Appleton Dock Refurbishment

The Port of Melbourne Corporation sought tenders to repair/strengthen the existing Appleton Dock Berths B to F to provide an additional minimum 15 years service. Appleton Dock Berths B-E are leased and operated by Qube Ports Pty Ltd as part of a general cargo terminal, whilst Berth F is operated by ABA.

Appleton Dock is located on the Yarra River in the Port of Melbourne and the berths are subject to continuing operations, by both ships and yard vehicles, during the execution of the Contract.

The $20 million works included remediation of timber piles at Berths B to F and remediation of concrete elements including concrete piles and deck at Berths E to F. All works were undertaken in accordance with agreed requirements of the Contract and Access Agreements.

A significant challenge to the project was the concrete demolition of the pier underneath. To ensure safe footing, a temporary stable platform was supplied and installed to enable hydro demolition and concrete repair to be undertaken safely.

Fitzgerald chose hydro demolition concrete removal technique using high-pressure water to remove deteriorated and sound concrete in lieu of historical jack hammering techniques.

In continuing with Fitzgerald’s philosophy of undertaking the works with their own personnel to ensure quality and program compliance, Fitzgerald undertook extensive training and equipment procurement.

This resulted in Fitzgerald undertaking all the deck reinstatement works directly rather than through subcontractors. Their resultant works exceeded all specified requirement in terms of bond strength, compressive strength and anticipated repair durability.

Each old timber pile was inspected, reviewed and an appropriate rectification procedure determined with acceptance by the Port of Melbourne Corporation.

Fitzgerald introduced an innovative repair system which reduced repair activity time which in turn offered the Port of Melbourne Corporation a reduced cost. The success of this new innovative process has now caused it to be adopted by other marine authorities.