KAEFER Australia recently completed a major refurbishment project on Ship Loader 3 at Berth 3 of BMA’s Hay Point coal export terminal in Queensland.
The project involved a multi-disciplinary scope delivered in a live operational environment, requiring detailed planning, strong coordination and a consistent focus on safety.
At peak, the project engaged a workforce of 184 personnel across scaffolding, coatings, electrical and logistics.
Delivering Complex Access at Height
A key component of the project was the design and construction of large-scale scaffold access across the ship loader structure.
This included:
- Access to the A-frame and mast up to 74 metres
- A base scaffold structure measuring 30m x 45m, narrowing to 20m x 20m at height
- Engineered heavy duty cantilevered loading bays
- A hung scaffold on the boom with integrated access and loading systems
In total, 525 tonnes of scaffold was installed over 49 days, enabling safe and efficient access for all work fronts.
Safety innovations such as engineered netting systems were implemented to eliminate dropped object risks and allow concurrent work below. Dual stretcher stair systems and dedicated access walkways further supported safe movement and emergency response.
Protective Coatings for Long-Term Performance
The coatings scope focused on restoring and protecting critical structural elements.
Works included:
- Full encapsulation of work areas up to 74 metres
- Hot washing and surface preparation
- Abrasive blasting and repair works
- Application of zinc primer, stripe coat and topcoat systems
This ensured long-term durability of the structure in a harsh marine environment.
Coordinated Logistics and Support
Logistics played a critical role in maintaining productivity across the project.
The team provided:
- Continuous transport of personnel, materials and equipment between berth and onshore
- Day and night shift bus services with five buses in operation
- Forklift and vehicle support to manage material flow
This enabled seamless coordination across all work fronts and shifts.
Electrical Disconnection and Reinstatement
To support coatings access, all electrical components within the work zones were safely disconnected and repositioned.
Once coatings were completed and inspected, systems were reinstalled, tested and returned to service, ensuring operational readiness.
One Team Delivering Results
In addition to the planned scope, KAEFER provided rapid-response support to the client, mobilising 14 boilermakers at short notice to assist with additional works.
The Ship Loader 3 MSD project highlights KAEFER Australia’s ability to deliver large-scale, multi-discipline projects safely and efficiently, even in complex operating environments.
