Expressway Spares: 60 years of growth, legacy, and strategy

How PKF helped an Australian heavy equipment pioneer strengthen governance, succession planning, and long-term resilience

For over six decades, Expressway Spares has been synonymous with high-quality reconditioned parts and components to suit Caterpillar and Hitachi open-cut mining equipment. What began as a modest operation on the mid-north coast of NSW has evolved into a nationally recognised business supporting customers across Australia and globally.

As the family-run business transitioned into its third generation of leadership, it became clear that to support continued growth and long-term sustainability, Expressway Spares needed a more distinct corporate structure, a defined succession pathway, and a governance framework that would align family values with modern business strategy. And that’s where our expertise was called upon.

Strategic growth, scaling nationally and succession planning for family business

The story of Expressway Spares starts in 1951, when the Cassegrain family immigrated from France and settled near Port Macquarie. Gerard Cassegrain, grandfather to current Managing Director James Dunn, began working in a sawmill before saving enough to buy a truck and start a small logging operation. Always one to spot an opportunity, Gerard began buying and selling parts to keep his fleet moving.

“There was a real shortage of parts at the time,” James said. “He saw a gap in the market and eventually sold the truck business, bought a block of land, and began wrecking machines for parts. That’s where it all started.”

Officially incorporated in 1964, Expressway Spares spent the next few decades operating as a local parts and machinery wrecker. However, it wasn’t until the early 2000s that the business would enter a new era of rapid expansion.

By the early 2000s, Expressway Spares had around 40 staff, and with the purchase of land in the Hunter Valley in 2001 and an increasing focus on open-cut mining gear, the business accelerated rapidly. Today, Expressway Spares has five major branches across Australia, including Mackay, Perth, Port Macquarie, the Hunter Valley and Gunnedah, with over 380 staff.

“Mining equipment runs the hardest and needs the most maintenance,” James explained. “Once we had the facilities in key locations, our ability to deliver quickly to customers was really what enabled our growth to take off. We’re now the largest operation of our kind outside the OEMs [Original Equipment Manufacturers].”

Naturally, as businesses grow, so does the complexity, and in 2007, PKF (then Lawler Partners) was introduced to Expressway Spares by a trusted legal advisor. The relationship started with auditing, led by one of our Newcastle Audit and Assurance Partners, Clayton Hickey, and soon evolved into a deep advisory engagement with Business Advisory Services Partner, Simon Rutherford.

At PKF, the role of adviser always extends far beyond traditional accounting services. Simon, bringing his necessary skill set to implement holistic and effective business plans, came in during an internal restructuring and supported the family through the creation of a more formalised business and ownership structure.

This included:

• A revised shareholder agreement
• New company constitutions
• Establishing family trusts to hold assets
• Developing a Family Charter to guide future generations
• Ongoing advisory to ensure compliance with best governance practices
• Support for long-term planning and business diversification

“There’s no way we could’ve done it without him…he was exactly what we needed,” recalled James.

While PKF brought technical expertise, it was the relationship and values alignment that truly mattered to the family.

“From the first meeting, we just got a really good feel from Simon. He’s genuine and trustworthy; that was more important to us than anything else. He became our knight in shining armour, really.”

James described the working relationship with PKF as ongoing and collaborative. While the firm holds the family accountable to high standards, they also understand the pace and culture of a family business.

For Simon, his passion to develop and implement strategies for clients, with the ultimate aim of achieving their financial and personal goals, is obvious when talking about the 15 years of knowing James, the family and the team.

“Working with James and the family over the past 15 years has been a deeply rewarding experience. There’s a strong sense of pride in the legacy they’re continuing, and a genuine commitment to making decisions that honour the past while preparing for the future. Our work together has covered everything from restructuring and governance to succession planning and long-term strategy — but at the heart of it all is trust. Being a part of their journey, helping them grow the business while keeping it in the family, has been a real privilege.”

Legacy, values and resilience

With a strong operational foundation, Expressway Spares is now looking to diversify beyond its core mining business. With global uncertainties in mining and technological shifts like electrification on the horizon, the family is preparing for the next evolution of the company with our help.

“We’ve got a three-year plan, maybe a five-year plan, but we’re also looking 25 years out,” James shared. “We’re asking: what happens when the fourth generation wants to come in? How do we make sure the business is strong, diverse, and still family-owned?”

The steps taken today through PKF, setting up a family office, formalising governance, and aligning on long-term goals, are all part of preparing for that future.

On the 60th anniversary of the company’s incorporation, James reflected on how far the business has come and the role we have played in that journey.

“My grandfather would be proud of what we’ve built and how we’re preparing for the future. We’ve worked hard to keep the business in the family, and now with the help of PKF, we’re building something that can last for generations.”

As of July 2025*.

At PKF, we understand the unique challenges and opportunities that come with running and growing a family-owned business. Whether you’re planning for succession, restructuring ownership, or preparing for long-term diversification, our experienced advisory team can help you build a strong foundation for future generations, just like we did with Expressway Spares.

If you're looking for practical, down-to-earth advice to support your next phase of growth, get in touch today.