Overland Conveyor Construction Plant and Equipment: 50 Example Fleets by Work Type

This page provides 50 example plant and equipment mixes for different stages of
overland conveyor projects – route clearing, earthworks, foundations, galleries, stringing,
mechanical installation, electrical/controls, tie‑ins and rehabilitation.

Each card represents a practical plant + equipment fleet that works together as a system.
Use these as starting points when developing methodology‑led estimates, programmes and
Efficient Construction Cost (ECC) models. Always adjust for your specific
terrain, climate, material type, access, staging and safety requirements.

Corridor Preparation & Access

1. Corridor Survey & Set‑Out

Use case: Mark overland conveyor centreline, offsets and structures.

Plant & Equipment Mix

Total stations and GNSS rovers
Drones for aerial mapping and orthophotos
4×4 survey vehicles / ATVs for rough terrain

2. Vegetation Clearing Along Conveyor Route

Use case: Clear brush and trees along alignment and access tracks.

Plant & Equipment Mix

Dozer with rake blade or forestry blade
20–30 t excavator with grab and saw head (if required)
Mulcher or chipper + light trucks
4×4 utes for crew and small equipment

3. Access Track Construction

Use case: Build temporary/permanent access parallel to conveyor route.

Plant & Equipment Mix

20–30 t excavator
Grader
Rollers (padfoot + smooth)
Watercart
Light trucks for culverts and small structures

4. Steep Terrain Access Benches

Use case: Benched tracks for tower footings on steep slopes.

Plant & Equipment Mix

30–40 t excavator with rock bucket & breaker
Dozer for bench trimming
Long‑reach excavator if working from one side only
Compactors for bench stability

Earthworks, Foundations & Structures

5. Footings for Conveyor Gantries & Towers

Use case: RC pads or bored piers for trestles and galleries.

Plant & Equipment Mix

Mini/midi excavators for spread footings
Small bored pile rig (if deep foundations needed)
Concrete line pump + agitators
Plate compactors around pads

6. Transfer Tower & Transfer Station Foundations

Use case: Heavier foundations at feed, transfer and drive stations.

Plant & Equipment Mix

20–30 t excavator
Compactors (padfoot + smooth drum)
Formwork systems and rebar handling via small crane
Concrete pump and finishing tools

7. Tunnel/Portal Foundations (Portal Conveyor Sections)

Use case: Portal slabs/walls where conveyor enters/exits tunnel or building.

Plant & Equipment Mix

Mini/midi excavator and skid steer
Formwork & falsework for portal frames
Concrete pump
Compaction tools for backfill

8. Elevated Gallery Foundations on Piles

Use case: Piled gallery supports in soft/riverine ground.

Plant & Equipment Mix

CFA or driven pile rig (≤600 mm typical)
Crane for rebar cages and pile heads
Excavator for pile cap excavation
Concrete pump and formwork gear

Civil Works – Conveyor Pits, Heads & Short Tunnels

9. Primary Crusher Pocket / Dump Pocket

Use case: Excavation and structure for crusher and conveyor feed.

Plant & Equipment Mix

30–40 t excavators with rock breakers
Dump trucks
Rock bolts & shotcrete rigs (if rock faces)
Formwork & concrete plant for pit walls/slabs

10. Transfer Station Structures

Use case: Concrete plinths and walls under transfer towers.

Plant & Equipment Mix

Mini/midi excavator
Formwork and reo handling crane/telehandler
Concrete pump & finishing tools

11. Short Conveyor Tunnels / Culverts

Use case: Short tunnel sections under roads/rail or bunds.

Plant & Equipment Mix

Excavators with trench support or box culvert install
80–150 t crane for culvert units
Backfill and compaction plant

12. Reclaim Tunnel Civil Works (Under Stockpile)

Use case: RC reclaim tunnel for overland conveyor tie‑in.

Plant & Equipment Mix

Tunnel/box excavation plant (30–40 t excavators + support)
Formwork for walls, roof & hoppers
Concrete pumps/agitators
Shotcrete & rock support equipment if in rock

Steelwork – Galleries, Towers & Gantries

13. Ground‑Mounted Stringer Conveyors

Use case: Low‑level trestle conveyors on plinths or sleepers.

Plant & Equipment Mix

Light crane truck or 80–120 t mobile crane
Telehandler for steel stringers
Scissor/boom lifts for bolt‑up

14. Elevated Gallery Installation (Portal Frames)

Use case: Steel portal bents with gallery sections.

Plant & Equipment Mix

150–250 t mobile crane (depending on span/height)
Telehandler for purlins and small members
MEWPs for bolting and bracing
Survey tools for plumb and line

15. Long‑Span Trestles over Valleys/Infrastructure

Use case: Overland conveyor spanning creek/road/rail.

Plant & Equipment Mix

200–400 t mobile crane(s) or crawler crane
Support cranes/telehandlers
MEWPs or rope access for connection

16. Transfer Towers & Junction Houses

Use case: Structural steel transfer stations along route.

Plant & Equipment Mix

80–150 t mobile crane
Telehandler for stair modules & platforms
MEWPs for cladding and detailing

Mechanical Installation – Idlers, Pulleys & Belt Stringing

17. Idler Frame & Roller Installation

Use case: Fit idler sets along overland conveyor framework.

Plant & Equipment Mix

Telehandlers for pallets of idlers
Scissor lifts/MEWPs for elevated galleries
Hand tools and torque gear

18. Head, Tail & Bend Pulleys

Use case: Install drive, tail, take‑up and bend pulleys.

Plant & Equipment Mix

80–150 t mobile crane (depending on pulley size/height)
Chain blocks, jacks and alignment tools
MEWPs for access at height

19. Belt Stringing – Straight Ground‑Mounted Conveyor

Use case: Single pull on straight, accessible section.

Plant & Equipment Mix

Belt reels and stands
Winch truck or static winch
Chain pulls and alignment rollers
ATVs/utes for crew movement along route

20. Belt Stringing – Hilly, Multi‑Flight Conveyor

Use case: Complex pulls with snubs/reversals over terrain.

Plant & Equipment Mix

Multiple winches and intermediate pull points
Belt handling frames at breaks and bends
MEWPs where belt feeds through elevated galleries
Radio communication and safety systems

Drives, Take‑Ups & Ancillary Mechanical

21. Drive Station Installation

Use case: Drive frames, gearboxes, motors and couplings.

Plant & Equipment Mix

80–150 t mobile crane or gantry system
Skates and toe jacks for final positioning
Laser alignment tools
MEWPs for access to guards/couplers

22. Gravity Take‑Up Tower

Use case: Counterweight and sheaves for belt tensioning.

Plant & Equipment Mix

Mobile crane(s) for sheaves and counterweight installation
MEWPs for rope rigging & guides
Chain blocks and jacking gear

23. Horizontal Take‑Up (Winch‑Driven)

Use case: Take‑up trolley or carriage system for long overland line.

Plant & Equipment Mix

Cranes/telehandlers for trolley system
Small winch and anchor foundations
MEWPs for guides and structure

24. Scrapers, Ploughs & Belt Cleaners

Use case: Cleaning equipment at discharge and return points.

Plant & Equipment Mix

Pallet jacks and light cranes
MEWPs or scaffolds for tight access
Torque tools and jacks

Electrical, Instrumentation & Controls

25. Cable Tray & Ladder Installation Along Conveyor

Use case: LV/MV cables and controls along gallery or ground line.

Plant & Equipment Mix

MEWPs or man‑lifts
Scaffolds for long runs in galleries
Drills & fixings tools for tray supports

26. LV/MV Cable Pulling

Use case: Power and control cable pulls along corridor.

Plant & Equipment Mix

Cable drum stands
Cable winches and capstans
Rollers and guides
Test equipment for insulation and continuity

27. Instrumentation & Protection Devices

Use case: Belt drift switches, pull‑cords, speed sensors, rip detectors.

Plant & Equipment Mix

MEWPs or mobile scaffolds
Hand tools, torque drivers, test instruments
Small cable pulling aids

28. MCCs, VSDs & Local Control Stations

Use case: Electrical rooms at drive and transfer stations.

Plant & Equipment Mix

Forklifts / pallet jacks for MCC cabinets
Small mobile crane (if upper levels)
Scissor lifts for overhead bus duct and trays

Tie‑Ins, Commissioning & Testing

29. Tie‑In to Crusher or Plant Feed

Use case: Interface with upstream crushing or loading plant.

Plant & Equipment Mix

Cranes/telehandlers for chutes and feeders
MEWPs for connection points
Hot‑work tools and liner installation gear

30. Tie‑In to Stockpile or Tripper Conveyor

Use case: Connect overland conveyor to stacker/tripper.

Plant & Equipment Mix

80–150 t crane for tripper structures
MEWPs for walkway and chute connections
Instrumentation tools for interlocks

31. Dry Commissioning (No Load)

Use case: Rotate belts, test drives, interlocks and trips.

Plant & Equipment Mix

Portable test equipment (megger, multimeters, vibration sensors)
Temporary power where needed
Access platforms/MEWPs for adjustments

32. Wet Commissioning (Load Testing)

Use case: Test under material load, calibrate scales & trip settings.

Plant & Equipment Mix

Stockpile and loading plant for test material
Sampling and belt scale calibration tools
Inspection trolleys/ATVs for monitoring full length

Maintenance, Modifications & Refurbishment

33. Belt Replacement on Existing Overland Conveyor

Use case: Replace full belt or long belt sections in shutdowns.

Plant & Equipment Mix

Belt reels and stands
Winches and pulling lines
Portable belt vulcanising press
MEWPs where elevated

34. Idler & Frame Replacement Campaign

Use case: Systematic idler frame swap‑out along route.

Plant & Equipment Mix

Telehandler for palletised idlers
4×4 utes/ATVs with tool racks
Scissor lifts/MEWPs for high‑level frames

35. Drive Upgrade (Motor/Gearbox Replacement)

Use case: Increase capacity or replace aged drives.

Plant & Equipment Mix

80–200 t mobile crane or gantry system
Skates and hydraulic jacks
Laser alignment kit

36. Structural Modifications (New Trippers, Crossovers)

Use case: Add trippers, crossovers or diverters to existing line.

Plant & Equipment Mix

Mobile cranes (80–150 t)
MEWPs
Hot work and steelwork tools

37. Dust Control Retrofits

Use case: Enclosures, sprays, fogging and hood upgrades.

Plant & Equipment Mix

Scaffolds/MEWPs along transfer points
Plumbing tools for sprays and fogging lines
Light cranes/telehandlers for hood sections

38. Belt Scale & Weighbridge Installations

Use case: New inline scales and calibration setups.

Plant & Equipment Mix

Small cranes or telehandlers
Instrumentation test kits
MEWPs or scaffolds for install & calibration

Demolition, Decommissioning & Rehabilitation

39. Removal of Redundant Conveyor Line

Use case: Disassemble full overland conveyor.

Plant & Equipment Mix

Mobile cranes (various capacities)
Telehandlers and forklifts
Skid steers for scrap handling
Trucks for steel scrap and equipment removal

40. Demolition of Transfer Towers & Galleries

Use case: Remove structural steel towers and galleries.

Plant & Equipment Mix

Cranes with man baskets or demolition attachments
MEWPs
Oxy‑cutting and shear tools
Skips & trucks

41. Civil Demolition – Foundations & Pits

Use case: Remove or reduce structures back to grade.

Plant & Equipment Mix

20–30 t excavators with breakers and pulverisers
Skid steers
Dump trucks for rubble
Compaction plant for backfill

42. Rehabilitation of Conveyor Corridor

Use case: Restore landform and revegetate former corridor.

Plant & Equipment Mix

Excavators and dozers for regrading
Rollers for stabilisation
Hydroseeding rigs
Light trucks for plants and fencing

43. Hazard & Asset Removal (Cables, Services)

Use case: Remove or make safe residual services along route.

Plant & Equipment Mix

Cable pulling gear
Mini excavators for trench exposures
Access platforms/MEWPs as needed

44. Emergency Stabilisation After Collapse or Failure

Use case: Stabilise damaged conveyor galleries or supports.

Plant & Equipment Mix

Mobile cranes for capture & controlled lowering
Shoring systems and temporary bracing
Excavators for clearing debris

45. ECC/TOC Pilot Section for New Conveyor Methodology

Use case: Trial installation method and plant mix on short section.

Plant & Equipment Mix

Scaled‑down structural & mechanical erection fleet
Survey & monitoring instruments
Full QA & safety setup matching main works

46. Overland Conveyor Crossing a Major Road

Use case: Install gallery or pipe conveyor over existing highway.

Plant & Equipment Mix

250–400 t mobile crane during road closure
Smaller assist crane/telehandler
TMA vehicles and traffic management equipment

47. Overland Conveyor Crossing Live Rail

Use case: Install structures over/adjacent to rail during possessions.

Plant & Equipment Mix

High‑capacity crane timed with rail windows
Hi‑rail protection vehicles (if required)
MEWPs with rail‑adjacent controls

48. Overland Conveyor Interface with Wharf/Shiploader

Use case: Connect land conveyor to wharf or shiploader structure.

Plant & Equipment Mix

Cranes on land + crane barge (if over water)
MEWPs for joint & chute installation
Alignment and tolerance checking tools

49. Overland Conveyor in Extreme Terrain (Rope/Hybrid Systems)

Use case: Ropecon, cable‑supported or pipe conveyor in mountains.

Plant & Equipment Mix

Helicopters or winch systems for remote tower erection (where justified)
Crawler cranes on limited pads
Rope access for high‑altitude works

50. Online Monitoring & Reliability Upgrade Campaign

Use case: Install condition monitoring, cameras and sensors along route.

Plant & Equipment Mix

MEWPs / mobile scaffolds
Instrumentation tools and data logging hardware
4×4 utes/ATVs for corridor access

Need Help Selecting or Optimising Overland Conveyor Plant and Equipment Mixes?

These example fleets are starting points only. On a live overland conveyor project, the optimal plant
and equipment mix depends on:

Route length, terrain, climate and ground conditions
Interfaces with crushers, stockpiles, ports, rail and process plants
Staging, shutdown windows and production ramp‑up targets
Required throughput, safety constraints and ECC/TOC objectives

We can help you:

Develop methodology‑led plant and equipment mixes for each overland conveyor work package
Align structural, mechanical and electrical staging with realistic productivity and Efficient Construction Cost (ECC)
Compare routing, support types and installation methods on a time–cost–risk basis
Feed real project learning back into future overland conveyor bids and planning

Use the form below to discuss your project.