Reconstruction Work on Lyttelton Port of Christchurch, New Zealand, Marine Oil and Gas Terminal Utilising an Innovative Cable Stayed Fender System

Lyttelton Port of Christchurch (LPC), New Zealand, was required to upgrade the fender and mooring system on their oil and gas marine terminal while keeping the terminal operational throughout the construction period. The existing terminal was constructed in 1934–1938 on a the edge of a reclamation that was constructed 1874 – 1910 and is prone to liquefaction. The terminal has a high berth occupancy from a variety of vessels ranging in length from 65m to 225m ( 215ft to 740ft) LOA and LPC wished to retain the existing bunkering customers at this berth. Therefore only 3 x 12 hour shifts per week were made available for the contractor to undertake the reconstruction work. This requirement drove both the construction and the design of berthing and mooring components. The resulting system comprised four concrete filled tubular steel piles, supporting a fender system strutted back to passive anchors on shore. A novel system of heavy cables was used to resist along-wharf berthing loads and transmit these back to the shore thus minimising work on the berth face which had to be undertaken in the 12 hour windows. The standard mooring blocks for bollards doubled as anchor points for the cables. LPG and oil marine loading arms and bunkering points also required relocating together with a new oil manifold structure being constructed on land behind the berth. Detailed programming of the contractor's works around vessel visits was a major challenge as during each week different days were allocated to the contractor, and only "locked in" each Thursday for the following week's work. Communication with LPC's customers was an essential part of the project management as was the implementation of an extended common permit to work system covering the berth and the oil manifold area. This paper will discuss the design, construction, operational and risk issues associated with reconstruction work in an operational oil and gas marine terminal.