Customer: Fortescue Metals Group (FMG) Contract: Design and Construct  Location: Pilbara, Western Australia

Fast Facts 4 major wharves completed over 5 years Berth 1: 270 m wharf, 100 m approach jetty, load-out conveyor Berth 2: 400 m wharf and extension to load-out conveyor Berth 3: 375 m wharf, duplicate load-out system Berth 4: 415 m wharf, elevated conveyor system

At the height of the Australian resources boom (2004-2014), we became the marine partner of choice for Fortescue Metals Group (FMG), as they developed the infrastructure to support their new iron ore export business.

We delivered the following four major projects:

• Berth 1: 270 m wharf; 450 m lay-by berth and 100 m approach jetty; transfer deck & transfer tower structure; supply & installation of load-out conveyor.
• Berth 2: 400 m wharf and extension of load out conveyor; relocation and installation of head end from Berth 1 to Berth 2 during shutdown.
• Berth 3: 375 m wharf; all mechanical components to duplicate the existing material handling system.
• Berth 4: 415 m wharf; elevated conveyor bridge; transfer tower and equipment; wharf conveyor. Works also included: dolphins, fenders, and navigation aids.

It was during this period we pioneered large-scale modular wharf construction using heavy-lift ships. 

Because of acute labour shortages and the difficulty in attracting experienced personnel to projects in the northwest of Australia, we decided to adopt modular construction techniques to maximise off-site construction. This enabled rapid construction of the major wharf elements, as well as reducing the reliance on large on-site teams of workers.

Putting the strategy into action also involved us establishing our precast concrete facility in Perth for all the precast and pre-stressed concrete slabs, planks, and berthing dolphin shells, with all products trucked to the site.

The major structural units, including the wharf topside modules, were manufactured in China and shipped to Fremantle. There, they were fitted out with locally supplied handrails, quick-release hooks, and conveyor units, before being loaded onto a heavy lift ship and transported directly to the job for quick installation. For example, on Berth 2, eight modules that comprised the entire 400 m of the wharf, were landed and installed on the pre-installed piles in just five days.