ForSHORE by Brady : Building the Future of the Port of Newcastle

Located in New South Wales, Australia, the project will enable vessels of up to 300 metres in length overall (LOA) to berth at Mayfield Berth 4, enhancing the Port’s operational flexibility and capacity to meet future trade demands.

The successful award follows a collaborative Early Contractor Involvement (ECI) phase, during which Brady Marine & Civil worked closely with the Port of Newcastle and design partner Royal HaskoningDHV to optimize the project design, construction methodology, risk management strategies, and delivery approach before construction commenced.

The ECI phase played a key role in identifying and addressing constructability challenges, operational constraints, and stakeholder requirements early in the process. This collaborative approach helped establish certainty around safety, environmental management, scheduling, and commercial outcomes, ultimately paving the way for the execution of the final construction contract.

Following site establishment in early 2026, the project team completed a series of enabling works, including access roads, car parks, crane pads, and heavy-duty working platforms designed to support 320-tonne crawler cranes.

An important early stage of the project involved the demolition and removal of aging infrastructure along the eastern section of the existing berth. This included dismantling a timber-piled wharf and removing an in-situ concrete deck structure.

Using specialist marine construction techniques, the team safely removed both above-water and submerged structures while minimizing disruption to ongoing port operations.

At the heart of the redevelopment is the construction of a new piled quay wall that will extend the berth and create valuable additional waterfront operating space.

The new retaining structure consists of 81 interlocking tubular steel piles, each with a diameter of 1,200 mm, designed to support reclaimed land and future operational loads. To ensure the high degree of installation precision required, the project team developed a dedicated pile gate system to maintain strict alignment and positioning tolerances throughout construction.

A significant project milestone was achieved with the delivery of more than 2,000 tonnes of structural steel and piling materials supplied by Sino Pacific, including 1,200 mm and 1,500 mm diameter piles. Managing the transportation and installation of these materials required detailed planning and close coordination between marine and landside operations.

A key component of the design was for the quay wall to act as a retaining structure to store dredge material.

In addition to the 1200mm quay wall piles being interlocked with clutches, a sheet pile anchor wall will be installed and connected to the quay wall piles using a waler beam and tie rod system.

This then allows dredge material to be stored locally on site behind the quay wall, reducing disposal costs as well as reclaiming the land for future use.  

Dredging is required to extend the berth pocket to achieve the navigable depths required for larger vessels. In line with the project’s environmental commitments, material unsuitable for offshore disposal will undergo stabilization treatment before being placed behind the quay wall.

Dredging and the reclamation is being delivered by Brady and has to be carefully scheduled into the works and coordinated with other activities on site to deliver the project on time whilst also minimising disruption to port activities.

Additional mooring dolphins will be installed at both ends of Mayfield Berth 4, providing increased vessel restraint capacity and supporting the safe berthing of larger ships.

Together, the quay wall extension, dredging program, reclamation works, and mooring upgrades will significantly enhance the Port of Newcastle’s ability to accommodate a broader range of vessel classes while improving operational resilience and throughput capacity.

The Mayfield Berth 4 Waterside Expansion represents a major investment in the future of the Port of Newcastle and the wider region.

Through collaboration, innovative engineering solutions, and specialist marine construction expertise, Brady Marine & Civil is helping deliver critical infrastructure that will strengthen port operations, support future trade growth, and create lasting value for decades to come.