The Project

In June 2024, Rio Tinto and DCI Electrical began addressing the deteriorating condition of an existing steel culvert beneath a crucial mining railway line in Karratha, WA. The culvert had surpassed its service life, showing heavy corrosion that raised significant safety concerns for the active railway, which operates 24/7. After careful consideration, relining the culvert was identified as the most effective and efficient solution to extend its service life while minimising disruption to the railway operations.

The Challenge

The project faced multiple challenges due to the unique environmental conditions and site constraints. The culvert was located in a coastal area with high levels of alkalinity, leading to a highly corrosive environment that had deteriorated the steel structure over time. This posed a major risk for any future installations if materials were not chosen wisely. Additionally, the proximity of the railway line and ongoing operations limited access and complicated the logistics of the installation, requiring a precise plan to ensure minimal disruption and maximum safety.

Our Solution

Global Synthetics proposed the use of Dur-a-Span Pipe Arch, an aluminium product that could withstand the corrosive conditions of the site far better than traditional steel. Aluminium’s natural resistance to corrosion made it the ideal material for the coastal location. To ensure a successful installation, Global Synthetics’ technical team visited the site before construction commenced. We collaborated closely with the contractors, discussing potential obstacles and proactively developing strategies to mitigate any issues that might arise.

Thanks to this thorough preparation, the installation process proceeded smoothly and was completed without any significant issues, ensuring the longevity of the culvert and maintaining the safety of the railway above

If your project faces similar environmental or structural challenges, Global Synthetics offers tailor-made solutions backed by expert technical support. Contact us today on 02 9725 4321 to discuss how our innovative products like Dur-a-Span can provide long-lasting, reliable results for your infrastructure needs.