SFT completes challenging fender installation

The project involved designing and installing 14 pile fender systems, each fitted with CSS Cell Fenders ranging from CSS1000 to CSS1250, with panels stretching from 2,550 mm by 9,090 mm up to 3,100 mm by 10,640 mm.

Unlike standard solutions, each fender was customised to accommodate the full operational range of ferries, including varying tide levels and berthing angles. The geometry of the fender panels added complexity, featuring reclining front faces and double chamfers at multiple angles, which required extensive 3D modelling and repeated design iterations.

Each system used more than five times the typical number of steel plates, and engineering hours for the design phase were three to five times higher than usual, reflecting the demanding nature of the project.

In addition to the main fender panels, custom rear panels were included, equipped with pin and bolted connections to interface with the contractor’s headstock plates. These panels allowed pre-assembly on dry land, streamlining installation and eliminating the need for diving operations.

Kangaroo Island relies heavily on the Cape Jervis–Penneshaw ferry, making the reliability of berthing structures critical for both tourism and the local economy. The government of South Australia, through the Department for Infrastructure and Transport, commissioned a full upgrade of the ferry terminals, with McMahon Services Australia as contractor and WGA leading the project design.