Port Extension Boosts Queensland's Coal Export Capability

Location:	Abbot Point, Queensland
Country:	Australia
Project Size:	8,000 tonnes of XLERPLATE® steel
Client:	Ports Corporation of Queensland
Builder:	John Holland
Fabricator:	RPG Australia
Products Used:	AS/NZS 3678 - 350 XLERPLATE® steel

Overview

Ports Corporation of Queensland (PCQ) is using over 8,000 tonnes of XLERPLATE® steel in a major expansion of its Abbot Point Coal Terminal. XLERPLATE® steel will be used in the construction of a new wharf and ship loader, including piling, headstocks and rail track. The extension will enable the port to increase coal export capacity from 25 to 50 millions tonnes per year.

Background

Ports Corporation of Queensland is responsible for the development and management of sea port facilities which are vital to the export performance of Queensland. One of the ports it manages is Abbot Point, situated about 25 kilometres north of Bowen. Abbot Point is of significant strategic value as one of the few sites along Queensland’s seaboard where deep water is close in shore.

PCQ has commissioned a major expansion of Abbot Point to ensure that Queensland's A$16 billion coal export industry can meet future demand. Global demand for coal is growing at a phenomenal rate. Predictions for growth in demand for Queensland coal range between 5% and 13% per annum through to 2009/10, fed by industrial growth in China and India.

With miners contracting to export increasing quantities of coal, PCQ is acting to ensure that Abbot Point is able to cater for the demand. Upgrading the port's export infrastructure will boost export capacity by 50% from the current 25 million tonnes per annum.

Project

John Holland's SMP business, RPG Australia and BlueScope Steel are working in alliance for the Abbot Point expansion. John Holland, which specialises in the expansion of marine facilities, is responsible for project management, coordinating a team of 300 people on site over what will be an 18 month construction period. The team will be building on the existing jetty to create a new wharf and a new ship loader. The construction will amount to a duplication of the existing facility and is expected to use between 8,000 to 11,000 tonnes of XLERPLATE® steel.

RPG is responsible for fabrication of the piling, which will be used to support the new wharf. The piling varies in length between 49 and 57 metres, meaning that each one must be created in three sections or 'cans'. These cans are created using 16mm Grade 350 XLERPLATE® steel which is cut to size, rolled to a 1,200mm diameter and then moved onto rotators for welding.

"The sections are welded by submerged arc process," explains Matthew Stewart, General Manager - Pipe Division, RPG Australia.

"This means they can be welded internally and externally, eliminating double handling. We consider sub arc to be the most efficient technique for this type of job, bearing in mind the structural purpose and the thickness of the steel."

RPG also ensures at the end of the pile there is a 25mm thick diving shoe welded on with a bevelled edge. The bevelled edge provides a cutting tool which allows the pile to slice through marine rock more easily. The surface finish of the pilings is also critical, they need to be painted to resist corrosion in a salt water environment.

John Holland is responsible for the fabrication of all other project components. There are a number of different applications of steel planned, with the team converting XLERPLATE® steel into sections including modules, box sections, chutes and headstocks.

"The John Holland team is responsible for driving the piles into the seabed and then scalloping the top of the pile so the headstock can sit on top of it to create the new wharf," said Alban Manning, Manager - Fabrication and Coatings, John Holland's SMP business.

"The team is also working on the fabrication and construction of the rail girders and support beams that the new ship loader will run along when moving across the wharf. Finally, we are also fabricating rail fenders for the wharf. These are rubber guarded buffers that the ships 'bounce' against when they dock."

When it comes to the welding process, John Holland uses the same submerged arc approach as RPG. Unlike manual welding processes, this is an automated method which offers a high deposition rate and a lot of weld pool. Practically, this means that the team can complete the weld in a single flow rather than going over it numerous times, making the process far more efficient.

Working Together

One of the biggest challenges in a project of this scale, is making sure that there is open communication between all members of the project team. Ongoing dialogue, as well as an understanding of each other’s working practices, is critical to the smooth roll out of the expansion work.

"It is important that the teams at RPG, John Holland and BlueScope Steel are sharing information," said Matthew Stewart. "If all parties are aware of changes in scheduling and logistics we are able to adapt accordingly."

"It is also imperative that we understand what is required at each stage of the construction process," Matthew continued. "For example, one of the biggest challenges for RPG has been to adhere to very tight dimension and straightness tolerances when fabricating the piles. This is because we are aware that if the diameters of the piling are too varied, John Holland will face problems when constructing the piles on site. It is this commitment to thinking through the project as a whole that has fostered an effective working relationship."

Steel Specific Focus

"This project impacts the export capability of the whole state and, as such, it is fundamental that construction runs to schedule," said Alban Manning. "A key factor in using XLERPLATE® steel was BlueScope's inherent reliability. With BlueScope supplying local steel, the product arrived quickly. This has contributed to a speedy construction process."

"XLERPLATE® steel can be pressed heavily without cracking and is easy to weld given as it has no major flaws," Alban emphasised. "We also find that when working with XLERPLATE® we do not encounter any lamination issues there are no layers of separation in the steel so no potential cracks."

Looking Forward

PCQ is already planning two additional stages of development. The X80 expansion will increase export capability to 80 million tonnes per year, with the X110 expansion lifting capacity to 110 million tonnes per year.