Port Kembla Coal Stacker Reclaimer Demolition Stage 2

Port Kembla Coal Stacker Reclaimer Demolition Stage 2

Wollongong, NSW
Port Kembla Coal Terminal Ltd
9 months
Completed 2018


Liberty Industrial was engaged to carry out the demolition of a 1,250t bucket- wheel reclaimer and two 500t stackers at Port Kembla Coal Terminal located in Wollongong, NSW.


  • The induced collapse method was not possible as three machines were straddling live conveyor lines and were close to operational assets.
  • Relocation of machines for an induced collapse was unachievable due to the presence of new machines blocking the way out.
  • Designing the lifts and sequencing the works to ensure optimum balance between financial viability and technical feasibility.
  • Manoeuvring a heavy lift mobile crane is an expensive and time-consuming exercise as they usually require complete disassembly and reassembly.

Robust Solutions/Exceptional Outcomes

Robust solutions

  • Our structural engineers modelled the redundant reclaimer and worked together with the demolition team to identify the optimum deconstruction sequence. The Liebherr LR1750, a lattice boom crawler with a maximum rated lifting capacity of 750t was concluded to be fit-for-purpose.
  • The methodology was further refined to allow efficient sequencing of the lifts and minimise crane relocations.
  • Structural engineers conducted a complete assessment of the redundant machines at each step of the dismantling to ensure structural stability.
  • Demolition works began with the separation and extraction of the impact tables underneath the coal handling machines without causing any damage to live conveyor belts. This was achieved by erecting hoarding protections.
  • Hazardous materials such as bonded asbestos and hydrocarbon substances were removed from the stackers and reclaimer.
  • The mobile crane was utilised for rigging, separating, lifting and lowering the modules into designated laydown locations – the heaviest being 220t.
  • The modules were demolished on the ground using a range of 25 and 48t excavators, fitted with shear and grab attachments and sent to recycling locations.


Exceptional outcomes

An extensive engineering phase led to the safe and controlled demolition of the bucket-wheel reclaimer and stackers. Activities that would normally require a complete shutdown, were phased in a manner that allowed for minimal disruption to daily activities.

Value Add


Demolition Simulation and Modelling

With exclusive license to demonstrate using Extreme Loading® for Structures (ELS) software developed by Applied Sciences International (ASI).



Use of best approach demolition and dismantling such as explosive using world class fleet, safety and engineering methodologies in explosives and rigging.


Decontamination and Industrial Cleaning

Designing engineered solutions for decontamination such as removal of asbestos, heavy metals, PCBs, dioxins, PFAS and NORMs.


Asset and Resource Recovery

Comprehensive waste and recycling management to contribute to the circular economy to extend the lifecycle of materials.


Site Remediation

Site rehabilitation via methods such as bioremediation, containment, decontamination, dewatering, stabilisation, treatment and tracking to disposal of contaminants.



  • 2019 World Demolition Awards, Contract of the Year Under US$1M - Finalist

Managing PFAS in Site Closure Remediation


Bioremediation for Closure


Demolition and recycling phase completed for first major closure project for Rio Tinto at Argyle Diamond Mine, WA.

integrated capability responsible decommissioning

decommissioning closure and asset liability consulting

consulting risk management engineered solutions 3d simulation

and simulation liberty modelling dismantling and asset

dismantling and asset recovery synchronised safety

deconstruction resource recovery and recycling expert delivery

high expert industrial delivery reach consulting

expert delivery high reach explosive induced collapse

collapse specialised contracting decontamination

decontamination cleaning remediation environmental stewards

stewards risk mitigation and management waste disposal

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