Case study

Caltex Jet Fuel Pipeline

In 2014, Dunstans Construction Group was awarded a major project by Caltex to install a 250mm steel pipeline under the Brisbane River to deliver jet fuel from their refinery in Lytton, to the Brisbane Airport.

  • Dunstans successfully completed four crossings as part of the first two stages of this project, including the longest HDD crossing of the Brisbane River, installing 1100m of 250mm poly coated steel pipe in the record time of fifteen working days.
  • Our state-of-the-art German-built Herrenknecht 250 tonne directional drill, the largest ‘crawler’ rig in Australia, completed three of the four crossings: 1100m of 250mm pipe under the Brisbane River and two 540m crossings – one of 200mm and one of 250mm – linking the River crossing to the Caltex refinery. The fourth crossing of 270m was completed using our Vermeer D100 drill.
  • Working within metres of high-pressure gas, water and fuel pipelines as well as electricity, fibre optic and copper telecommunications cables, our team successfully negotiated the challenges of this busy industrial corridor
  • Welding and coating the pipe was carried out on Port of Brisbane land adjacent to the Caltex refinery. The longest of the pipe strings stretched from close to the River’s entry point in an arc 1.1km back to the Brisbane River. Dunstans strung this out on poly rollers manufactured in house, with bespoke side rollers to protect the pipe coating as it was pulled around the stringing alignment and under the River.

Despite the challenging coastal geology of the Brisbane River and surrounding area, both installations were achieved ahead of schedule, on budget and most importantly safely, with no time lost due to injury.

Project quick facts


Caltex Refineries (QLD) Pty Ltd


Installation of new 250mm poly -coated steel jet fuel pipeline and a replacement section of 200mm poly-coated steel fuel line

Project date

September 2014 – February 2015

Project location

Lytton and Pinkenba, Brisbane

Pipe type

250mm Poly Coated steel
200mm Poly Coated Steel

Crossing lengths

2 x 540m
1 x 270m
1 x 1100m

Project cost

$5 million