Rock solid.

Kooragang Expansion Project - KEXP 4, Kooragang Island, NSW.

  • Primary panel with stop end arrangment
    Primary panel with stop end arrangment
  • Cages and stop end
    Cages and stop end
  • Concreting of a Primary panel
    Concreting of a Primary Panel
  • Bauer BC 32 Cutter in Action
    Bauer BC 32 Cutter in Action

Project Outline

Diaphragm Wall construction for Stage 4 (Project 145) for a fourth Dump Station and associated conveyor infrastructure at the Port Waratah Coal Services (PWCS) Kooragang Coal Terminal (KCT).


The work was carried out for Bechtel on behalf of PWCS.


The project included the following relevant elements:

  • A dump station which is approximately 15 m deep, 12 m wide and 66 m long. The walls were formed using diaphragm wall construction with a jet-grouted base plug.

A conveyor exits the base of the dump station through a tunnel which slopes up to a surface exit point about 200 m to the east and was constructed using a similar methodology to the main dump station.

Scope of Works

All construction associated with the diaphragm wall system and supporting base plugs (jet Grouting Plug) between the walls for both the dump station and the tunnel.

Dump Station area was divided by cross DW panels into 3 cells. Tunnel area was divided by (Jet Grouting) cross cut-off walls into 4 equal cells.


Dump Station

No. of Cells: 3

No. of Diaphragm Wall Panels: 25

Size of Panels: 11nos.x800mm wide x (2800mm-7000mm) length x 20m-28m depth.

                         24nos.x640mm wide x (2800mm-7000mm) length x 14m-21m depth.



No. of Cells: 4

No. of Diaphragm Wall Panels: 48

Size of Panels: 48nos.x640mm wide x (2800mm-7000mm) length x 11.3m-17m depth.


Works include:

  • Design and Construct Guide Wall.
  • Supply and installation of  all concrete,  reinforcing steel,  hold-down bolts, couplers, embeds and ferrules.
  • Supply and installation of Inclinometer pipes.
  • Installation of A base block plug (Jet Grouting Plug) throughout  both the dump station and the tunnel to limit the inflow of water as specified.
  • Jet Grouting Cut-off Walls to separate the Tunnel into 4 sections.
  • Water Tightness Testing for all 7 Cells in the dump station and Tunnel.


Concrete used: 40MPa for DW panels (volume 4,673.8m3)

                             25MPa for Guide Wall (volume 476.2m3)

Reinforcement: 522.75 ton

Industry leading techniques and equipment

Our clients

  • Roads & Maritime
  • Department of Main Roads & Transport
  • Main Roads Western Australia
  • Transport for NSW
  • Queensland Rail
  • Sydney Water
  • Queensland Urban Utilities
  • Water Corporation
  • CPB
  • Lend Lease
  • John Holland
  • McConnell Dowell
  • OHL
  • Acciona Australia
  • Meriton
  • Brookfield Multiplex
  • Hutchinson
  • Probuild
  • JQZ Developer
  • Dragados
  • Samsung C&T
  • Bouygues Australia
  • Jaxon Construction
  • BMD
  • PTA WA
  • PTA WA 1