Hay Point Coal Terminal Expansion 3 (HPX3) Installation of Materials Handling Structures and Equipment

BHP Billiton Mitsubishi Alliance (BMA)

Hay Point, Queensland, Australia

The multi-billion dollar third expansion at the Hay Point Coal Terminal involved building and commissioning a new berth to increase throughput capacity and export capability to support eight mines located in the Bowen Basin. 


Multidisciplinary and integrated expertise

G&S Engineering undertook the structural, mechanical, piping and electrical instrumentation (SMP&EI) erection, installation and commissioning for all onshore materials handling structures and equipment. The works included the integration of seven pre-assembled towers and surge bin modules, and receipt and handling into position of pre-assembled conveyor gallery modules and pre-assembled buildings. Where works involved tie-in to existing operating equipment G&S undertook the shutdowns for each plant to allow works to be completed.

G&S’ fabrication workshop facilities were utilised for the pre-assembly of client supplied items, as well as supply and fabrication of structural and piping items required for brownfield and tie-in works.

The second phase of work included onshore and offshore tie-in shutdown planning and execution, as well as commissioning support from pre-commissioning through to wet commissioning, and handover.


Delivering value beyond the initial project scope

The Hay Point Expansion project is one of the largest construction projects undertaken by G&S, totalling approximately $220m in fees and with a peak construction workforce of over 350 personnel.

The safe, timely and high quality delivery of all scope services by G&S onshore works resulted in G&S being the contractor of choice to take on further packages outside the original contract scope. The extra packages awarded to G&S included tie-ins to existing plant, offshore works and commissioning.