Rocktec partnered with Thiess Pty Ltd to deliver a purpose-built remotely operated feed hopper for the Onesteel Project Magnet in Whyalla, South Australia. This rail-mounted solution was engineered to transfer iron ore from the stockpile to an overland conveyor system—boosting safety, control, and productivity in a demanding mining environment.
Project Overview: Remote-Controlled Ore Transfer System
- Client: Thiess Pty Ltd
- End User: Onesteel (Project Magnet)
- Location: Whyalla, South Australia
- Industry: Iron Ore Handling
- Scope: Design and supply of a remotely operated mobile feed hopper
The Challenge: Controlled Ore Transfer Across Stockpiles
Thiess required a remotely operated feed hopper that could travel up to 175 metres along a rail track to access various iron ore stockpiles. Moreover, the system had to be operable from both the wheel loader and the central control room. This would ensure safer handling, reduce manual movement, and improve blend accuracy across the different ore grades.
Rocktec’s Solution: Smart, Mobile Rail-Mounted Hopper System
To meet these needs, Rocktec designed and built a custom solution that combined mobility, control, and resilience. As a result, the system could move along the rail line with precision while supporting continuous material flow. The final unit featured:
- A 7.2m long apron feeder with 1.2m wide pans and a D4 salt chain
- An integrated hopper capable of handling dense iron ore
- Feed capacity exceeding 150 tph for reliable performance
- A Motor Control Centre (MCC) to enable remote operation
- A cable reeler system to manage movement across 175m of track
Additionally, Rocktec reinforced the hopper’s structure to endure the harsh Whyalla site conditions. With this system, operators gained a safer, more efficient way to manage material transfer with minimal effort.
Implementation Process: From Planning to Performance
- Consultation: Rocktec worked closely with Thiess to assess their material flow, operational layout, and control requirements.
- Engineering: The design team developed a tailored feeder system that combined mechanical stability with automated control logic.
- Fabrication: Rocktec manufactured the entire unit in-house, using high-quality materials and rigorous testing protocols.
- Delivery: Following assembly, the system was shipped as a complete package and installed quickly to meet project deadlines.
Results and Benefits
- Flexible Operation: Operators can control the hopper from a loader or central station—improving safety and speed.
- Efficient Flow: Iron ore moves directly from stockpile to conveyor with minimal loss or interruption.
- Smooth Mobility: The rail-mounted system, guided by a cable reeler, enables precise travel between stockpiles.
- Long-Term Durability: Robust design ensures the system can handle abrasive materials and heavy loads daily.
Conclusion: Smart Material Movement for Modern Mining
This project highlights Rocktec’s ability to engineer advanced remotely operated feed hopper systems for high-output mining sites. By combining remote control, rail-mounted mobility, and reliable performance, Rocktec enabled Thiess to optimise ore transfer while reducing risk and improving operational control.
Want to Learn More?
For insights on conveyor-fed hopper systems and bulk handling innovations, visit the Australian Bulk Handling Review.
If you’re planning a rail-mounted feed hopper or an automated ore handling system, contact Rocktec today to explore your options.