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Ports

Capability brochure

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Tailored solutions for port infrastructure

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Tailored solutions for port infrastructure

Building a solid foundation for Australian trade

Fulton Hogan creates, connects and cares for communities; building the roads, ports, airports, infrastructure and property which brings people together.

Over the past three generations, Fulton Hogan has built a formidable reputation as a leader in the civil construction market, initially in New Zealand and more recently in Australia. Our work takes us from suburban roads to major highways, airport runways and more.

So it will come as no surprise that we also understand the extreme performance requirements for civil infrastructure in resource ports, heavy-duty pavements in container handling facilities and the unique demands of their owners and operators.

As a largely self-performing civil contractor, Fulton Hogan brings together a comprehensive set of abilities, products and processes that allow us to provide tailored solutions for the complete construction of port civil infrastructure including earthworks, base layers and surfacing, through to their repair and long-term maintenance. We also bring on board our expertise in associated civil works including water infrastructure, electrical, access roads, rail and bridge infrastructure.

Fulton Hogan’s construction teams are frequently called upon to work in potentially hazardous environments such as airports, both civil and defence facilities. Our project managers and their teams are well aware of the stringent safety and security requirements when working in an operational port or container handling facility.

As well as acquiring wide-ranging experience, Fulton Hogan has developed intellectual property and a number of specialty products specifically for heavy-duty pavement construction applications.

With these advantages it is little wonder that Fulton Hogan, already a leader in so many areas of civil construction, is becoming a force to be reckoned with in the construction of Australia’s ports.

Cover image: Over 8700 square metres of RIGIPHALTE®pavement completed at the Port of Newcastle by Fulton Hogan

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Experts in port civil infrastructure

We build and maintain civil infrastructure Australia-wideFor more than 80 years the Fulton Hogan brand has been synonymous with all aspects of civil infrastructure, from earthmoving to surfacing. We are one of Australia’s major manufacturers of binders and asphalt and a dominant force in pavement surfacing. We have extensive experience in the construction of significant roads, airports, ports and heavy-duty pavements. Fulton Hogan is also a major player in road network and infrastructure maintenance. Our focus is on working with our customers to deliver quality outcomes that are on time, on budget and on target.

Value for money We provide our customers with value for money solutions that minimise operational downtime by focusing on long-term performance with minimal maintenance. Our teams work closely with the customer during the entire process, from design to final delivery, to ensure the optimum solution.

One stop shop Fulton Hogan is able to provide whole-of-life solutions tailored to the specific needs of the owners and operators of resource ports and container facilities. As part of our civil infrastructure offer, we provide a comprehensive suite of services from bulk earthworks through base layer construction, to asphalt and concrete surfacing, drainage, gas and electrical services, access roads, rail tracks, bridge structures and the long-term maintenance of this infrastructure.

Leaders in innovationBy going beyond convention and constantly seeking new and innovative solutions to our customers’ needs, Fulton Hogan is committed to achieving outstanding results. Specialist products and processes such as RIGIPHALTE® and our high modulus Hardstand Asphalt have been developed in-house specifically for heavy-duty pavement uses to provide cost and efficiency benefits for port owners and operators. DustBloc® and BaseBind provide effective solutions for dust control and stabilisation of bases respectively.

Self-performing, vertically-integratedAs Australia’s complete civil construction company, Fulton Hogan has the in-house resources to undertake a broad range of projects, supplemented where appropriate, by specialists. We operate our own quarries, construction teams, asphalt and binder manufacturing plants, asphalt laying and asset maintenance crews. By managing the internal supply chain through this vertically-integrated business model, we minimise delays, maximise value, improve control and quality and deliver effective, long-term outcomes.

We have the people and technology to construct hardstands and infrastructure for the harsh conditions of Australia’s ports.

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Access to specialist

Fulton Hogan’s broad geographical footprint – over 1900 employees in over 40 locations across mainland Australia – is complemented by access to specialist people and resources in areas as diverse as transport, water infrastructure, quarrying, bitumen, asphalt, precast concrete and infrastructure maintenance. Our in-house technical teams add a high level of quality assurance from pavement design review to high performance material design and manufacture.

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Fulton Hogan’s collaborative approach

CollaborationWe work closely with our customers to address issues and are proud to say that Fulton Hogan has a non-litigious approach. This has been proven during our entire history of over 80 years.

With these advantages it is little wonder that Fulton Hogan, already a leader in so many areas of civil construction, is becoming a force to be reckoned with in the construction of Australia’s ports.

Financially able and stableFulton Hogan is an unlisted public company. With assets of over $1.5 billion and a long history of financial stability, the company has the strength and resources to ensure its services are successfully and consistently delivered.

We work closely with our customers and partners to optimise solutions and outcomes.

East Swanson Dock, Melbourne

Client: Patrick

Patrick required a commercial solution that would resist hydraulic spills from parked straddle carriers. Fulton Hogan constructed a RIGIPHALTE® pavement for their straddle carrier parking bay providing easy cleaning of the pavement and to support the point loads.

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Focused on our customersFulton Hogan understands the unique loading and operational requirements of maximising throughput inherent in resource ports and container facilities. We are able to work closely with our customers during the design phase to ensure a quality long-term solution that will maximise productivity in a cost-effective manner. This close collaboration continues during construction to guarantee minimal operational disruption and an optimal outcome. Our dedicated Ports team work closely with our local operations to ensure optimum service levels.

The right cultureThe company has the resources and experience to enter into successful formal collaborative arrangements or joint ventures with allied contractors and customers.

Fulton Hogan’s customers appreciate working with a non-litigious, employee and family owned business who values long term relationships, yet is sizeable with revenues of around $3 billion per annum.

Here for the long haulFulton Hogan is predominantly owned by its employees and the Fulton and Hogan families. We value and foster open and honest, long-term relationships with our customers, employees, alliance partners, suppliers and subcontractors. This has translated into a high level of employee and subcontractor loyalty and stability, repeat customers and contract renewals.

Industry-leading safetyWorking safely is Fulton Hogan’s number one priority. We understand that working in a live bulk handling port or container terminal environment places extraordinary demands on safety and security. Our project managers work intensely with their teams and subcontractors to ensure our excellent record is maintained. The company’s ‘Zero Harm’ policy has ensured a safety performance that is second to none.

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Experts in civil infrastructureThe construction of a mining and energy port has the potential to bring together many of the processes that have helped make Fulton Hogan one of Australia’s leading civil construction companies:

• Bulk earthworks and baseworks for stockpiles

• Treatment of acid sulphate soils and contamintaed areas

• Ground stabilisation

• Footings for conveying equipment

• Hard-stands and heavy-duty pavement construction for laydown areas and general cargo

• Rail and access roads construction

• Ancillary civil works such as drainage, gas and electrical

• Construction of bridge structures, culverts, revetments and other associated structures

• Infrastructure maintenance & pavement repairs

• Specialist products such as DustBloc® for effective dust control and BaseBind for base course stabilisation.

Vertically integratedFulton Hogan has the capacity, capability and experience to work in all these areas and more. As a vertically-integrated and largely self-performing company, we can focus on managing and delivering the project to the highest quality standard within budget and on time while managing specialised subcontractors as required.

Innovative solutionsAs a technical leader in its field, Fulton Hogan takes pride in developing innovative solutions that provide benefits, both financial and functional, for our customers. We also understand that project time frames and maximising throughput is crucial in a bulk handling facility.

Fulton Hogan is well placed to assist in the construction of efficient bulk handling facilities that are essential if we are to maintain the momentum of Australia’s commodities market.

We have solutions for mining and energy ports

We understand time is critical in constructing a port for our resource customers. Our project management and risk management processes deliver a quality project on time.

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Port Hedland Berth 2, Western Australia

Client: Sandfire Resources

RIGIPHALTE® was the cost effective and timely solution for the heavy-duty lay down area to store copper concentrate stored in full containers stacked four high.

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Curtis Island, Australia Pacific LNG

Client: Bechtel

Fulton Hogan’s experience in earthmoving and civil construction was pivotal in meeting the challenges of the earthworks associated with the Australia Pacific LNG project, which included clearing 160 hectares of land, stripping of acid sulphate soils and cut and fill of over 3 million cubic metres of earthworks. Additionally, at the peak of this contract up to 250 staff and one million tonnes of water and materials were required to be barged across to Curtis Island every day.

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ExperienceThe unique operating conditions in ports and container handling facilities require equally unique pavement solutions. With more than 20 years experience in these specific applications and generations more experience in broader civil construction, Fulton Hogan is well placed to provide efficient and effective heavy-duty pavement construction solutions for facility owners and operators.

We have solutions for container terminals

Many customers are turning to our approach for ‘Value Engineering’ – maximising the long-term utilisation of their assets at the lowest costs.

Lyttleton Container Terminal, Christchurch New Zealand

Client: Lyttleton Port Company

This major project in Christchurch required the milling of 36,000 square metres of existing asphalt pavement and construction of more than 70,000 square metres of heavy-duty pavement, predominantly of interlocking concrete segmental pavers mechanically laid on a sand bed. Construction also included heavy-duty reinforced concrete slabs for wash and exit areas, upgrading of rail slabs including new track and turnouts and the construction of a substation and concrete abutment kerbs.

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Specialists in heavy-duty pavementsAs our customers seek a cost-effective solution, Fulton Hogan has developed a number of proprietary flexible pavement products and processes specific to ports and container handling facilities, including Hardstand Asphalt and RIGIPHALTE®. We are able to provide heavy duty pavement surfacing in a variety of materials including concrete and concrete pavers.

Packaged solutionFulton Hogan is able to offer a complete package including earthworks, base course preparation, surfacing, drainage and services. We are also experienced in ancillary works such as rail, access roads and bridge structure construction.

Mitigating risk and downturnWe understand that your port requirements are very different. The mitigation of downtime is crucial to efficient and profitable container handling operations and we have developed solutions accordingly.

RIGIPHALTE®RIGIPHALTE®, a composite of cement-based grout and open grade asphalt, offers many benefits over concrete, including reduced time and lower cost. It has extreme load-bearing capacity (both static and dynamic), and resistance to container corner castings, channelising, fuel, hydraulic and oil spills.

Port safety & securityContainer handling facilities also create unique safety and security issues. Our project managers and their teams have broad experience in both ports and airports and a record that is second to none.

Port maintenanceFinally, we offer a complete ‘after-sales-service’ approach with infrastructure maintenance services from pavement repair and maintenance of port road furniture through to vegetation control, all tailored to the specific requirements of each customer.

Port Botany, Sydney, NSW

Client: DP World

Fulton Hogan worked with DP World’s design consultants and operation’s teams to manufacture and lay its high performance Hardstand Asphalt under its container stacking rows with minimal disruption to operations.

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West Swanson Intermodal Terminal, Melbourne

Client: DP World

DP World contracted Fulton Hogan to redevelop their container intermodal terminal. Works included excavation and stabilisation of sub-grade, construction of drainage, water and electrical services, asphalt and post tension slabs.

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Minimal riskAs a largely self-performing, vertically-integrated civil contractor we are able to offer our customers a level of confidence and risk minimisation that few of our competitors can match, let alone exceed.

ResourcesThis is backed up by a workforce of over 1900 across mainland Australia, including 40 asphalt plants, 11 emulsion plants, quarries in three states and our own specialist concrete precast plant.

Intellectual propertyFulton Hogan offers the experience and expertise of its in-house pavement design engineers and the intellectual property they have created over the years. Our specialist engineering staff are able to provide assistance in the technical analysis of pavement conditions, assess loadings and provide practical advice on structural design and selection of materials to reduce the risk of delays and interruptions to port operations.

We have the people, technology and the know-how

Port Botany Sydney, NSW

Client: Patrick

Fulton Hogan’s Hardstand Asphalt was specially designed as a high modulus, deformation resistant product to stand up to the extreme conditions of heavy loads such as straddle and channelised wheel paths of Patrick’s truck grid.

We are known for our innovative approach including materials R&D, pavement design and application of new techniques.

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RIGIPHALTE® is a cost effective port hardstand solution, consisting of a flexible open grade asphalt and stiff cementious grout. It provides resistance against container corner castings, high static and channelised loads and hydraulic fluids.

Deformation resistance test of Hardstand Asphalt

Dynamic modulus testing

Hardstand Asphalt has superior performance against premium asphalt blends, tested under temperatures of 65°c and 60,000 passes of wheel tracking.

One of many tests performed in developing our specialist pavement products.

Number of cycles

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Pavement design quality controlOur in-house pavement specialists and project managers work closely with our customers and design consultants. They provide practical advice and harness our experience and resources to ensure the most effective structural design and material selection, and a value for money construction process that minimises operational delays.

Proprietary productsOur asphalt and binders R&D laboratories have an international reputation for excellence and have helped develop industry-leading products and processes specifically for heavy-duty port applications including RIGIPHALTE® and Hardstand Asphalt.

RIGIPHALTE®

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Sulphur Point Container Terminal, Tauranga New Zealand

Client: Port of Tauranga Limited, Beca

The project at New Zealand’s largest port involved the construction of 28 hectares of pavement over dredged sand. The works were staged as reclamation was completed. Fulton Hogan prepared the subgrade, 154,000 cubic metres of base course and laid over 60,000 tonnes of deep-lift asphalt manufactured in an on-site asphalt plant complete with quality testing facilities.

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w w w . f u l t o n h o g a n . c o m

Victoria/Tasmania (and Australian head office)

Level 1, Building 7, Botanicca Corporate Park, 572 Swan Street, Richmond PO Box 56, Hawthorn VIC 3122 T 03 9340 6200

New South Wales/ACT

Level 3, 61 Dunning Avenue, Rosebery PO Box 6099, Alexandria NSW 2015 T 02 8346 9400

Queensland

Building 8, Garden City Office Park, 2404 Logan Road, Eight Mile Plains PO Box 6263, Upper Mt Gravatt QLD 4122 T 07 3291 5600

South Australia

Level 1, 1 Greenhill Road, Wayville SA 5034 T 08 8177 8500

Western Australia

Lot 1, Talbot Road, Hazelmere WA PO Box 104, Midland DC WA 6936 T 08 9454 0100

Northern Territory

Marjorie Street Berrimah NT PO Box 167 Palmerston NT 0831 T 08 8932 2700