The Eastern Expansion is a multi-year project to deliver the infrastructure to support the rapid growth of Lyttelton Port, New Zealand’s largest South Island Port. Operating within a programme of six major projects sharing multiple key dependencies. It’s required a flexible yet critical approach to schedules, quality and costs.

The Eastern Expansion will deliver an additional 781 TEU ground slots which facilitates an annual yard volume of 117,000 TEU (23% increase on 2021 capacity). A second receive and deliver (R&D) area for trucks will be established utilising gate automation driven by PLC, 3D spatial scanners and remote HMI interfaces. An expansion of LPC’s modern LAN network with a vision to deliver on the future 2050 design that includes a second Quay.

Working closely with the Ports nominated digital suppliers and main contractor Fulton Hogan. I have led the design, procurement and implementation of an additional 21 CCTV cameras, 15 external IP rated enclosures and network installations (fibre and switches). The work requires detailed planning as the surrounding areas are live operational spaces with significant H&S risks.

The new R&D area required extensive requirements gathering from the business while navigating physical constraints. A smart but lean design was formulated,  constructed and successfully delivered in March 2023. I led the team to design a new safe truck exchange interlock gate area, designed to eliminate the Ports critical risk of person versus machine. Our very talented business analyst Dagmar Linder did an incredible job to iteratively capture the requirements. The use of Sick 3D LiDAR spatial scanners allows us to identify a 17m high straddle within a small lane without conflicting with the truck/container or equipment in the next lane. Dual gate automation driven by a local PLC ensures the safety of truck drivers and provides confidence to straddle drivers the area is safe to enter.

LPC is one of only a few Ports worldwide that leverages cellular connectivity for large plant. Due to the proximity of residential areas several telecommunication towers are available within the harbour. However, as the Port continues to expand east away from the towns and towers a need to retain strong cellular coverage forced the addition of a Cellular RFP into the project. I led the creation of requirements, construction of the RFP and led the tender evaluation team with the support of LPC’s Procurement Specialist. A primary and secondary provider was selected, and detailed designs are currently underway to prepare for the installation of cellular sectors on two of LPC’s lighting towers.

The size and extent of new designs made this project a special one. Regular and extensive communication across the organisation and supplier network has ensured successful delivery and hand over of each area throughout the project. You can check out a 3D image of the area that includes the Reefer Tower and New Workshop project I led digital on.

Special thanks: Jack Foley, Craig Meaclem (M&H Communications), Darren Maw, Simon Heatley (Fulton Hogan), Jeremy Storer, Eddie Russell (Cobalt EDS), Thomas Burt, Abbey Clapp, Ryan Ash (LPC), Guy Lascelles (Rubix), Aaron Ness, Cameron Hawke (Bremca) and Dagmar Linder (Independent Contractor)