Water management was a constant focus on the project. Images: S&Z Australia

Besides being considered a major International Container Terminal with its 944-metre wharf relying on three container-handling berths, Swanson Dock must accommodate increasing volumes of containers carried into Melbourne by some of the largest ships in the world.

As it was constructed in several stages between the 1960s and 1980s, the asset, in this the age of sustainable global logistics, was long-overdue to have its design life extended.

With pressure mounting on ports to reduce their emissions, port electrification is an opportunity to upgrade, among other things, the high voltage network.

At present, maritime gantries and cranes at many of the world’s leading ports are being electrified alongside other core operations. At the Swanson Dock in Melbourne, specifically at Berths 1 and 3, this is no different. Demands on port infrastructure and for lowering operating costs are increasing at once.

With that the ability to deliver reliable power to heavy‑lifting equipment is imperative not only to remain competitive but also to optimise efficiencies. Multiple obstacles, however, were preventing the port cranes accessing the electrical capacity that would be needed for future installations.

Not least of all in the existing berth structures, each of which presented significant restrictions.

The project, in sum posted multifarious problems for Qest Infrastructure who had been engaged by DP World to find a solution. Enter S&Z Australia, the Victorian-based specialist in horizontal directional drilling, underboring and microtunneling solutions.

As the concrete deck is an established, heavily trafficked asset, excavation through it was not permitted. This restriction immediately ruled out traditional open‑cut trenching. Installation of the new HV conduits beneath the berth required a method that avoided surface disruption, protected the marine environment, and navigated complex subsurface conditions.

S&Z Australia would need to provide a trenchless solution capable of delivering new conduits without disturbing the dock surface. Installation of four 150mm conduits at each of Berth 1 and Berth 3, would provide the necessary capacity for future crane power requirements.

The works involved penetrating the existing sheet pile wall above water level, then sealing the wall post‑installation to prevent any water ingress.

Precision with careful sequencing, would be critical, what’s more, incorporating methodology that could operate safely in a marine‑adjacent environment.

The brief was inherently challenging. No relief hole or launch shaft could be excavated through the established dock structure. Zero liquid waste was permitted to enter the ocean, ruling out methods with uncontrolled slurry or fluid returns.

Meanwhile, directional drilling posed significant steering challenges in the known ground conditions, which included variable soils and obstructions.

A controlled work zone was necessary for laser boring.

Because of these critical constraints, it was ultimately decided that laser boring, as it afforded greater accuracy, control and environmental protections, was going to be the most effective and appropriate trenchless method put to use. In addition to this, complex ground conditions would need to be navigated.

The subsurface profile included running sands, Coode Island Silt, and unknown in‑ground piles not easily detected or visually confirmed.

These conditions demanded a methodology capable of maintaining line and grade while managing instability and obstructions. Working below the water table would introduce an additional risk.

“To create a safe and stable environment for laser boring, the team installed a sheet‑pile box and jet‑grouted the base, forming a controlled work zone,” recalls Jim Pound, General Manager S&Z Australia.

“Emergency dewatering systems were established to respond immediately to any unexpected water ingress.”

Water management, subsequently, became a constant focus given the proximity to the bay. Controls on this task included having pumps on standby and emergency egress plans for personnel.

Drilling activities were carefully coordinated around the timing of tidal movements.

“These measures ensured both safety and environmental protection throughout the works,” said Pound.

Productivity at the port was rarely impacted. In fact, during construction the port remained active with straddle carriers and other dock traffic operating nearby.

To ensure safe coexistence, third‑party engineering assessments were undertaken to confirm safe approach distances, allowable loads, and required depths during drilling and installation.

Construction activities were sequenced to minimise operational impacts while maintaining safety for all personnel.

Works involved penetrating the existing sheet pile wall above water level.

Despite the constraints of the berth structure, challenging ground conditions, and the need to protect the marine environment, the project successfully delivered a trenchless solution that meets the port’s long‑term HV capacity needs. In short, S&Z Australia delivered a safe, future ready outcome for its client.

Now that installation of new conduits at Berths 1 and 3 has been completed, it ensures the infrastructure is ready for future crane upgrades while preserving the integrity of the dock and safeguarding the surrounding bay

For more information, visit www.sandz.com.au

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