Cape Lambert A (CLA) Dolphins – Wharf Upgrade

Client: Austral Construction
Location: Cape Lambert, Pilbara, WA

Project Scope

Austral Construction was contracted to upgrade the Cape Lambert A wharf for the four iron ore berths, including demolition of 24 existing dolphins and installation of 20 new dolphins, supply and installation of associated dolphin walkways, stairs and services, wharf strengthening, and additional piling and bracing of 9 anchor bents. The project was made more complex by a tight schedule and an operational facility that only permitted access to one berth at a time.

CLA berth 1 complete 1

Roam Marine's scope

Temporary loadout jetty

Roam Marine designed a temporary loadout jetty to support a 300t crawler crane, including the concept and location of fender piles, pontoon and gangway for small boat access, across two spans with central piles positioned at the toe of the armour and seaward piles in the dredge slope. Scope included assessing the capacity of existing beams — originally sized for a 250t crane — and modifying as required for the larger crane, plus detailed design of new piles accounting for shallow embedment on bedrock, with smaller conical-tipped abutment piles to penetrate the seawall. A 400t jackup installed all piles except the abutment piles, which were installed using a land-based gate. The pontoon combines a 12m and 6m float with custom brackets and fendering at the piles, connected by a 20m-span gangway. A section of the seawall was removed for crane access, with sea-containers available to close the gap during a cyclone and prevent inundation of the laydown area.

Temporary works for 50-year storm events

Roam Marine designed the temporary works supporting construction across the wharf, engineered to withstand 50-year storm events. This included temporary bracing of spud piles and jackets, access along the wharf via modular walkways spanning up to 15m, and access to jackets, piles, bracing and stair towers up to deck level. Roam Marine also developed the installation method for longitudinal walkways between piles and under the maintenance deck, along with the associated lift studies, lugs and spreaders. A custom lift C-beam — 9m high with a 7m reach — was designed to lift up to 14t at 7m or 31t at 3.25m, and a monorail system was developed to install 25t lateral walkways between dolphins under the wharf.

Transverse walkway installation method

For the most complex lift on the project, Roam Marine designed the installation method for a 26t transverse walkway beneath the operating wharf. This included a 20m monorail rated to a 26t SWL with a 6m cantilever, installed using a 10t monorail and the 9m-high, 7m-reach C-beam. Roam Marine also designed the test load, lifting lugs, spreaders and rigging selection — including hoists and girder trolleys — for the sequence of transferring the walkway load from the crane hook onto the monorail, then rolling it under the wharf into position beneath the far dolphin deck.