Dalrymple Bay Coal Terminal 7X Project

3rd largest terminal in the world at time of completion

~50% increase in capacity to 85 million-plus tonnes per annum

1,100 workers in construction at project peak

AUD$1.26 billion, the largest construction program in the terminal’s history

Challenges

Provide engineering and project management solutions that allow for easy construction within a fully operational facility, with minimal disruption to current activity.
Carefully integrate multiple disciplines and stakeholder requirements.
Include a third inloading system, a stockyard expansion, a third outloading system and a fourth berth.
Upgrade major power and control systems, and provide additional controls to reduce the impact of noise and dust emissions.

Solutions

The stockyard volume was increased by 43% within the same terminal footprint.
Innovative vertical concrete bund walls and two additional stockpile rows improved reclaiming efficiency.
Automated wagon vibrators were implemented to eliminate manual handling and noise-related health and safety hazards.
Jetty was widened on a single row of vertical piles to reduce cost and improve constructability.
The new outloading system included a full 3D anti-collision avoidance system for the yard machines, significantly increasing efficiencies for the stacking and reclaiming operations.

Highlights

Winner, Queensland Engineering Excellence Award – Industrial Development and Manufacturing Engineers Australia, 2010
Winner, 2009 Products and Manufacturing Facilities Excellence Award, Engineers Australia
Throughput capacity for all major components of the inloading and outloading materials-handling systems reached nameplate capacity almost immediately after commissioning.
During the project’s peak, approximately 1,100 workers were involved in construction, many of whom were mid-tier local contractors, which boosted the local economy with employment opportunities.

Project Numbers

5.5 million total project hours worked.
Approximately 1,100 workers involved in construction at the project’s peak.
AUD $1.26 billion total project cost.
Aurecon Hatch managed safety for the construction activities on site, and completed the project with a lost-time injury frequency rate (LTIFR) of 0.92.