Grande Côte Mineral Sands Infrastructure Upgrade

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  • OfferingsBulk materials handling, Heavy haul rail and transportation systems
  • CommodityMineral Sands
  • LocationSenegal, West Africa
  • ClientGrande Côte Operations SA
  • Timeframe2011-2013
  • ServiceEPC/EPCM

Award winning EPCM Services for Rail & Port

Ausenco provided engineering, procurement and construction management (EPCM) services for the rail and terminal infrastructure for TiZir’s Grande Côte Mineral Sands Project in Senegal, West Africa.

The project won the 'Premier Transport Project of the Year' Award at the 8th African Transport Awards held in Johannesburg, South Africa. The award recognised Ausenco’s contribution in the areas of innovation, meeting challenges, impact and effectiveness, operational excellence and safety.

The scope of the project included the design of 22 km of new track including earthworks connecting the client’s new mine site load out to existing track infrastructure.

Ausenco was also responsible for designing the port track infrastructure, port material handling and storage facilities for 90,000 tonnes of bulk product, a port container facility, and port ship loading facilities for the export of bulk material.

Procurement and expediting of all equipment, construction materials and sub-contractor contracts was completed by Ausenco in addition to construction management.

Construction included:

  • 22 km of new track construction, including mine load out tracks, excluding earthworks
  • 30 km of abandoned single track rehabilitation
  • 25 km of operating single track railway repair work and replacement of two bridges
  • 65 km of operating multi-track railway repair (one track plus 12 crossovers)
  • Port material handling and ship loading facilities, including the supporting rail track infrastructure

This project delivered high value, fit-for-purpose solutions such as:

  • Tri-Gen set fuel saving locomotives
  • Specially designed top loading, bottom dump wagons
  • A curved pipe conveyor for dust controlled delivery of ilmenite to shipside portable ship loaders

Safety plan

A strong safety culture was developed, implemented and adhered to for this project which resulted in the project surpassing 2 million man hours without an LTI; and the multi-disciplined project sites of all contractors achieving 4 million man hours worked without an LTI.

These statistics are a reflection on how a well-planned and delivered safety program can be successfully followed in a location that has previously had no safety culture.

“This kind of performance, given the wide spread and varied works fronts and the large number of people on the job, is very impressive and reflects the high safety focus of the Ausenco team.”

Adam Smits, Project Manager, Grande Côte Operations SA

The project will be one of the largest producers of zircon in the world with production estimated at 85,000 t/y of zircon and 575,000 t/y of ilmenite.

This rail and port infrastructure component of the project follows on from a feasibility study completed by Ausenco in 2011-2012.