21°16' 24'' S | 149°17' 47'' E

Hay Point Expansion Stage 3, Queensland, Australia Overview

Scope of Work Engineering, procurement, and construction
Value $2.45 billion
Business Mining & Metals

Challenging project will help meet increased energy demand

hay pointThe third expansion of the Hay Point Coal Terminal will dramatically increase throughput capacity at one of the largest coal export facilities in the world. Built by Bechtel for the BHP Billiton Mitsubishi Alliance (BMA), this challenging commission entails building a new berth at the coal terminal and includes offshore and onshore construction and land reclamation as well as building and fitting out new trestles, conveyers, and ship loaders. 

Hay Point ships coal mined from Queensland’s Bowen Basin, which contains one of the world’s largest reserves of metallurgical coal. Bowen Basin coal is used mainly as a fuel for steel production and as a reducing agent in blast furnaces.

The project will increase throughput capacity from 44 million metric tons to some 55 million metric tons of coal per year, and enable BMA to keep pace with increased mining production in the region and intensified international demand.

Inside the project

hay point expansionThe Hay Point Coal Terminal serves eight coal mines in central Queensland with an integrated rail-port network. The terminal has rail facilities for unloading coal from the mines, onshore stockpile yards, and offshore wharves.

The offshore wharves are served by a conveyer system, supported on jetties that run out to sea and enable ship loading in deep water.  The $2.45 billion expansion presented a number of construction challenges:

  • Working under difficult conditions 1.2 miles (2 kilometers) offshore
  • Reclaiming some 25 acres (more than 10 hectares) of land adjacent to the existing stockyard area
  • Assembling offsite (on account of limited space) new transfer towers, surge bins, and a ship loader
  • Dredging in an environmentally sensitive manner to remove silt, clay, and hard rock to make way for the new berth

The project plays an important role in the local economy. The construction phase created more than a thousand jobs.

Milestones at Hay Point

On December 9, 2014, coal was loaded out through the new 1.18-mile (1.9-kilometer) long trestle to the existing Berth 1, which helped prove the reliability of one of the out loading streams prior to commissioning the new berth and ship-loader. In January 2015, a customer ship docked at the new Berth 3 for the first time, with first coal loaded shortly after on January 12. Apart from the new jetty and berth, Bechtel’s work for BMA, which is now in the final stages, includes onshore reclamation and coal materials handling facilities. 

Innovative execution center optimizes performance

The bisbane hubStage 3 expansion is one of several large efforts being managed through the innovative Brisbane Hub.

The Brisbane Hub is a Bechtel execution center formed to plan and optimize large-scale projects owned by BHP Billiton and its partners. These include four nearby coal-mine projects in Queensland’s Bowen Basin: Caval Ridge (pictured), Daunia, and Broadmeadow. 

The Hub model allows Bechtel and our customer to work together directly in a planned long-term arrangement:

  • Saving money and time
  • Improving safety and quality
  • Reducing risk
  • Facilitating better planning