Duratec & BHP & AECOM – BHP Berth C & D Structural Remediation


    BHP (Asset Owner), AECOM (Owner’s Engineer), and Duratec (Contractor) completed the BHP Berth C & D Structural Remediation Selection Phase Study Project (The Project) in 2022, setting a new standard for the procurement and scoping of major marine asset remediation projects. The project involved innovative approaches, including a 2-5mm 3D reality model for 1.2km of wharf structure, bespoke online software for
    defect management, and a collaborative approach to inspection, testing, and design, resulting in a robust procurement framework for the asset’s life extension. The project was delivered over approximately 12 months, starting in mid-2021.


    Use of Best Practice Asset Management Principles, Degree of originality and ingenuity of solution, Program and project management, Benefit/Value of the project or service to the community or organisation, Submission.


    The scope of the project was defined by BHP and AECOM, who aimed to address the commercial, schedule, and technical risks associated with remedial works on existing infrastructure in an innovative manner. The project aimed to create a 3D reality model of Berths C & D, which form part of BHP’s port facilities at Finucane Island, WA. In addition to the model, a detailed schema of information was required to be linked to each unique defect identified on the model. This requirement pushed the limits of proprietary 3D Model
    visualization and analysis software, which prompted Duratec to develop a customizable online defect database software tool, AnnoView, that could integrate with a state-of-the-art 3D model software package, Skylines’ TerraExplorer.


    Duratec worked with BHP and AECOM to finalize the details of the bespoke AnnoView schema and the mobilization process, which enabled the site team to capture the reality model during a back-to-back extended shut down of the Berths in 2021. During the shutdown, Duratec’s site team had a total of 14 day shifts to capture the entire wharf, while also completing other scopes of work, including concrete sampling
    and testing, steel pile NDT, control survey grid establishment, 3D laser scanning, pile jacket repair trials, close visual inspections of representative areas, and strain gauge installation.
    Duratec’s spatial team took over 60,000 45 Megapixel images using a combination of Remote Piloted Aircraft (RPAs), ground-based photography, and photography from a small work vessel. This resulted in over 1 terabyte of raw data that was constantly being backed up and uploaded to a cloud server so the reality model processing could be commenced off site in Albany, WA. After the successful completion of the shutdown works, Duratec’s spatial team constructed the 3D reality model using Bentley’s Context Capture
    software and their in-house computing cluster. Data technicians painstakingly reviewed the software outputs; realigning and training the software to mesh the considerable data set together. The structure was broken up into manageable sections so the model could be delivered to BHP and AECOM’s team of
    engineers incrementally. Once the model was constructed, the engineers could start to identify and tag every single structural element and numerous defects across the whole structure. The defects were tagged in TerraExplorer and
    linked through a custom application programming interface (API) to the online AnnoView database. After several months, the final outcome was a comprehensive 3D reality model of the structure with every structural element uniquely identified and a highly detailed defect database that could be used to scope the required remediation works to extend the life of the asset and maintain its reliable performance.


    Once the model and database were completed, BHP had sufficient information to go directly from the selection study phase through to estimating and programming, and then onto procurement without the need for the typical detailed design phase. During the procurement phase, The Model and Database were made available to all the bidders, reducing the number of site visits required and allowing proponents to develop highly detailed access and execution strategies. After a tender process, the $48M remediation
    project was successfully procured in late 2022, and preparatory works started early 2023.
    Overall, the project was a highly collaborative effort between BHP, AECOM, and Duratec, underpinned by regular and clear communication. The project successfully delivered a comprehensive 3D reality model of the structure, which enabled the identification and tagging of every structural element and numerous defects, thus reducing the common risks associated with remedial works.


    The ultimately successful outcome of The Project was due to the contributions of all key stakeholders involved. BHP and AECOM initially had the vision to undertake The Project by employing state-of-the-art technology, despite the lack of prior testing on a similar scale. Although theoretically possible, there were numerous practical unknowns. Duratec’s engineering and spatial team understood the challenges and had the courage to push the limits of the technology to achieve the overall objective. Despite these efforts, specific software development was necessary to fill remaining gaps. This process led
    to the development of AnnoView, a new product that integrated with TerraExplorer. Duratec’s development and spatial team worked in parallel with The Project, continuously improving through direct feedback loops between AECOM and Duratec. This direct feedback accelerated the improvement process during the project. Throughout the project, BHP continued to support The Project Team and recognized that the innovative concepts being pursued would provide greater benefits beyond this specific project.


    The project has successfully demonstrated how implementing innovative technology can enhance asset management principles and practices. By leveraging new and emerging technology, asset owners and engineers can realize significant commercial and technical benefits. Furthermore, a collaborative and respectful approach between key stakeholders can amplify innovation and deliver transformative changes within a relatively short timeframe. Several images associated with the project effectively illustrate the
    power of the innovation to revolutionize the approach to asset remediation within the Asset Management Life Cycle.

Scroll to Top