Rocktec partnered with the Port Hedland Port Authority to design and deliver a high-capacity mobile feed hopper system for the UTAH Point Berth project in Western Australia. Built to handle demanding ore transfer operations, this rail-mounted hopper train supports bulk material movement directly from loaders to conveyor systems. As a result, it improves both operational efficiency and site mobility.
Project Overview: Mobile Hopper Train for Bulk Ore Handling
- Client: Port Hedland Port Authority
- Location: Port Hedland, Western Australia
- Industry: Port Infrastructure & Bulk Material Handling
- Scope: Design and fabrication of six mobile feed hoppers with integrated apron feeders
- Completion: UTAH Point Berth project timeline (year not specified)
The Challenge: Time-Critical Ore Handling Solution
The Port Authority needed a robust, high-throughput ore handling system capable of feeding a 1500mm belt conveyor directly from front-end loaders. Moreover, the system had to travel 280 metres along rails, deliver consistent output, and meet a tight project deadline. Therefore, Rocktec had to deliver a solution that was both powerful and fast to deploy.
Rocktec’s Solution: Rail-Mounted Mobile Feed Hopper Train
To meet these demands, Rocktec engineered two trains of three mobile feed hoppers, designed to operate as a coupled unit. Each hopper was rail-mounted and built for high-capacity ore transfer. The system included:
- Six mobile hoppers (two trains of three)
- Each hopper delivered 2750 tph via a 1700mm wide apron feeder
- D4 salt chain for long-term durability and performance
- Integrated 1500mm belt conveyors for smooth material handling
- Control/MCC rooms for each train to ensure accurate operation
Furthermore, Rocktec’s in-house team in Matamata completed all design and fabrication. To avoid delays, they chartered a dedicated ship and transported nearly 700 tonnes of preassembled equipment directly to site. This move eliminated on-site reassembly and reduced overall installation time.
Implementation Process: Designed, Built and Delivered on Time
- Design: Engineers developed hopper and feeder systems to match loader height and desired throughput.
- Fabrication: The manufacturing team constructed all units using high-strength steel and custom controls.
- Shipping: Rocktec chartered a ship to deliver the units preassembled—bypassing disassembly delays.
- Deployment: Technicians installed the system quickly, allowing commissioning to proceed on schedule.
Results and Benefits
- Rapid Delivery: Modular fabrication and direct shipping allowed Rocktec to meet the project timeline.
- High Throughput: Each mobile feed hopper achieved 2750 tph, maximising ore transfer rates.
- Mobility: Rail-mounted trains travelled 280m, enabling flexible loading operations.
- Reliable Performance: Rugged components ensured low maintenance and consistent flow.
Conclusion: Proven Mobile Feed Hopper Design for Heavy-Duty Port Applications
This Port Hedland project demonstrates how Rocktec’s mobile feed hopper systems can transform high-volume port operations. By combining rail mobility, modular design, and high-capacity output, this solution delivered performance under pressure—and on time.
Want to Learn More?
To explore bulk handling trends and global project insights, visit the Australian Bulk Handling Review.
If you’re planning a high-capacity bulk material handling system or a custom apron feeder solution, contact Rocktec today to discuss your requirements.