Project Summary

The Whyalla Port Expansion was constructed primarily to double Arrium Mining’s export capacity of iron ore feed material. The 85m extension of the existing quay wall is capable of handling vessels up to 50,000 DWT and accommodates a single 4200ton per hour capacity ship loader which is has a maximum travel of 110m.

Madsen Giersing (MG) was appointed by Leighton Contractors to provide the detail design and technical support services for the design and construct contract for an 85m extension of the existing quay wall for Arrium Mining to use for export of iron ore.

The construction of the new berth consisted of an L-shaped sheet pile wall. The top of the wall was at RL +5.8m with a berth pocket of RL -10.0m. The quay wall consisted of a 1.5m by 1.0m insitu concrete capping beam and AZ37-700 sheet piles with alternating sheets strengthened to form CAZ37-700 sheet piles. The wall was tied back at 2.4m intervals to a 1000mm tubular steel anchor pile. The design of anchor ties used steel plates instead of propriety anchor ties that allowed for shorter lead time

Five (5) fenders at 16.8m spacing are located along the front of the wharf. The fenders are connected to a steel frame which is bolted directly to the capping beam.

The transfer tower for the conveyor system was supported by a piled concrete deck. The deck consisted of precast concrete units with an insitu concrete topping tying all the units together. This form of construction provided a fast on site construction.


Whyalla, South Australia


Arrium Mining


Leighton Contractors

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