PROK supplied over 28,000 conveyor components for a new 13.6km overland conveyor system, supporting Fortescue’s commitment to operational efficiency and sustainability.
Fortescue (Chichester Metals Pty Ltd), one of the world’s leading iron ore producers, launched the Christmas Creek Hall Hub Development Project to unlock new deposits and enhance operational efficiency at its mine site in Western Australia.
The project forms part of Fortescue’s broader strategy to reduce truck haulage and improve ore handling through targeted infrastructure investment.
The challenge: Engineering for endurance
To streamline ore transport from new deposits to the existing OPF1 processing plant, Fortescue initiated the construction of a new primary crushing plant and a 13.6km overland conveyor system – designed to operate at 5,000 tonnes per hour.
The system would be expected to perform under demanding conditions, including remote site access, continuous operation across 6,700 production hours annually, and exposure to extreme environmental factors. Each component needed to meet strict durability, safety and performance requirements while aligning with Fortescue’s internal specifications and relevant Australian standards.
The scale and complexity of the project demanded a reliable supply partner with the technical expertise and manufacturing capability to deliver quality components, on time and at scale.
The solution: Conveyor components that go the distance
With decades of experience in conveyor technology and a track record of successful overland conveyor projects, PROK was engaged to design, manufacture and supply key conveyor components for the new system.
PROK supplied 7,052 idler sets, 18,831 rollers, and 1,976 guide rollers, as well as a take-up winch (active) and eight engineered conveyor pulleys.
All components were manufactured in Western Australia, supporting local industry and ensuring full traceability and compliance with Fortescue’s standards.
The solution featured PROK’s high-density polyethylene (HDPE) rollers with friction-welded end caps, engineered for maximum strength, corrosion resistance, and reduced noise levels. Their lighter weight also improves manual handling safety during maintenance and installation.
PROK coordinated closely with project stakeholders to ensure timely delivery and seamless integration with the broader system. Every component was fabricated, tested, packaged and transported to site in line with Fortescue’s project timeline.
The outcome: Long-term performance, locked in
PROK delivered the full component package in the fourth quarter of 2023, ready for system commissioning in the second quarter of 2024.
Once operational, the new conveyor system will help Fortescue eliminate extended truck haulage, reduce fuel use and vehicle emissions, and lower the overall cost of ore transport across the life of the deposit. With a projected design life of 20 years, the system is built for long-term reliability, with minimal maintenance downtime.
“This project demonstrates what PROK does best,” says PROK General Manager Wade Guelfi. “Engineering high-performance, fit-for-purpose conveyor components and delivering them reliably at scale. We’re proud to support Fortescue’s long-term goals at Christmas Creek.”
The Hall Hub Development Project is a critical enabler for Fortescue’s future production strategy – and PROK’s contribution reinforces its reputation as a trusted, high-performance partner for major mining operations.
Want to know more? Explore PROK’s conveyor component capabilities at prok.com.
