Project Overview
The Nelson Point Tug Haven is a critical part of Port Hedland’s marine infrastructure, providing safe berthing and operational support for tugs that guide vessels through one of the busiest bulk export harbours in the world. After decades of service in the Pilbara’s extreme conditions – characterised by abrasive ore dust, saline waters, and significant tidal ranges – the Tug Haven’s outer wall and associated structures had reached the end of their serviceable life. The 200-metre sheet pile wall, pontoons, gangways, and supporting piles had deteriorated to the point where operational safety and reliability were at risk.
Recognising the urgency, Pilbara Ports Authority initiated a comprehensive upgrade to restore the Tug Haven’s resilience and secure its vital role in sustaining uninterrupted port operations. Delivering this upgrade presented considerable challenges: construction had to proceed within a live marine environment where tugs remained indispensable to port throughput. Pilbara Ports Authority entrusted TAMS with the project, drawing on both their technical capability and a long-standing partnership built on trust and collaboration. Between September 2023 and June 2024, the upgrade was successfully completed without interruption to tug services.
Scope of Work
The program required both careful deconstruction of deteriorated infrastructure and the installation of durable, modern replacements. Deconstruction involved removing the 200-metre sheet pile wall, extracting 15 pontoon and cyclone piles along with 55 raking support piles, and safely dismantling three ageing pontoons and gangways. Each activity demanded precision to ensure tug operations could continue throughout.
Construction then focused on delivering a new clutched Outer Pile Wall system and associated facilities. This included driving 147 clutched piles, fabricating and installing a capping beam walkway, and driving nine heavy-duty pontoon piles ranging up to 1500mm in diameter. Three new 120-tonne, 30-metre pontoons and three 30-metre gangways were installed, supported by upgraded hydraulic and electrical systems. To strengthen the harbour against harsh marine conditions, a 65-metre recurved seawall was constructed, while 5,000 cubic metres of dredging restored the Tug Haven to its design depth.
The works were supported by TAMS’ specialist self-perform capability and integrated marine fleet, which ensured direct control of safety, schedule, and quality. Key plant included the TAMS 9 Piling Barge, Westsea 11 Crane Barge, hydraulic piling hammers, vibratory hammers, multicats, and tug assets. This combination of fleet and in-house expertise provided the certainty required for a project of this complexity.
Solution
Collaboration underpinned every stage of delivery. From the outset, TAMS and Pilbara Ports Authority held joint planning and coordination sessions, aligning methodology with operational needs. Risks were managed transparently, sequencing was optimised around tides, weather, and tug movements, and adjustments were made to vessel schedules and environmental constraints without losing program momentum.
Execution progressed in two phases: first, the careful removal of deteriorated structures; then, the construction and integration of the new system. The result was a modern, fit-for-purpose facility designed for long-term performance in the Pilbara’s harsh conditions.
The project delivered tangible benefits. Tug operations continued uninterrupted, sustaining safe and efficient vessel movements throughout construction. Worker safety improved through purpose-designed systems and specialist plant. The new pile wall, pontoons, and gangways provide a resilient facility tailored for the environment, while local resources and streamlined logistics enhanced efficiency and reduced mobilisation costs.
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