By Mike Simmers, Chief Infrastructure Officer, Lyttelton Port Company

THE $85-million Eastern Development has been completed as the port pushes out with increased demand.

Lyttelton Port Company (LPC) is the South Island’s largest international trade gateway, facilitating the movement of billions of dollars worth of imports and exports each year.

Lyttelton Port, the largest port by container volume in the South Island, is an integral part of the region’s economy, serving as a crucial link in the supply chain.

LPC plays a vital role in facilitating the movement of billions of dollars’ worth of imports and exports each year, ensuring that South Island goods reach markets worldwide.

In the 2021–22 financial year alone, Canterbury witnessed remarkable growth, with exports reaching a staggering $8.61 billion – a 37.5 per cent increase from the previous year. Imports into Lyttelton also experienced a significant surge, jumping 44.5 per cent to nearly $6 billion. These figures demonstrate the port’s critical role in facilitating trade and driving economic prosperity.

Moving to the east

LPC manages an impressive 70 per cent of all South Island imports, ensuring that goods flow smoothly throughout the region.

In 2015, the government approved the Port Lyttelton Recovery Plan, which laid out an ambitious expansion plan for the east to meet the increasing freight demands and unlock much-needed capacity.

The plan was approved after extensive consultation and hearings involving the Lyttelton community, Environment Canterbury, the government, and Christchurch City Council.

This multi-staged plan included reclaiming land, and constructing an additional container terminal area to enhance the port’s efficiency and capacity.

The decision to expand eastward was driven by the desire to shift some of the port’s operations away from the township of Lyttelton, mitigating noise and other challenges associated with port activities.

Enormous earthquake led to extraordinary expansion

The recovery plan has been a remarkable journey for LPC. It started after the devastating 2010–11 Christchurch earthquakes, and when the port experienced extraordinary growth. What was once a seaport handling around 260,000–270,000 20-foot-equivalent units before the earthquakes surpassed 500,000 20-foot-equivalent units in the 2021–22 financial year.

This forecast growth compelled the company to secure consent to the reclamation of 34 hectares of land to the east, and 16 hectares have been successfully reclaimed.

$85-million Eastern Development project

Recently, LPC has completed a two-year, $85-million Eastern Development project, expanded the port’s footprint, introduced modern infrastructure, increased yard space and enhanced operational efficiency.

A focus of the Eastern Development project was ensuring the highest safety and efficiency standards. The new layout of the receipt and dispatch (R&D) truck lanes demonstrates a remarkable step forward in enhancing health and safety practices.

More than five hectares of pavement has been added to the 20-hectare container facility, paving the way for further growth. Expanding the refrigerated container (reefer) capacity and constructing new reefer towers has effectively doubled the port’s reefer capacity. This development allows for the handling of containers at the eastern end of the terminal, aligning with the port’s growth trajectory.

Furthermore, the new $20-million mechanic’s workshop improves staff working conditions, reinforcing the port’s commitment to its employees.

Significant infrastructure investment

As LPC continued its expansion to meet growing demands, the infrastructure developments undertaken as part of the Eastern Development project showcase the port’s commitment to efficiency, safety and the wellbeing of its employees.

The sealed surfaces at the Eastern Development site are a testament to LPC’s commitment to constructing durable infrastructure. Comprising three layers of cement base course and impressive 110-millimetre layers of asphalt, these surfaces are designed to withstand heavy usage and the weight of the port’s equipment.

The investment in this high-quality pavement design underscores the port’s focus on creating a robust foundation for its operations, even under challenging circumstances.

The significant investment in sealed surfaces, reefer towers, a new workshop, and redesigned truck lanes demonstrates LPC’s dedication to creating a state-of-the-art facility that can handle the heaviest equipment and ensure smooth operations.

Reefer towers

The reefer towers are simple yet essential structures that have been strategically designed to prioritise the health and safety of the port’s employees. LPC has minimised risk by keeping reefer attendants separate from the container patch. These attendants can easily access the towers, walk up and down the structures, and safely control refrigeration to the containers. Investing in the workforce’s wellbeing has ensured a safer work environment and boosted overall operational efficiency.

State-of-the-art mechanical maintenance workshop

LPC’s commitment to providing state-of-the-art facilities is further demonstrated by its construction of a new purpose‑built, 23-metre-high workshop.

This workshop has been meticulously designed with input from staff and users to ensure it meets the specific needs of LPC’s mechanical engineering, electrical, and stores teams.The three-level combined building, which includes workshop spaces, amenities and offices, features a 23-metre-high service bay capable of accommodating four high straddles. A separate straddle wash area further enhances the port’s maintenance capabilities, with a particular focus on environmental outcomes.

The old maintenance facility will be demolished, providing more container yard space and improving efficiency.

R&D truck lanes

One of the most significant improvements in the Eastern Development project is the delivery of the R&D truck lanes, where trucks pick up and deliver containers.

The new layout represents a massive leap forward to the east in LPC’s journey to enhance workplace safety, with complete separation of truck drivers and straddle operators.

After backing vehicles into the R&D area, truck drivers must exit and stand on designated painted pavement areas.They can safely close the gates and call the straddle operator forward to move the container on or off the truck. The separation of people and machines is a significant milestone for LPC, demonstrating a commitment to creating a safer working environment.

LPC’s strong track record of successful infrastructure projects

Since the beginning of the rebuild after the earthquakes, LPC has invested more than $650 million in capital infrastructure projects, including the construction of Waterfront House, as well as an extensive upgrade of dry dock amenities, building and electrical improvements, numerous wharf upgrades, a cruise and container wharf, an oil berth, the Te Ana Marina, Midland Port, and rail sidings.

A $4-million upgrade at City Depot is underway, including a one-way truck flow, combined container survey area, electrical power upgrades for the reefer container repair area, construction of three new concrete pads, and a dedicated service area.

There is also a $4-million upgrade of the Inner Harbour, including resurfacing, walkways, hopper wash pad, mechanical working area, and log truck park up.

LPC’s significant investment in the Eastern Development project completes a crucial piece of the supply chain puzzle, and is a stepping stone for plans to expand the port further east.

This investment underscores LPC’s commitment to creating a world-class supply chain facility.