Karara Marine Piles Wharf Berth 7 (W978)

Project status: 
Major Project >$25m
Industry sector: 
Mining & Resources
Falsework/ Hydraulic Leader
Marine & Falsework
Our Client: 
Laing O'Rourke
End Client: 
Karara Mining Ltd a subsidiary of Gindalbie Metals
Project Time Frame: 
Geraldton WA

Key Challenges and achievements

  • Proactive tender approach working with Main Contractor to secure contract for both parties
  • Short lead time to mobilise, successfully achieved
  • Fast turnaround for temporary works design and fabrication
  • Use of local resource (labour, engineering, fabrication etc..) for temporary works for leader, falsework and headstock  design and fabrication
  • In house design and fabrication of a 60t track mounted hydraulic rotating Leader
  • Continuous improvement in systems and engineering
  • Working with our client with shared resources, jointly achieving overall project goals

Advantages of Using falsework

  • No disruption to the existing port operation
  • Avoids increase to the already limited vessel movements allowed in harbour
  • Ability to continue our scope of works independent of tides and sea states
  • Ability to  open up numerous work fronts without needing additional vessels
  • Ease of access for following trades
  • Capacity for cranes up to 280t operating at safe operational limits
  • Difficult ground conditions are better suited to land-based plant


  • This work forms part of a dedicated Shipping Berth (Berth 7) for Gindalbie Metals $2.6B Karara Mine, Port and Rail Development that allows shipping of 16 MTPa of Iron Ore from a Panamax Vessel berth
  • Installation of 38 No. 900mm Dia Vertical Piles (20mm wall thickness and 20 tonne) to 45m depth
  • Installation of 42 No. 900mm Dia Dolphin Raker Piles (1 in 3) (25mm wt and 30 tonne) to 50m
  • Design, supply and installation of 180 linear m of 300t capacity falsework (4No sets of 30m falsework, installed and extracted a total of 6 times)

Geotechnical conditions

  • Driving through limestone encountered at seabed level for many piles
  • Limestone strength varied across the site and was high strength in places, which resulted in difficult driving conditions

Key Plant

  • Piling Leaders – Rotating Leader, Fixed Leader, Flying Leader, numerous Crawler Cranes up to 280t, Hydraulic Hammers & Vibrators up to 16t, 150m of 300t capacity Falsework and 50m of 100t capacity Falsework

Please click to access a downloadable copy of our Karara Marine Project Brochure