The objective of a capital investment programme valued at approximately $270 million is to ensure that the terminal facilities are positioned to meet customer expectations and Hunter Valley coal chain demand beyond 2030.

The investment programme is headlined by the procurement of a new shiploader, to be installed at Kooragang’s K4 berth as a replacement for Port Waratah’s original Shiploader 7.08 which commenced operations in 1984. It is expected that the new shiploader will enter operations in 2028. 

Also included in the programme are major upgrades and life extension works on the other two Kooragang shiploaders, both commissioned in the 1990’s. The first of these projects commences in July 2025 with a four-month outage of Shiploader 7.09. Further similar outages will follow over the next four years and include life extension works on Shiploader 7.10.

“This significant investment in our assets ensures Port Waratah is positioned to meet the demands of the Hunter Valley coal industry reliably, flexibly and cost-effectively into the future,” said Port Waratah’s CEO, Hennie du Plooy.

“The Kooragang Terminal shiploaders are all reaching key milestones within their lifecycles. One of our iconic yellow shiploaders has delivered 40 years of service, with the other two installed in the 1990s. An asset assessment and continued use study completed in 2023 recommended a strategic programme of work on all three shiploaders.”

“As we have demonstrated at our Carrington Terminal which has been operating since 1976, strategic investment in maintenance, upgrades and replacement ensures that infrastructure such as this can perform reliably over long periods. Our aim is to find the optimum balance between investment in and the capability of our shiploading fleet over time to ensure that we can meet not only customer demand, but also changing stakeholder expectations for safety and environmental performance.”

Port Waratah has entered into contracts for the design, construction and delivery of the new shiploader, as well as the life-extension works on 7.09 shiploader for execution in 2025, with Civmec Construction and Engineering.

Civmec is an integrated, multi-disciplinary construction and engineering services provider to the Energy, Resources, Infrastructure, Marine and Defence sectors. With operations around Australia, Civmec are headquartered in Henderson, Western Australia, with a major facility in Tomago, New South Wales. The shiploader will be manufactured in Australia using Australian steel suppliers to support the domestic steel & manufacturing industries, wherever possible.

“We are looking forward to working with the Civmec team to deliver the first shiploader refurbishment and getting started on the design for the replacement shiploader."

“The refurbishment works on Shiploader 7.09 will commence in July with an outage of four months to complete structural and strengthening works, replacement of mechanical components, and surface protection. We are confident that Port Waratah will continue to meet customer demand despite this disruption through leveraging the redundancy available in the remainder of Kooragang Terminal and the capacity of the Carrington Terminal,” said Mr du Plooy.

Civmec CEO, Pat Tallon, commented, “Civmec’s balanced machine works portfolio continues to grow, with the award of a new shiploader project for Port Waratah. Design and engineering will be executed by our in-house balanced machines engineering team, with manufacturing, preassembly, and no-load commissioning undertaken at the Group’s fabrication facilities. Once complete, the shiploader will be transported to the Kooragang Terminal for installation via heavy-lift ship.

“We are proud to be able to deliver the design, manufacture, assembly and construction of this machine using Australian steel and our Australian workforce. We are equally proud of our position as a tier one contractor in NSW, having made significant investment into the community and growth of our business with extensive local facilities and development of a skilled workforce in Newcastle.”

The project is anticipated to create more than 100 highly specialised jobs throughout its duration and generate significant local employment and subcontractor opportunities, expanding on Civmec’s continued commitment to the NSW Hunter region and bolstering industry capability. The shiploader is due for delivery and handover in 2028.”

This substantial investment underscores Port Waratah's commitment to maintaining its position as a leader in the coal export terminal industry. By modernising its infrastructure and partnering with industry experts like Civmec, Port Waratah is not only ensuring operational efficiency but also contributing to the economic strength of the Hunter Region. This investment in the Kooragang shiploaders is a testament to Port Waratah's long-term commitment and dedication to meeting the evolving needs of its customers and stakeholders.