Fortescue Metals Group (FMG) awarded McConnell Dowell the design and construct (D&C) contract for the Pilbara Iron Ore Infrastructure Project at Port Hedland in Western Australia. FMG is positioning itself as the third major iron ore producer in Australia.

MacDow's scope of work included a load-out berth, a lay-by berth and navigation aids. The load-out berth comprises a 100 m long approach jetty complete with roadway and elevated conveyor trusses; a transfer station platform with wharf conveyor, drive and belt change-out areas; and a wharf structure to supports the shiploader. The wharf includes shiploader rails; six independent berthing dolphins including fenders and quick release mooring hooks and controls; and trafficable concrete deck required for maintenance and associated traffic.

The lay-by berth comprises eight independent berthing and mooring dolphins with interconnecting catwalks. Included on the berth were remotely controlled quick release mooring hooks and capstans on all dolphins.

A total of five new navigation aids were designed and installed within the confines of the Port Hedland Port Authority (PHPA) inner harbour.

Marine piling works were carried out by two piling barges with 350 tonne cranes, and a construction barge with a 180 tonne crane. Each of these barges was in turn supplied by four material/supply barges.

Piles were driven using a piling frame system specifically designed by the company and predominantly constructed by MacDow’s fabrication yard in Batam, Indonesia.

A modular approach was used to construct the deck structures. Steel modules form the main structural elements and incorporate pre-cast concrete planks, conveyor galleries and associated equipment. The modules were laser aligned off site to ensure on site alignment required only minor adjustment. The modular approach minimised on-site work, reduced the overall programme duration, and ensured achievement of our first milestone date for the arrival of the client's shiploader.

Overall the project was completed on time and on budget, and MacDow's performance was recognised by its peers with the awarding of the WA Civil Contractor's Federation 2008 Construction Excellence Award.

Based on the performance on this project, MacDow was awarded the first phase of the expansion of the facility. This includes the addition of a new approach jetty; a new transfer tower; new main loadout berth; new lay-by berth; new berthing dolphins and associated works.

With the current growth and expansions planned for the Pilbara area over the next few years, McConnell Dowell is at the forefront of the design and construction of new civil marine projects to service the resources boom.