Engineering safer ANE transport for Toll Group
Transporting hazardous materials carries inherent risk, particularly where heat and pressure can increase the likelihood of combustion. For this reason, Wormald was engaged by Toll Group to design and deliver a specialised vehicle fire suppression system to support the safe transport of ammonium nitrate emulsion (ANE) across Australia.
Widely used in the mining sector as a raw material in explosives, ANE is routinely transported over long distances by road tanker. While incidents are rare, the potential consequences are significant, particularly in environments where heat exposure can intensify combustion and increase the risk of explosion.
Following concept development and testing, the project commenced in 2024, with initial installations at Toll’s Tomago (NSW) and Kewdale (WA) facilities. The project formed part of a broader national safety initiative being undertaken by Toll.
Addressing the risks
Rather than relying solely on traditional fire protection methods, such as hand-operated extinguishers that require drivers to respond in close proximity to hazards, the focus shifted towards improving both early detection and safer intervention.
Additional risks can arise during normal operation from undetected faults, such as blown tyres or dragging brakes, which can generate heat through friction and create ignition sources in high-risk environments.
Addressing these risks required a considered engineering approach. Variations in trailer configurations, exposure to corrosive ANE materials, and the need for ongoing maintenance were key design factors, alongside ensuring the system remained practical and reliable for operators in high-pressure conditions.
A tailored solution
Wormald developed a purpose-built system combining targeted firefighting foam suppression with real-time tyre monitoring to strengthen
both prevention, detection, and response capabilities.
Strategically positioned nozzles deliver firefighting foam directly to high-risk areas, including tyres and braking systems, providing coverage to zones inaccessible to handheld extinguishers. The system is manually activated, allowing drivers to safely stop and assess conditions before deployment.
At the same time, an integrated tyre monitoring system provides continuous, real-time data, enabling early detection of faults before they escalate and supporting more informed decision-making on the road.
“Designing for ANE transport meant balancing durability, adaptability, and usability. The system had to perform across different trailer configurations, withstand a corrosive environment, and remain simple for operators to use in high-pressure situations,” said Wormald Technical Director, Justin Morris.
Engineering durability was also a critical part of the final design. Standard brass components were replaced with stainless steel to withstand ANE’s corrosive properties, while bespoke cylinder configurations were developed to suit different trailer types without interfering with operations, ensuring long-term serviceability.
Delivering safer outcomes
Delivery was also carefully planned. Installation was coordinated alongside Toll to align with fleet availability, with detailed pre-planning of cylinder placement, pipe routing and nozzle positioning enabling efficient rollout with minimal disruption.
The result is a measurable improvement in safety outcomes, from increased driver awareness through real-time monitoring, to earlier intervention and greater separation between operators and potential fire risk.
The project has also received external recognition, with Toll named a finalist in the 2025 WA Work Health and Safety Excellence Awards for Best Solution to a Work Health and Safety Risk.
With more than 135 years of experience, Wormald continues to support safer operations across some of Australia’s most complex and high-risk environments, delivering specialised fire protection solutions tailored to critical industries.
To learn more about our capabilities, visit: https://wormald.com.au
