity • extending rail life with rebuilding, improvement repairing and recycling technologies

30 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL ATTAR brings inspection technology up to speed Case study: automated inspection to identify components that do not and maintenance meet established criteria for Atlas Rail, an Australian supplier of high quality Australian company ATTAR has machine tools and engineering services developed an automated process for to the rail industry. rail vehicle component inspection that delivers accurate flaw detection and Designed by ATTAR and built by measurement of residual stresses in an Atlas (a division of Marand Precision entire rail wheel set in just eight minutes. Engineering), the new Wheel Qualifying Machine (WQM), is expected to run Non Destructive Testing (NDT) has been for 20 years. Fully automated and a crucial part of the rail industry since operator-configurable, the WQM can its inception. With increased rail traffic run in full cycle, individual testing or at higher speeds and with heavier axle manual modes. Integrating accurate loads today, critical crack sizes are measurements into systems allows shrinking, while efficiency and access rail maintenance planners to move to to historical information are becoming condition maintenance, which in turn more important. helps optimise asset availability while As well as time savings, automated reducing costs. The WQM is now part inspection of components offers of Atlas Rail’s product range and is the benefits of accurate, repeatable currently in operation at BHP’s facilities collection of data that can be analysed, in Port Hedland. evaluated and categorised according to set criteria. Using Phased Array Ultrasonics and EMAT (ElectroMagnetic Acoustic Transducers), ATTAR developed an accurate and repeatable means

Image courtesy of ATTAR

HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 31 No slowing down for Meridian Case study: train loading and with legal-for-trade accuracy better than in-motion weighing technology 0.5 per cent. Reliable train loading systems and Major mining company BHP Billiton’s accurate weighbridges are essential BHPBIO high-speed train weighbridges for mining operations, and Australian at Port Hedland and Newman (Western consultancy Meridian Engineers is Australia) weigh 30000 tonne trains producing state-of-the-art systems on the move at speeds up to 80 km/h. that combine high-speed performance Project requirements included the with international legal trade accuracy capacity to handle thousands of trains standards. each year (equating to millions of wheel crossings) without any operator input, Its Train Loading Improvement System to withstand extreme environmental (TLIS) controls in real time the loading conditions (cyclones, frequent lightning of wagons to better than 1 per cent strikes and ambient temperatures up tolerance. Because operators can be to 50° C) and achieve 99.9 per cent confident that the wagons will be loaded availability. The system also needed to an accurate level, in some cases to comply with international legal it has allowed them to bring in larger trade accuracy requirements. Meridian wagons as authorities had confidence Engineers is one of the few companies in they would be loaded accurately and the world with the skills and technology comply with the stringent local rail to have achieved these results. infrastructure limits on wagon loads. Its in-motion train weighing systems can weigh ore, freight and passenger trains from 0-100 km/h and in excess of 300 wagons length with multiple locomotives,

Image courtesy of Meridian

32 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL ASSET MANAGEMENT Railways have a special place in most • cost implication analysis INTRODUCTION pit-to-port or logistics supply chains • work order-based maintenance and Asset management begins with good because they are the longest and most project controls design and construction, but extends vulnerable arm. A railway has no easy INDUSTRY OVERVIEW • sophisticated fuel management and throughout the 30 to 50 year life of a ‘bypass’ available if it is not working. project to optimise the performance transfer systems. INDUSTRY STRENGTHS and cost of the railway and its mining Methods used for effective asset venture or intermodal distribution management in Australia’s railways COMPANIES AND network. have included: CAPABILITIES RAMS (Reliability, Availability, • ‘design to completion’ mentality, Maintainability and Safety) discipline is involving training and reinforcement FURTHER used to deliver the outcomes needed from all levels of management from the mine or logistics chain while • ‘management by measurement’ INFORMATION at the same time minimising costs approach over the full life of the project. • condition monitoring Asset management requires a whole- • condition-based maintenance workplace culture that looks to the • failure analysis and mitigation future and training of all levels of strategy management.

HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 33 INTRODUCTION INDUSTRY OVERVIEW INDUSTRY STRENGTHS COMPANIES AND CAPABILITIES FURTHER INFORMATION

The following table provides some examples of companies and their capabilities. Contact your local Austrade representative for assistance with connecting with the Australian businesses that best suit your requirements.

austrade.gov.au

34 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL • Provides advice/consulting • Supplies product, technology or service • Conducts research • Provides training or education

Company name Operationsasset and management maintenance,Planning and designTraining, andeducation personnel Signalling Rolling stock,and components systems Railway systemsinfrastructure, and components Intermodal freight solutionsLoading and unloading Projectsolutions risk managementProcurement Research and developmentEngineering Constructionmanagement and constructionEnvironmental sustainabilitySafety, testingmonitoring and solutions Aldridge Railway Signals • ATTAR • • • • • • • Australian Turntable Company • Abigroup Contractors • • • • • • • Aurecon • • • • • • • • • • • • • • Aurizon • • • • • • • • • • • • • Austrak • Australasian Transport Risk Solutions (ATRS) • • • • • Banlaw • • • • • Battery Energy Power Solutions • • • • Bradken • • • • • • • • Calibre Global • • • • • • • • • • • • • • C.A.T.E.R. • • • • Centre for Railway Engineering, CQU • • • • • • • • • • Centre for Excellence in Rail Training (CERT) • • • • • Coffey Geotechnics • • • • • Comsteel • • CQUniversity and Train@CQUniversity • • • • • •

HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 35 • Provides advice/consulting • Supplies product, technology or service • Conducts research • Provides training or education

Company name Operationsasset and management maintenance,Planning and designTraining, andeducation personnel Signalling Rolling stock,and components systems Railway systemsinfrastructure, and components Intermodal freight solutionsLoading and unloading solutionsProject risk managementProcurement Research and developmentEngineering Constructionmanagement and constructionEnvironmental sustainabilitySafety, testingmonitoring and solutions CRC for Rail Innovation • • • • • • • • • • • • C.S.I.R.O. • • • • • • • Gemco Rail • • • • • • • • GHD • • • • • • • • • • • Hardface Technologys • • HMA Techniplan • • • • ÷ Inspired Systems • • • • • • • • • • Institute of Railway Technology (IRT) • • • • • • • • • • International Transport Training & Development • • • • • JD Rail • • John Holland • • • • • • • • • Laing O'Rourke • • • • • • • • • • MRX Technologies • • • • • • • • Keech Australia • • Marand (Atlas Rail) • • • • • • • • • • Melvelle Equipment Corp • • Meridian Engineers • • • • • •

36 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL Company name Operationsasset and management maintenance,Planning and designTraining, andeducation personnel Signalling Rolling stock,and components systems Railway systemsinfrastructure, and components Intermodal freight solutionsLoading and unloading solutionsProject risk managementProcurement Research and developmentEngineering Constructionmanagement and constructionEnvironmental sustainabilitySafety, testingmonitoring and solutions OEM Technology Solutions • • • • • QUT • • • • • • • • Rail Personnel • Rail Skills Australasia • • • • • • • • • • • • Sedgman • • • • • • • Sinclair Knight Merz • • • • • • • • • • • • • • SMEC • • • • • • • • • • SolveIT Software • • • TAFE NSW • • • • • • • • TSG Consulting • Trackside Intelligence • • • • Trakblaze Global • • • • • • • • Trimble Planning Solutions • • • • • • TTG Transportation Technology • • • • • • • • • UGL • • • • • • • • • • • • • University of Wollongong • • • • • • • • • • • WorleyParsons • • • • • • • • • • • • • •

HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 37 GOVERNMENT AND The Rail Supplier Advocate is part INTRODUCTION of the Australian Industry Participation INDUSTRY ASSOCIATIONS Plan run by the Department INDUSTRY OVERVIEW The Australasian Railway of Industry and works to raise Association (ARA) is a not-for-profit competitiveness of Australian rail INDUSTRY STRENGTHS member-based association that suppliers, promote capabilities and represents passenger, freight, track, link suppliers to customers. manufacturing, construction, supply innovation.gov.au/Industry/ COMPANIES AND and other rail companies in Australia AustralianIndustryParticipation/ CAPABILITIES and New Zealand. SupplierAdvocates/Pages/ ara.net.au RailSupplierAdvocate.aspx FURTHER The Industry Capability Network Rail Skills Australasia is a not-for- INFORMATION (ICN) is a business network for profit industry body that provides Australian and New Zealand workforce education and training companies. The ICN Rail Directory is advice across the rail industry. an Australian government initiative rsa.org.au to help link buyers and suppliers of The following are some of the products and services. government and industry bodies rail.icn.org.au involved in the Australian heavy haul and freight rail industry.

Contact your local Austrade representative about connecting and partnering with the Australian heavy haul and freight rail industry.

38 HEAVY HAUL, INTERMODAL AND FREIGHT RAIL The Australian Trade Commission – Austrade – is the Australian Government’s trade, investment and education promotion agency. Through a global network of offices, Austrade assists Australian companies to grow their international business, attracts productive foreign direct investment into Australia and promotes Australia’s education sector internationally. Austrade helps companies around the world to source Australian goods and services. We can help you reduce the time, risk and cost involved in sourcing suppliers by: • helping you identify and contact Australian suppliers • providing insight on Australian capabilities • alerting you to the latest products and services out of Australia to help you grow your business. Austrade partners the strengths of Australian businesses with the needs of international markets. We can open the door to a world of opportunities for your business.

austrade.gov.au

HEAVY HAUL, INTERMODAL AND FREIGHT RAIL 39 austrade.gov.au