Port Kembla Gas Terminal Project
Port Kembla Gas Terminal Project
In August 2023, Commercial Diving Services was engaged by McConnell Dowell to deliver specialist marine welding and inspection solutions at the Port Kembla Gas Terminal (PKGT). This large-scale infrastructure project reflects our commitment to delivering robust, economical, and future-focused solutions in complex marine environments.
Scope of Work
Our team conducted both underwater and above-water operations on the newly constructed quay wall. The primary objective was to strengthen structural integrity using coded welding techniques and install a new cathodic protection system.
Underwater Operations Included
- Visual inspections via ROVs and diver-held video/still cameras
- Seabed dredging and targeted grout removal
- High-pressure water blasting and steel surface prep
- Coded underwater welding to AS/NZS ISO 9606.1-2017 (ISO 5817 Level B), positions 2F and 3F/PG
- Installation of curved steel plates for wall reinforcement
- Deployment of over 300 wet anodes (165kg each) as part of the cathodic protection system
Above-Water Operations Included
- Surface steel grinding and plate preparation
- Operation of a floating work barge fitted with a 2-tonne mini crane for plate handling
- Coordination of logistics for diver support and equipment transport
Achievements at a Glance
- Over 1.3 million mm of coded welds successfully completed
- 300+ curved steel repair plates fabricated, delivered, and welded in position
- Installation and welding of 300+ CP anodes, totalling over 49 tonnes
- Maintained 12-hour shifts, 6 days a week, for 276 days
Team & Resources
- 3 full-time dive teams working in rotation
- Specialist vessels and barges with crane support
- Dedicated Project Manager and surface crew on-site 6 days a week
Key Challenges & Solutions
This project presented challenges typical of high-risk underwater infrastructure work—tight timelines, environmental conditions, and critical structural requirements. Our ability to combine innovation with deep industry knowledge ensured precise execution and strict adherence to safety, quality, and environmental standards.
Client Collaboration
We’re proud to have delivered this project in collaboration with McConnell Dowell. Their partnership and trust in our expertise enabled the successful delivery of a major milestone in NSW infrastructure development.
Looking Ahead
At CDS, we’re continuing to push boundaries in marine construction and maintenance. This project is a clear example of how our team, technology, and approach deliver results that stand the test of time.
