Engineering Design
Lumsden Point
Project Management
The Lumsden Point development will create an additional two berths in Port Hedland to alleviate increasing congestion and constraints on existing general cargo infrastructure, as well as facilitate forecast trade growth in the Pilbara. The project required urgent, high-level project support to manage the complex development and coordinate multiple contract parties under strict timeline constraints.
AIE engineering staff (4+) were seconded directly to Pilbara Ports (PPA) to support the delivery of this major asset. Our team offered expert, site-based oversight to the principal contractor and other involved parties, scaling up resources to match the project’s demands. Ranging from contract and construction management to intensive stakeholder engagement, AIE’s regional presence ensured the client had immediate access to specialised skills and a deep understanding of the unique geographical and logistical challenges of the Pilbara.
The secondment model seamlessly integrated expert engineering staff into the client’s team, ensuring high-risk infrastructure development remained robust and strictly compliant.
Highlights:
- Regional capability: Overcame the challenges of procuring engineering expertise in remote locations, providing an immediate, deep understanding of the project context and regional business environment.
- Operational success: Delivered comprehensive contract and construction management that served as an invaluable asset to Pilbara Ports, keeping the multi-berth development aligned with delivery schedules.
Focus areas:
- Secondment, asset development
- Pilbara Ports’ Port Development Guidelines, marine infrastructure regulations
- Design review, project management, stakeholder engagement, construction supervision, contract administration
Mardie Salt and Potash Project
Independent certification
The Mardie Salt and Potash Project is the development of a large-scale, solar salt and fertiliser production facility on the Pilbara coast south of Karratha, over an area of 130km2. AIE was engaged by BCI Minerals and Pilbara Ports as independent certifier or the works, which includes a 2.4km jetty structure and significant civil works.
AIE’s regional presence, quality and asset management expertise, and deep experience in the ports and marine sector have helped efficiently perform the independent certifier scope, allowing the project to move ahead with confidence.
When complete, the project will be the largest solar salt operation in Australia and the third largest in the world.
Highlights:
- Compliance assurance: Confidence that this important infrastructure development is built-as-designed.
- Operational success: AIE’s regional presence meant staff were available at short notice for site-based tasks. Our service provided excellent value for money to this Pilbara-based project.
Focus areas:
- Marine environments
- Pilbara Ports’ Port Development Guidelines
- Independent certification
Tesla Battery Project
Multidisciplinary Engineering Design & Construction Oversight
AIE was engaged by CEM Alliance to complete the design for the TESLA Australia BESS Operational and Maintenance Facility. Set to be one of Australia’s largest BESS installations, the project required a robust design to support grid stability for the South-West Integrated System (SWIS). The solution needed to balance rapid delivery with strict compliance and operational reliability.
Our team delivered a comprehensive, multidisciplinary design that integrated electrical, instrumentation, civil, structural, and mechanical engineering. We successfully managed specialist subconsultants and navigated regulator approvals, while facilitating crucial safety in design, operability, and constructability workshops. Due to our practical approach, AIE was further retained to provide onsite oversight, supervision, and technical advice, working directly with the contractor to confirm construction methods and manage real-time site constraints.
The multifaceted design was completed seamlessly, enabling early construction and ensuring the facility meets all long-term operational requirements.
Highlights:
- Compliance assurance: Embedded safety, operability, and constructability directly into the design phase, streamlining regulator liaison and securing all necessary approvals.
- Operational success: The project was delivered ahead of schedule and on budget, with AIE’s ongoing construction oversight ensuring excellent value for money and technical compliance.
Focus areas:
- Stakeholder management and education
- SWIS grid regulations, Safety in Design (SiD)
- Scope: Electrical, Instrumentation, Civil, Structural & Mechanical Design, Construction Supervision, Regulator Liaison
Mondelez Wastewater Design
Multidisciplinary Engineering Design
AIE Engineering was engaged to deliver comprehensive engineering design services for the upgrade of the Suttontown Wastewater Treatment Plant. The primary objective was to improve treatment reliability and ensure the facility could effectively manage high-strength wastewater generated from cream cheese manufacturing while strictly maintaining compliance with environmental discharge requirements.
Our team faced complex engineering challenges, particularly regarding stormwater and containment design due to the site’s location within a high-priority drinking water catchment area. AIE provided an integrated, multidisciplinary design solution that successfully accounted for existing infrastructure constraints and future production demands. We developed the Basis of Design, managed environmental approvals, and delivered detailed civil, structural, and mechanical engineering documentation to support a practical, maintainable, and operationally reliable upgrade.
The finalised design seamlessly integrates new infrastructure within the operational constraints of the live facility, establishing a robust framework for long-term compliance.
Highlights:
- Environmental protection: Specialised stormwater and containment design ensures total isolation of high-strength food processing runoff, safeguarding the local high-priority drinking water area.
- Operational success: Delivered all required development approval documentation and procurement-ready packages to facilitate a smooth, compliant transition to the construction phase.
Focus areas:
- High-strength wastewater, stormwater containment
- Development approval regulations, drinking water catchment requirements
- Civil, structural and mechanical design, Basis of Design, stakeholder engagement, environmental approvals
