Client: John Holland Group
1. Project Background
The DBCT – Pile Wrapping Gantry project was commissioned by the John Holland Group for the Dalrymple Bay Coal Terminal (DBCT). The client required a mobile access system to facilitate safe and efficient maintenance of jetty piles. The traditional approach to pile maintenance involved manual setup of scaffolding around each pile, and then removal of scaffolding and reassembly at the next pile. This was very slow and labour intensive.
The solution was the development of a self-propelled gantry system capable of traversing the wharf structure and deploying swing stages for pile inspection and repair.
2. Challenge
The primary challenge was to design and implement a control and mechanical system capable of handling the complex operational modes required for pile wrapping, including parked, travel, hoist, maintenance, prestart inspection, refuelling, and storm-coupled modes. The system needed to ensure reliability under harsh environmental conditions, accommodate precise control and safety features, and integrate seamlessly with existing infrastructure. Constraints included tight timelines, strict safety standards, and the need for custom mechanical and hydraulic components.
3.Solution
CMP Engineers developed a comprehensive control system functional specification, detailing the external behaviour and internal logic of the gantry control system. Key steps included:
- Control System Design: Defined operational modes and functional requirements, including HMI screens for maintenance, fault logging, and system monitoring.
- Mechanical Engineering: Specified and sourced custom components such as landing legs, lifting hardware, hydraulic cylinders, and bearings from reputable suppliers (SAF Holland, Nobles, Nordon Cylinders, Thyssing Industrial Supplies, Martin
Trailer Parts). - Safety & Reliability: Incorporated emergency stops, proximity sensors, gate closed sensors, pressure sensors, and anemometers for operational safety.
- Testing & Validation: Conducted detailed mechanical calculations to ensure all components met or exceeded safety factors, with thorough documentation of load, shear, and bearing capacities.
- Collaboration: The project was managed and executed by a team of senior engineers, with direct involvement from Rowan Nicholas and Thomas Meutermans.
4. Outcomes
Tangible Results:
- Delivered a fully functional pile wrapping gantry system, meeting all client specifications and
operational requirements. - Achieved high safety margins in all mechanical calculations (factors of safety ranging from 5.1 to 14.1 in
critical components). - Enhanced operational efficiency and reliability at DBCT, reducing downtime and improving maintenance workflows.
Intangible Results:
- Strengthened CMP Engineers’ reputation for delivering complex, custom-engineered solutions in the
resources sector. - Fostered strong client relationships through transparent communication and technical excellence.
Key Learnings:
- Early and detailed specification of control and mechanical requirements is critical for project success.
- Collaboration with trusted suppliers and rigorous testing ensures reliability and safety in demanding environments.
Client Feedback:
- The project documentation indicates that stakeholders were kept informed throughout, with clear communication of deliverables and testing outcomes.