Overview

Liberty Industrial was engaged to carry out the demolition of a coal stacker and reclaimer at the Port Kembla Coal Terminal to make way for new machinery as part of a broader terminal restoration project.

Challenges

• Demolition works in an operational environment.
• The configuration of the site did not allow for the coal stacker to be relocated for demolition and recycling.

Robust Solutions/Exceptional Outcomes

Robust solutions

• Our team developed a demolition methodology that enabled all preparatory works to be carried out without disruption to the coal terminal’s operations, keeping shutdowns to a minimum.
• The 1250t reclaimer was transported from the operational coal terminal to a dedicated demolition area where it was pre-weakened to facilitate explosive demolition with cutting charges to reduce the structure to a suitable height for mechanical processing.
• The 400t stacker was dismantled in situ over live operational conveyor lines utilising a 600t crawler crane in a choreographed sequence designed to maintain structural stability.
• Various sections of the stacker, weighing up to 140t, were rigged to the 600t crawler crane, separated from the remaining and lifted down for downsizing and removal.
• 70 and 36t excavators fitted with shear attachments were used to process the structure for removal and recycling off-site.
• Engineered lift studies and structural engineering assessments and certain equipment from the coal stacker were removed to allow dismantling using a 600t crawler crane.
• Upon completion of each lift, the dismantled sections were downsized at ground level using a combination of oxy-cutting and mechanical shearing. The processed material was removed from the site for recycling.

Exceptional outcomes

Liberty Industrial’s calculated and safe methodologies, extensive planning and coordination ensured minimal disruptions to the operational coal terminal facility – a critical success point for the project. As a result of the outstanding performance, Liberty Industrial was engaged by Port Kembla Coal Terminal Ltd to dismantle another two stackers and a reclaimer.