Hay Point Coal Terminal


The project involved the demolition and removal of redundant coal handling infrastructure as part of BMA’s Hay Point Expansion Project at Hay Point Coal Terminal. The project was delivered in confined work areas within a live coal terminal facility amongst operational coal handling plant and infrastructure.

Liberty Industrial were contracted by prime contractor, Bechtel and the HPX3 Team, to undertake the demolition work package. The scope of work included the demolition of disused coal surge bins, associated conveyor systems, transfer towers and other miscellaneous structures. In addition, Liberty Industrial were also responsible for the development of the dismantling methodology and supervision for the removal of a 400t offshore transfer tower and associated infrastructure.

Liberty industrial’s project team was deployed 12 weeks prior to the commencement of physical works, completing methodologies, undertaking risk assessments, critical lift studies and preparing demolition work packs.

We engaged our preferred structural engineering partner GHD to complete structural analysis of the weakening methodology for key structures to be demolished. These analyses provided independent verification into the overall structural integrity throughout the sequence of pre-weakening and collapse of the various structures.

Liberty Industrial used state of the art risk mitigation technology, ASI Extreme Loading for Structures to model and simulate the controlled demolition of one of the coal surge bins. The precision and accuracy of the collapse of this structure was paramount, given it’s proximity to adjacent operational facilities. The Extreme Loading for Structures software was instrumental for testing and refining our methodology and analysing how the structure would react to our proposed demolition scenario prior to undertaking the work.

Both surge bins, transfer towers and selected conveyor sections were collapsed with cut and pull demolition techniques. Processing commenced on site with carefully designed preparation oxy cuts to weaken the 20m high surge bin structures and some of the lower conveyor sections in preparation for a mechanically induced collapse.

A 70t excavator was used to apply inertia to the pre-weakened structures to induce their controlled collapse. 

The transfer towers and the higher sections of the coal handling conveyor systems were dismantled using a 350t crawler crane assisted by a number of franna cranes. Traditional mechanical demolition techniques were used to demolish other miscellaneous structures.

A 70t excavator with a shear attachment downsized and processed the structures, assisting it was a 38t demolition excavator with a rotating demolition shear. Oxy Cutters assisted, downsizing sections of the structures unable to be processed mechanically. More than 8500 tonnes of material was recovered in total. 520 tonnes of non ferrous scrap material, 4700 tonnes of ferrous material and 3300 tonnes of concrete was recycled.

Liberty Industrial regularly interfaced and coordinated works according to prime contractor and adjacent contractor requirements while maintaining productivity, program and upholding rapport with all stakeholders.

Liberty Industrial’s key objective of safe and sustainable project delivery was achieved with the project completed without a single injury or environmental incident. The project delivered in line with BMA’s stringent health, safety, environmental and quality compliance requirements. All project control milestones, and safety, environmental and quality targets were met or exceeded.

Hay Point Drop

Hay Point Drop