Project Profiles_port kembla

Port Kembla Coal Stacker Reclaimer

DURATION6 months
CLIENTPort Kembla Coal Terminal Ltd (PKCT)

The project involved the demolition of a coal Reclaimer and a coal Stacker at Port Kembla Coal Terminal. These machines were removed to allow the installation of new plant as part of a broader PKCT restoration and compliance project.

The decommissioned reclaimer was relocated to a dedicated demolition area, away from any live plant. This happened in 2 stages: first the machine was pulled from its stockyard, over a bridge, and away from the live conveyor line. Then the machine was transported to a further designated area for demolition and processing.

Prior to moving the structure, Liberty Industrial disconnected and extracted the impact table from underneath the Reclaimer while it was still in the stockyard, without damage to the conveyor belt. Once disconnected from all its services, the 1250t structure was pulled over purposely built extension rails to a temporary position where the machine underwent all preparatory works required for its transport using Self-Propelled Modular Trailers. To pick-up and secure the Reclaimer in position during transport, a special-purpose 40t steel “transport frame” was fabricated and mounted on the bed of the SPMT trailers.

Once lowered to the ground and secured, the structure was pre-weakened to facilitate its demolition with explosive cutting charges. The charges were placed at strategic locations and the pre-weakening cuts verified by our consulting structural engineer. After the structure was safely collapsed to ground level, a combination of 70t & 36t excavators fitted with shear attachments processed the steel structure for removal and recycling off site.

In post tender consultation with the client, third party structural engineer and our cranage contractor, we developed a high level methodology with preliminary lifting plans, which ultimately secured the contract for Liberty Industrial.

The coal Stacker was straddling an operating conveyor line. Hence the demolition methodology involved dismantling the structure into smaller components using heavy crane lifts, with minimal impact on PKCT’s operations. To achieve this, Liberty Industrial utilised a 600t crawler crane located within one of the coal stockyards

Prior to the deconstruction, engineered lift studies along with structural engineering assessments was completed - the structure was then prepared accordingly.

After completion of the lifts, the lowered sections of the structure was downsized at ground level, lifted onto trucks and transported to the main demolition area for processing by excavators with shear attachments. The products of demolition was then transported off site for recycling.

The project also involved the salvage of a various range of items (i.e. drive units, electrical and PLC cabinets, cable reelers, transformers etc.) which was retained by PKCT as spare parts for the machines still in operation inside the terminal. The salvage must happen before the demolition works can occur in order to minimise potential damage to the items – this principally involved the use of mobile cranes to lower the items down to the ground.

As some of the works described above are shutdown dependant, all preparatory works were carried out when the plant was live, without disrupting PKCT’s operations.

Explosive Demolition of Port Kembla Coal Terminal Reclaimer

Explosive Demolition of Port Kembla Coal Terminal Reclaimer  

Dismantling of a redundant Coal Stacker at Port Kembla Coal Terminal

Dismantling of a redundant Coal Stacker at Port Kembla Coal Terminal  

Port Kembla Coal Terminal Stacker and Reclaimer Demolition Documentary

Port Kembla Coal Terminal Stacker Reclaimer Demolition Documentary