Construction of a New Aggregate Export Terminal

Mining projects invariably require capability for shipping to export markets, and deep sea shipping terminals usually comprise this critical element in the logistics chain. In March 2007, Polaris Minerals Corporation commissioned the Orca Sand & Gravel aggregate mine in Port McNeill, British Columbia, Canada, with the first loading of a ship at the mine's export terminal. The export terminal is located on tidewater with a berth capable of loading barges and deep sea bulk carriers up to Panamax size. The aggregate mine exports to customers and strategic alliance partners in California, Hawaii and south coastal British Columbia. Seabulk Systems was contracted to design and manage the implementation of the Orca Sand & Gravel bulk aggregate export terminal. The heart of the export terminal is a 4,000 metric tonne per hour offshore loadout conveyor system and quadrant ship loader. In addition, the team designed and project-managed the construction of all maritime structures for ship mooring and support of the conveying and ship loading equipment. The marine construction work presented challenges that included weather, shallow nearshore bathymetry and bedrock seabed that required innovative design and construction methods to resolve. This paper discusses the challenges and decisions that led to the successful implementation of a bulk aggregate export terminal within fourteen months of contract award.