DP World – Port Botany Terminal – Rubber Tyred Gantry (RTG) Concrete Beam Construction

Project Overview: The RTG Beam project aimed to enhance the container transfer process at DP World’s Port Botany Terminal by improving the efficiency and reliability of Rubber Tyres Gantry Cranes (RTG’s). These cranes are responsible for moving containers from trucks and internal transfer vehicles (ITVs) to designated container stacks. In order to accommodate the RTGs, a reinforced concrete runway beam was necessary.

Civilcraft was commissioned to construct an extension to the existing RTG Beam, which involved the construction of approximately 250 meters of new reinforced concrete runway beam. The primary goal was to ensure that RTG operations could continue uninterrupted and with improved performance. Additionally, the project included repairs to the asphalt in the immediate vicinity of the RTG Beam, ensuring a safer and more secure work environment.

Project Components:

• Site establishment including site facilities, temporary fencing, management plans, protection of existing services and dilapidation reports.
• Remove and dispose off-site of excavated pavement materials to the design depth. Removal and disposal to be undertaken in accordance with legislative requirements including all sampling, testing and classification in accordance with EPA requirements.
• Preparation of RTG runway beam including sub-base preparation, supply and placement of steel reinforcement.
• Supply, place and finish high early strength concrete to RTG runway beam.
• Mill damaged flexible pavement to repair identified damaged pavement to a depth of 50mm (where required) including disposal of millings off site.
• Supply, delivery and placement of asphalt re-sheet wearing course 50mm nominal thickness, AC14HD R116 A35P.
• Provision of as-built documentation.

Key Challenges and Risks:

• Working in a live round-a-clock environment.
• Works were postponed due to high winds. In order to achieve set target dates, additional resources were required.
• Access to the construction site was limited due to the terminal’s security protocols and operational requirements which included the MSICs and safety marshals. The construction team worked closely with the terminal operator to ensure that there was compliance with these regulations while minimising disruption to port operations.