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Ore inspiring: Rio Tinto’s boost to keep ore flowingOre inspiring Rio Tinto’s boost to keep ore flowing-

By Kate Dzienis

In the red dust heart of WA’s Pilbara region, a major chapter in Australia’s iron ore legacy is unfolding.

Earlier this year, in March 2025, mining giant Rio Tinto (ASX: RIO) committed $1.8b to the development of its Brockman Syncline 1 (BS1) project – an ambitious expansion poised to fortify the company’s iron ore operations for decades to come.

Located eight kilometres north of the existing Brockman 4 mine, BS1 is no ordinary development. It represents a critical component in Rio Tinto’s long-term strategy to sustain annual production rates in the face of declining output from ageing operations. With state and federal environmental approvals now secured, the BS1 project is powering ahead, marking a significant milestone for both the company and the region.

Construction is slated to begin this year with first ore anticipated as early as 2027 (having previously been anticipated in 2028) — one year ahead of schedule. Once operational, BS1 will process up to 34mtpa of iron ore, leveraging existing infrastructure within the Greater Brockman Hub.

In a March 6, 2025, press release, Rio Tinto iron ore chief executive Simon Trott said Brockman 4 produced 43mt of iron ore in 2024 and that “securing this project extends the life of the Brockman Hub…good for our business, good for WA and good for the Australian economy.”

With Rio Tinto mining iron ore in the Pilbara for almost six decades, Mr Trott stipulated that the company’s tranche of new mines would ensure it could continue to supply the globe’s ongoing need for iron ore for decades.

Generating employment

The economic ripple effects are substantial. During construction, the project is expected to generate about 1,000 jobs, with 600 permanent roles once operations are underway.

It’s a vital boost for the region’s economy and workforce, further reinforcing the Pilbara as Australia’s iron ore powerhouse and supporting local economies as well as contributing to regional development. The creation of jobs showcases one of Rio Tinto’s key elements in its strategic expansion.

BS1 is expected to contribute about 10% of Rio Tinto’s total Pilbara output – making it a powerhouse addition to the miner’s operational portfolio. In addition, with the project’s fast-tracked timeline, it highlights the urgency and importance in meeting global demand amid tightening market conditions.

For Australian suppliers, the implications are enormous, with BS1 set to take on significant procurement opportunities across mining services, construction, logistics, engineering, manufacturing and camp operations. The project will also require a continuous broad suite of infrastructure developments.

Key components include a run-of-mine (ROM) pad with a single tip point, the construction of an in-direct-fed primary crushing facility with a discharge conveyor, a 7.9km single-flight overland conveyor and a surge bin facility linking into the existing ore handling system.

Modifications will be made to current conveyor networks and transfer infrastructure, while a new production hub, heavy and light vehicle refuelling facilities and extensive internal road networks will also be established. Surface water management and dewatering infrastructure (including bores, pipelines, drains and levees) are planned, along with a suite of water transfer systems linking BS1 to nearby operations. The development will be powered by a new 33kV network and supported by upgraded communications infrastructure.

To house the incoming construction workforce, a temporary accommodation camp with a capacity of about 800 to 1,300 rooms will also be built, reflecting the scale and complexity of the build phase.

As Rio Tinto turns the key on one of its most substantial investments, businesses around the country stand well poised to benefit from the scale and speed of this transformative development.

Collaborative consultation

In the shadows of the land, Rio Tinto is working to forge a new path – one built on dialogue, not just development. The BS1 project has been shaped through ongoing consultation with the Puutu Kunti Kurrama and Pinikura (PKKP) people and the Muntulgura Guruma Traditional Owners.

These partnerships, the company has said, are central to its evolving approach to responsible development. Rio Tinto says it is committed to delivering the project with respect for the land, the people and the future.

Forward to the future

As global demand for steel remains strong and competition among producers intensifies, projects like BS1 will be critical in keeping Australia at the forefront of the iron ore market.

For Rio Tinto, it’s not just about replacing tonnes — it’s about reshaping the way the company approaches development, partnerships and long-term sustainability across its operations.

The red earth of the Pilbara is once again getting ready for a transformation with BS1 more than an infrastructure investment — it’s a strategic pivot, a test of trust and a bold bet on the future of one of the world’s most enduring mining regions.