The former Leeds Rhinos star left Salford in 2016 after helping them avoid relegation to the Championship.
However, the 30-year-old only made five appearances for Catalans this year due to a knee injury he suffered in April.
The former NRL forward has now signed a one-year deal at the AJ Bell Stadium as he tries to get his career back on track.
Confirming the deal, head coach Ian Watson said: "We're delighted to bring Luke back to the club. He's going to be another big signing for us going forward.
"I've been keeping tabs on him since Luke impressed in his spell with us at the end of 2016 and bringing him back is massive for us.
"He gives us even more size and power to our already solid pack and he adds a lot of experience which will help the younger lads in the squad."