As part of a major expansion of the world’s largest bulk export port, a new multi-user facility is taking shape, designed to meet the dual demands of Australia’s critical minerals boom and the global transition to cleaner energy.
The Lumsden Point development at Port Hedland in Western Australia is more than just a capacity expansion.
Identified as a priority project by Infrastructure Australia, it’s a technically complex logistics hub engineered to support the export of lithium and copper concentrates, while also enabling the import of oversize renewable energy components such as wind turbine blades and solar infrastructure.
Once complete, it will also be able to support the growth of direct shipping services to the Pilbara.
In 2023-24, direct shipping and container imports on Direct Freight Vessels averaged 359 containers a month at the Port of Port Headland, a 53 per cent increase on the previous financial year. The expansion at Lumsden Point, which is strategically located near the Great Northern Highway and Port Hedland International Airport, aims to alleviate the demand on existing cargo berths at the port.
“The Lumsden Point development plays a crucial role in increasing capacity at the Port of Port Hedland,” said Clare Lugar, Executive General Manager Corporate Affairs at Pilbara Ports. “It will diversify trade at the port, unlocking new trade pathways and creating hundreds of jobs.”
Structural innovation
Several major milestones have been met since construction commenced, including completing seawalls, dredging and causeway construction. The new multi-user facilities and berths are expected to start operating once the first of two wharves is finished in mid-2026.
Two multi-user wharves – PH5 and PH6 – are at the heart of the development and designed to meet demanding load, corrosion and longevity requirements. The wharves are built using a combi-pile wall system, combining 1625 mm diameter tubular steel piles with interlocking Z-sheet piles to form the retaining structure.
Tie rods connect this primary wall-to-rear anchor piles (1422 mm in diameter), providing lateral support and stability, Lugar said.
“The two multi-user wharfs at Lumsden Point, known as PH5 and PH6, have been designed with a 50-year design life. The design incorporates proven methods to ensure durability, including designing for section loss due to corrosion and incorporating cathodic protection via sacrificial anodes,” Lugar said.
The wall is also backfilled with material dredged from the berth pocket – a move that optimises resource reuse but introduces settlement challenges, which requires careful geotechnical modelling and consolidation planning to ensure serviceability over the life of the structure.
“The wharf utilises material recently dredged from the berth pocket as backfill behind the combi-wall. A particular challenge in the design and construction is managing settlement over approximately 23 m of backfill material.”
Introducing mobile cranes
To service both import and export operations flexibly, Lumsden Point will be equipped with mobile harbour cranes, which represents a shift from fixed infrastructure, such as dedicated shiploaders, to mobile, scalable and multi-user handling systems.
It is a move that is key to Lumsden Point’s role as a logistics hub for the emerging clean energy economy. As the market evolves, these cranes can shift between tasks: such as importing blades for wind turbines or exporting critical minerals.
“The two state-of-the-art ESP.9 mobile harbour cranes from Konecranes will be integral to the efficient operation of Lumsden Point,” Lugar said. “They will feature industry-leading hybrid technology to improve energy efficiency and reduce onsite exhaust and noise emissions.”
Construction of the cranes started offsite in December 2024 and will be delivered fully assembled in mid-2026.
Supporting systems
A network of supporting infrastructure designed for reliability and future scalability lies behind the development, including a 2.4 km water main to ensure both potable water supply and process water availability for dust suppression and operational needs.
“Pilbara Ports is completing essential upgrades to install a new water main to the Lumsden Point development. This includes constructing a 200 mm diameter water pipeline to service the development and installing 22kV underground power to connect Lumsden Point with the grid.”
Land-side access has also been engineered with purpose. Intersection upgrades on Great Northern Highway include two new bridges, four access ramps and a roundabout underpass – designed to accommodate oversize renewable energy components, including wind turbine blades exceeding 70 m in length and solar panels.
“These upgrades have been designed to facilitate the import of renewable energy infrastructure,” Lugar said.
The engineering team is also working closely with stakeholders, including mining companies and infrastructure partners, and will also install ship loader rails and steel pile foundations.
“As the market for bulk exports grows, these early works ensure Pilbara Ports will be ready to install a ship loader and conveyor system when it is needed by customers.
“The export of critical minerals remains a key pillar of the Lumsden Point development, and facilitating growth across these sectors will ensure the Pilbara remains the nation’s economic engine room long into the future.”
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