McCoy Crusher Wall and Rom Tip

Design and Analysis Pty Ltd was engaged to deliver a comprehensive engineering solution for the McCoy Crusher Wall Replacement project at Alcoa's Huntly Mine. The project involved replacing a structurally degraded retaining wall and verifying the structural integrity of the ROM Tip Bridge to support the relocation of a 160 Crusher from Myara to McCoy.

The new wall was designed for a ten-year service life and to accommodate up to 18 million tonnes of bauxite annually. Using advanced digital engineering tools, including 3D finite element modelling and structural analysis software, the team developed detailed models and drawings to optimise the wall geometry, reinforced concrete elements, and load-bearing components.

The design accounted for heavy vehicle loads, tipping forces, braking impacts, and environmental conditions, including wind and seismic activity. Wall panels were precast and reinforced to withstand high localised pressures, while the sill beam and deadman anchor system were engineered to safely and efficiently transfer loads.

The ROM Tip Bridge was independently verified to accommodate large mining vehicles, with all steel members and connections satisfying strength and deflection requirements. Safety in design was a key focus, with measures incorporated to reduce construction risks, improve long-term durability, and facilitate the safe deconstruction of the existing wall.

Services and drainage systems were fully integrated into the design, including cable pits, water pipelines, and electrical utilities. Overall, the project demonstrated a high level of engineering precision, digital modelling, and structural compliance, delivering a robust solution to support Alcoa's ongoing mining operations.