Mt Arthur Coal Collision Avoidance System (CAS) Project

Delivering Safety & Excellence at BHP Mt Arthur Coal

Project Snapshot

Client: BHP – Mt Arthur Coal
Location: Hunter Valley, NSW
Category: Fleet Safety Technology Deployment
Timeframe: Completed December 2025
Scope: CAS installation and commissioning across 500 vehicles
Disciplines: Auto Electrical, Communications and IP Networking, Electrical Installations, Mechanical Fitment
Outcome: Large-scale CAS rollout delivered safely, on time, and to specification

CAS installation equipment on truck at Mt Arthur Coal

Project Overview

AVE Technologies delivered one of the largest Collision Avoidance System deployments in the Hunter Valley, installing a world-class CAS across more than five hundred mine vehicles at BHP Mt Arthur Coal. The fleet included ultra-class Liebherr 9800 and 996 trucks, Hitachi 3600 and 5600 excavators, Caterpillar dozers and graders, service trucks, water carts, and extensive light vehicle fleets, including Hilux and D-Max. The program improved situational awareness, reduced collision risk, and standardised safety technology across a mix of assets.

Scope Of Works

Program planning, method development, and site integration strategy
CAS hardware supply coordination and interface engineering
Installation across approximately five hundred heavy and light vehicles
Auto electrical works, communications and IP networking, electrical installations, and mechanical fitment
System configuration, calibrations, and functional testing
Operator familiarisation, supervisor briefings, and handover documentation

Delivery And Management

AVE provided a single point of contact and turnkey delivery. A staged rollout commenced with slower-moving equipment to validate performance and installation methods before scaling to high-demand fleets. Works were coordinated with production and maintenance planners to align with service windows and minimise impact to availability. Quality controls included pre-fitment checks, installation sign-off sheets, and post-install validation runs. All activities were tracked against a live schedule, with daily progress reports sent to the client.

Technical Approach

Standardised install kits and templates to streamline fitment across mixed OEM platforms
Clean power and data pathways with shielded cabling and protected terminations
Network connectivity and back-end integrations to support alerts, logs, and analytics
Vehicle-specific mounting solutions for sensors, antennas, and operator interfaces
Commissioning checklists and recorded performance tests for assurance

Safety, Innovation, And Sustainability

Zero safety incidents across the program
Delivery on budget and on schedule
Innovative access and handling methods to safely position equipment on three-hundred-and-fifty-tonne trucks and eight-hundred-tonne excavators
Conscious resource management with minimal waste and catalogued surplus components for future maintenance or expansion

Outcomes

Consistent CAS coverage across heavy and light fleets
Improved operator awareness and reduced collision risk
Efficient installation program with minimal impact on production
Positive client and peer feedback on technical quality and professional delivery
Scalable framework for future upgrades and additional vehicles

AVE Technologies is one of the largest multi-faceted electrotechnology companies in NSW. We have a team of over 70 employees, including specialists in each field, who can collaborate to provide a comprehensive, integrated solution for any project.

From small business phone and CCTV systems to large-scale, fully integrated technology projects for various industries like financial institutions, schools and universities, mining sites, sporting clubs and government facilities – we do it all!

Incorporating Electrical, Data Cabling, Control Systems, Audio Visual, Security Cameras & CCTV, Intercom Systems, Operational Technology, PA Systems, Telephone Systems, MATV and Excavator and Plant GPS Systems.

Don’t hesitate to get in touch if you have any questions or need help planning your next project!