Utah Road is a critical freight corridor linking the Great Northern Highway to the Utah Point Bulk Handling Facility at the Port of Port Hedland - the world’s largest bulk export port.

The road supports continuous, 24/7 access for high-productivity vehicles, including triple road trains transporting iron ore and other bulk commodities.

Originally constructed in 2009 and realigned in 2014, the corridor had experienced significant pavement deterioration due to sustained heavy vehicle traffic far exceeding its original design capacity. The Utah Road Pavement Rehabilitation Project was initiated to address these structural issues and ensure the corridor’s long-term performance.

The key challenge was to deliver the works within a live port environment while maintaining uninterrupted access for freight operations, ensuring safety, meeting environmental compliance requirements, and minimising disruption to port users.

This was the first project awarded to Ventia’s Transport Western Australia (TWA) team by the Pilbara Ports Authority, marking the beginning of a new client relationship in a high-profile, operationally sensitive setting.

The Solution

Ventia was engaged to deliver Stage 5 of the rehabilitation program, focused on Zone 7 of Utah Road. The works covered approximately 1.7 km of dual-lane carriageway with varying widths and included the reconstruction of the Northern Extension (from the Utah Point entrance to the BHP security gate) and the resealing and asphalt overlay of the adjacent BHP slip lane.

The scope of works included:

• Foam Bitumen Stabilisation (FBS): 28,000 m² treated using 450 tonnes of emulsion and 140 tonnes of cement to strengthen the upper pavement layer.
• Two-Coat Bituminous Seal: Applied across 29,000 m² to enhance surface durability and skid resistance.
• Asphalt Placement: 3,750 tonnes of 50 mm asphalt laid to improve ride quality and structural performance.
• Kerbing and Safety Infrastructure: 250 metres of kerb reinstatement and 320 metres of safety barrier and guardrail replacement to improve roadside safety.
• Environmental Management: Dust suppression, erosion control, and vegetation clearing conducted in accordance with native vegetation clearing permit CPS 7859.
• Live Traffic Management: Staged construction and real-time coordination ensured uninterrupted access for port operations throughout the 15-week program.

Ventia’s team adopted a collaborative and agile approach, working closely with the Pilbara Ports Authority to adapt to operational constraints and deliver the project safely, efficiently, and to a high standard.

The Outcome

The project was completed ahead of schedule and delivered a commercial outcome that exceeded expectations. Key results included:

• Zero unplanned disruptions to port operations during construction.
• Enhanced pavement durability, safety, and freight efficiency
• Strengthened resilience of a critical logistics corridor
• Reinforced Ventia’s reputation as a trusted delivery partner for complex infrastructure in remote and operationally sensitive environments.

This successful delivery supports the Pilbara Ports Authority’s long-term infrastructure strategy and ensures Utah Road can continue to meet the demands of one of the world’s busiest bulk export ports. It also establishes a strong foundation for future collaboration between Ventia and the Pilbara Ports Authority, demonstrating the capability and commitment of the TWA team in the Pilbara region.