• Design, fabrication and erection of mobile access gantries to enable safe access to unstable structures for their demolition, replacement, repair
• Design and installation of encapsulation systems to enable sand blasting and reapplication of protective coating to steel structures over environmentally sensitive waters
• Reconstruction of the wharf substation
• New HV cabinets, conduits and cabling
• New motors and controls for conveyors, feeders, and ship loaders
• Lighting
• Switchboards
• Repairs to mooring dolphins, including access stairs and platforms
• Repairs to berthing docks
• Replacement of navigation devices
• Replacement of cathodic protection
• Mooring capstans and winch box repairs
• Repairs to jetty support piles, above and below waterline
• Hydraulic works to loaders and conveyor braking system
• Replacement of fire services including controls, pumps, electrics
• Structural repairs to tower platforms and link bridges
• Replacement of more than 2,000 concrete decking slabs, precast, post-tensioned in situ and grouted
• Removal and replacement of damaged cladding and structural steel, above and below deck
• Removal and reapplication of protective coatings

Much of the existing, damaged structure needed to be demolished to make way for reconstruction and repairs. Nearly all of the works were on unstable structures, at heights, over water, up to 5km out to sea. Other works were under water. A team of divers, barges, tender boats and specialised marine access work platforms and lifting equipment were required.

The key element was a Sea Lift 4 jack-up barge, with a capacity of up to 250t, supported by four hydraulic “spud” legs. The Sea Lift 4 provided a stable work platform above the high-water level in depths up to 36m. A 150t lattice jib crawler crane and two smaller cranes worked from the jack-up barge platform. The tug, barges and cranes enabled temporary mobile gantries and access platforms to be erected to support reconstruction.

The Lucinda Bulk Sugar Terminal was established in 1958. It has a storage capacity of around 230,000 tonnes of raw sugar, servicing businesses in Australia and overseas. After the cyclone swept across in 2011 and severely damaged the structure, a fast-tracked program was critical to get the facility running again in time for the 2012 sugar harvest.