VOL 2 NO .5 (March/April 2010)

ACN 132 670 261

VOL. 2 NO. 5 MARCH 2010

PRINT POST NO. PP424022/2324

ALL ENQUIRIES PHONE: (07) 5478 9432 EMAIL ENQUIRIES: apen@worldpacific.com.au

Circulated to key personnel within all State Departments of Road and Infrastructure throughout Australia including their Regional Directors and Metropolitan Project Directors including their top personnel throughout their State. Key Civil Engineering personnel from all Australian Road Civil Engineering companies. Key Road Personnel within every Australian Local Government Council each issue

SIMULATORS ENHANCE CONSTRUCTION TRAINING In a world first, Abigroup is providing trainee construction workers with a virtual front line experience in a new state of the art, multi-purpose training facility at Yatala in Queensland.

See Page 2 for all details

Above: Left to right: Antony Riley, Dave Anderson, Gary Steen (Abigroup) Left to right: Dump Truck Simulator, Grader Simulator, 2 Scraper Simulators

Above: Left to right: Gary Steen (Abigroup) Steve Abson, General Manager Northern Region (Abigroup).

Trialling the Scraper Simulator

Above: Left to right: Dave Anderson (Abigroup); The Hon Anna Bligh MP, Premier and Minister for Arts. M Series Grader Simulator explaining the controls to the Premier

SIMULATORS ENHANCE CONSTRUCTION TRAINING N a world first, Abigroup is providing trainee construction workers with a virtual front line experience in a new state of the art, multi-purpose training facility at Yatala in Queensland.

Abigroup’s $6 million Operation and Training Facility was officially opened on March 4th by Queensland Premier, the Honourable Anna Bligh and its equipment level is such that it will take the process of construction training way beyond the classroom.

For the first time in Australia, trainees will be able to learn how to operate scrapers, excavators, graders and off-highway heavy trucks in simulators that replicate a frontline experience. It is an exciting development in the world of training particularly in the construction sector. The use of these heavy machinery simulators will not only make the training process more efficient but will enable trainees to learn how to operate these machines in a much safer environment.

It’s fair to say that Abigroup has always placed an emphasis on providing extensive and appropriate construction training and not without good reason. Abigroup has the largest blue-collar workforce in the Australian construction industry and does not rely on subcontractors. It has a very large self-contained team at its disposal so it’s very much hands-on in its approach to every project. Of course this requires that all employees are trained in their respective skills to be self sufficient in the field and it is an important feature throughout the company.

Apart from providing comprehensive support for construction workers on every project, Abigroup also encourages and rewards innovation throughout all levels of its substantial workforce.

In 2006, partly in an effort to address a serious skill shortage in the Australian construction industry, Abigroup gained accreditation as a Registered Training Organisation (RTO) and now delivers nationally recognised assessment, training and qualifications for all employees. Abigroup has invested heavily in improving skills and opportunities for its workforce through the application of various programs such as Industry Training Strategies Program; Australian Apprenticeships; Industry Pathfinders, and Productive Ageing.

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Above: Gary Steen (Abigroup) doing a final check on the simulators

Above: left to right: Richard French, General Manager Plant (Abigroup), Gary Steen, Maintenance & Operations Coordinator, Mt Kuring-gai (Abigroup), Dave Anderson (Abigroup) The Hon Anna Bligh MP, Premier and Minister for Arts M Series Grader Simulator functions being explained to the Premier Many mature-age people find it extremely difficult to find employment in Australia and with the Government’s decision to extend that working life even further beyond the current retirement age, the lack of opportunities for older workers will need to be addressed. To Abigroup’s great credit they are extremely proactive in this area, having implemented programmes designed to encourage mature-age involvement and to capitalise on that wealth of lifetime experience within the company’s operations.

The company is also focused on providing training and work opportunities in an effort to encourage more women to enter the construction industry. In 2009 it established a Women’s Leadership Forum which brings together senior male and female managers from across the business in order to drive initiatives to support and encourage women in their careers.

In October 2008 Abigroup opened a new training facility in Victoria. The Truganina Learning and Operations Facility offers employees the ability to undertake formal training throughout the construction sector from civil construction to mining. However, the facility has a distinct advantage because the training programme also includes practical on the job experience all at the one location.

The new facility at Yatala is an expansion of that in-house approach to training and with the introduction of simulation technology it is clearly a masterstroke in terms of efficiency.

The scraper simulators are the first of their type in the world and were developed by Caterpillar to suit Abigroup’s specific on-thejob requirements.

Publisher: AUSTRALIAN MAIN ROADS CONSTRUCTION NEWS PTY LTD ACN 132 670 261 ABN 52 132 670 261 Publishers of s

Importantly, the new training facility will continue to address the problem of skills shortages in the construction industry and will train over 1000 workers per year.

Emphasis will also be placed on up-skilling and retraining existing operators.

However, the mobility of the simulators is a distinct advantage as they can be transported to major Abigroup construction sites throughout Australia for specific on-site training and up-skilling.

According to Abigroup’s Queensland General Manager Steve Abson this new technology provides not only a current training advantage but promises much for the future. “The use of mobile simulators allows us to source operators from the local communities in which we work and for them to familiarise themselves with the operation of expensive machinery in a risk free environment on their own construction sites.

This technology also provides new construction entrants with a ‘safe way to fail’ and accelerates operator knowledge of plant performance. We can foresee many applications for this type of technology in the future as it provides a terrific interactive training

Above: Gary Steen (Abigroup) keeping an eye on the scraper bowl loading behind him as he’s moving forward

experience as well as demonstrating Abigroup’s commitment to the safety of our workers.”

Overall Abigroup’s comprehensive employee training, support and work safety strategy allows the company to retain quality control over every aspect of operation and that holds many obvious benefits for clients.

There is a wealth of evidence to suggest that the company’s consistent operational strength is a huge advantage when competing in the world of construction. Abigroup has successfully completed an extensive construction portfolio featuring many major headline projects. Abigroup constructed the M2 in NSW and provided more venues for the 2000 Sydney Olympics than any other contractor. Abigroup’s contribution included the technically complex Sydney SuperDome (now referred to as Acer Arena).

In 2003, in a joint venture, Abigroup was awarded what was, at the time, the largest single infrastructure contract in Australian history, construction of the $1.5billion Western Sydney Orbital (now the Westlink M7 Motorway).

By 2004 Abigroup was clearly recognised as a major industry player and was acquired

by Bilfinger Berger AG, regarded as one of the world’s largest multi-service construction groups. Now with Bilfinger Berger’s backing Abigroup, a wholly owned subsidiary of Bilfinger Berger Australia Pty Ltd, has access to the immense global resources of that organisation.

This international connection has produced strong growth and Abigroup has more recently expanded its operations significantly and has set up three specialist national businesses covering Mining Services, Water and Telecommunications.

Abigroup has also expanded the reach of its engineering expertise to service Western Australia.

Already major achievements are flowing thick and fast including the $1.14 billion Adelaide Desalination Plant; the Western Corridor Recycled Water Project; the Salisbury to Kuraby Railway and Bauhinia Rail; the new Mater Hospital in Newcastle; the Tugan Bypass and Gateway Bridge Upgrade in Queensland.

Abigroup has also contributed to specific LNG projects and other projects in the resources sector and has also worked with major telecommunication clients such as Telstra and Optus. The Yatala facility will also serve as the head office for Abigroup’s Queensland Telecommunications and Plant Maintenance businesses.

Despite the huge pressures faced by the construction sector during the global financial crisis, Abigroup continues to shine and the new Operation and Training Facility at Yatala clearly demonstrates the company’s confidence in the future. It’s also an investment that highlights Abigroup’s commitment to quality by expanding its training base to ensure the skill level of all employees is of the highest standard.

Circulated to key personnel within all State Departments of Road and Infrastructure throughout Australia including their Regional Directors and Metropolitan Project Directors including their top personnel throughout their State. Key Civil Engineering personnel from all Australian Road Civil Engineering companies. Key Road Personnel within every Australian Local Government Council each issue

Also Publishers ofe Australia’s Leading Power Industry Newspaper Head Office: 14 Merriman Court, Palmwoods QLD 4555 Postal Address: PO Box 1176, MOOLOOLABA QLD 4557 Telephone: (07) 5478 9432 • Facsimile: (07) 5445 9431 Email: apen@worldpacific.com.au Page 2 - Australian Main Roads Construction News

Above: Layout of simulators at the opening

Work on construction of the new railway overpass at Molong is progressing well

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TA Country West Road Services (CWRS) based at the Orange Works Centre are the head contractors for the project under an RTA internal alliance model.

Work to date has consisted of: • Installation of sediment and erosion controls • Building fencing to provide visual guides to pedestrians to ensure they do not inadvertently stray onto the work site • Stripping and stockpiling of topsoil • Installation of drainage • Earthworks consisting of the placement of fill layers on a major embankment at the eastern end of the project • Excavation along the railway cutting for the arch foundations The majority of the 39 pre-cast concrete arches from Humes at Blacktown have been delivered to the work site, and stockpiled

Above: Works on Molong Railway Overpass progressing well

Above: The majority of the concrete arches have been delivered to the work site

before being moved into position in a few months time.

During November, PanCivil from Sydney undertook the shot-creting and rock bolting work on the cutting faces in the rail corridor.

In late November Makcrete from Grenfell started forming up and pouring the concrete strip footings. Positional accuracy of the footings is paramount to ensuring a successful placement operation of the arch units.

CWRS will return to carry out placement of the Humes arch units by craning them into position, in parallel with completion of the upper zone of formation, pavement layers, and tie-ins.

Power and lighting work is being carried out by NJ Construction from Parkes, with water and sewer relocations being undertaken by the local Council crew from Cabonne.

Above: Placement of earthworks on major embankment

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Australian Main Roads Construction News - Page 3

Polymer Stabilisation Trials - Santa Teresa Road NT S

ANTA Teresa Road – an unsealed sandy road near Alice Springs - is the focus of a trial to develop protocols to measure traffic induced roughness and wear on unsealed roads, and assess the use of polymers in retarding the rate of this damage. The road is one of the low volume (less than 200 vehicles per day) unsealed roads that comprise about 70 per cent of the national road network.

Many unsealed roads are important transport and community links. The Northern Territory Department of Lands and Planning owns the road network in the Territory.

A series of 200 metre-long test sections, 22 km from Alice Springs, has been used to examine the impact of two polymers, lime, and polymer combinations with lime. These have been tested relative to

untreated (control) sections.

As part of the growing the Territory initiative, the Northern Territory and Commonwealth governments are collaborating with ARRB Group Ltd in the project. ARRB is involved in project research, reporting, and training local personnel. To date, both the Commonwealth and Territory governments have provided $343,000 for the project.

Unsealed roads are subject to potholing, greater surface erosion and dust production. Processes and products that retard this degradation can reduce maintenance costs. On Santa Teresa soils, a water soluble acrylic polymer powder – Polycom - has demonstrated superior performance during an ongoing year-long investigation with current indications

Above: Polymer added to a pipe filling the water truck

Above: Polycom-treated road (foreground) and untreated water-soaked road (background) Water damage due to recent flooding

Polycom-treated road Page 4 - Australian Main Roads Construction News

suggesting that grading the road, which currently occurs up to four times per year, can be extended to about once every two years.

Polycom crystals are added from a 2kg bottle through an eductor connected to the pipeline filling a water truck. They are mixed into the road material prior to shaping and compaction to create a hard wearing surface. Polycom has conferred a more durable, less deformable road pavement, reducing cracking in the test segments. There is no evidence of rutting associated with Polycom, and the treatment is also providing a smoother vehicular ride, less slipperiness in wet weather and low dust generation because of the soundness of the surface and lack of loose road material.

The action of the Polycom stabiliser is to provide greater soil binding and water resistance. By retarding water penetration the easily applied additive prevents the surface softening that makes roads unnavigable. Polycom-shielded sections have withstood flood impacts that made other parts of the road untraffickable for some time. Predictably, the control sections showed no improvement.

Assessments of the engineering qualities and cost effectiveness of Polycom continue. As part of the monthly monitoring of treated and control sections, the ARRB Group Roughometer is being used to measure road vibrations (roughness) on the axle of a car.

Roughness relates to driver comfort and can significantly affect vehicular wear and transport costs. Other performance attributes being scrutinised include loose particles and associated dust generation factors affecting surface degradation and transport safety.

The stabiliser is ideal for poor quality, highly mobile road components – such as sand – that lack gravel armouring. Also, the small quantity of Polycom needed (20 kg per km) is most suited to remote area road operations compared to alternative powder spread cement or lime (12 tonnes per km).

Polycom may also be used in association with gravel surfaces. It has been used successfully on two floodways on the Tanami Road to reduce erosion from flooding. It has potential applications for other department-owned sand and claybased roads in the Alice Springs region, and the Territory generally, in reducing maintenance and material replacement costs and creating a safer unsealed road network.

GEOFABRICS GEARED FOR EXCELLENCE W

HEN Parliamentary Secretary for Innovation and Industry, Richard Marles MP launched Geofabric’s, Geosynthetic Centre of Excellence, at Molendinar in South Queensland on March 4th 2010, it signalled a new era of research and development for Geofabrics Australasia.

The new $2.4 million research laboratory is an appropriate expansion for Geofabrics, after all the company has been successfully developing and manufacturing geosynthetic products for just over 30 years. The new facility is also part of a $6 million investment in research and development across all areas of the company’s operation.

For far too long government investment in R&D has been less than significant in this, the lucky country blessed with so much talent.

It’s a lack of foresight and support which has, in the past, led to a ‘brain drain’ as the clever people have reluctantly taken their dreams overseas.

However, on this occasion the Federal Government should be congratulated for their investment and support for this particular venture, not least because the Centre for Excellence also has a unique ‘community’ aspect to its operation. The laboratory’s research programme will be important for the civil engineering, mining and construction industries and will operate with an ‘open

Above: Brendan Swifte MD Geofabrics speaking at the opening of the Geosynthetics Centre of Excellence Although technicians and engineers at the Centre will initially focus their talents on finding better ways to contain potentially hazardous leaks from mine waste, domestic tips, tank farms and dams, in the future the quality of road drainage and paving textiles will certainly become part of the Centre’s research and development programme.

Geofabrics’ subsoil drainage system, Megaflo and the company’s road paving fabric, Sealmac are already extending the life and durability of many Australian roads.

Internationally, Geofabrics is also spreading its influence, with its unique Megaflo drainage system now installed beneath six major sporting arenas that will feature in the FIFA 2010 World Cup in South Africa.

The Megaflo drainage system has been selected because it will ensure a world class playing surface for the international teams that will participate in this prestigious global event.

The contract also represented a big win for an Australian manufacturer and the development of that particular product highlights just how much R&D is fundamental to the future success of Australian enterprise in the highly competitive, global market.

Above: Megaflo Installation

access’ policy allowing regulators, consulting engineers, contractors and academics to carry out application based research and testing to develop site-specific solutions.

This feature represents a significant R&D advantage across all of those sectors and one which is clearly recognised and encouraged by Geofabrics Australasia’s Managing Director, Brendan Swifte.

Brendan Swifte also expressed his gratitude for the Federal Government’s Strategic Investment Program grants, the Researcher in Business program and tax incentives for R&D expenditure. Mr Swifte stated that all these programs had helped to further motivate the company’s innovative approach beyond their own substantial private investment.

The Geosynthetic Centre of Excellence will test the chemical reactivity, UV resistance and friction properties of materials used to line waste facilities and will also be used to test and develop coastal protection products, which are in demand not only along Australia’s eastern coast but internationally.

The Geosynthetic Centre of Excellence will

provide an exciting opportunity for extensive research and development and over time, as it continues to expand its theatre of operation, the Centre will undoubtedly produce many environmental benefits as new and better quality products are created.

Geofabrics is the only Australian manufacturer of geotextiles and geosynthetic clay liners and currently exports its products to New Zealand, Asia, the South Pacific, Europe, South Africa and South America.

It has manufacturing plants in Molendinar, Queensland, and Albury, Victoria. Now with the launch of its new research centre, Geofabrics Australasia deserves to be congratulated on its latest and unique R&D initiative.

Above: Warren Hornsey and Richard Marles MP in dry lab

GEOSYNTHETIC CENTRE OF EXCELLENCE PROVIDING APPLICATION-BASED RESEARCH TO DEVELOP GEOSYNTHETIC SOLUTIONS

“This was driven by the Australian engineering industry searching for answers to questions relating to geosynthetic performance that were not able to be tested in the traditional quality assurance laboratories.

It is a world class R&D laboratory that will improve our understanding of geosynthetics and their performance in critical applications.” Mr Swifte said.

“The Centre of Excellence means we can work locally with clients who want to develop responsible, evidence-based solutions for their particular sites. That means better outcomes for our customers and the environment.”

The Geosynthetic Centre of Excellence houses equipment that is the first of its kind in Australia. The range includes a 300mmx300mm shear box, transmissivity apparatus and high pressure liner testing apparatus. It will soon incorporate a geosynthetic clay liner overlap apparatus. It is also equipped with flexible wall permeameters for use with aggressive liquors; a 50kN Instron Tensile apparatus, large volume screw compressor; dropcone apparatus plus a microscope and UV equipment.

Mr Swifte also stated that Geofabrics had worked with Monash University, University of SA, the National Marine Science Centre, Manly Water Research Laboratory and the University of Wisconsin. He hoped the Centre would promote further local and international collaboration. “This innovation will not only drive our business in a competitive global market, it will also foster Australian academic expertise in this critical field and provide opportunities for students.”

Advanced technology delivering better roads Geofabrics Australasia, manufacturer of market-leading bidim® and Megaflo®, has launched a dedicated R&D laboratory.

The Geosynthetic Centre of Excellence will work collaboratively with contractors, consulting engineers, regulators and academics to develop site-specific drainage and waste containment solutions.

For more information contact Daniel Gibbs: d.gibbs@geofabrics.com.au

Australian Main Roads Construction News - Page 5

The Australian Main Roads Construction News Interview Geoff Southwell, National Manager of Operations for Wirtgen Australia IRTGEN Australia P/L was established in Sydney in 1989 as a wholly owned subsidiary of Wirtgen GMBH of Germany. The Australian company’s headquarters are located at Emu Plains in NSW and imports and sells roadworks and mining machinery designed and manufactured in the Wirtgen Group of factories in Germany.

W

Q: Geoff, 2009 was a difficult year for most businesses throughout the world so how did Wirtgen Australia cope with the global financial crisis?

A: Well as you know, they say when times are tough etc, and rather than minimise our activities we actually expanded operations in 2009. In fact we increased our staff numbers by 20% and established new facilities at Yatala in Queensland and at Knoxfield in Victoria. We also wanted to expand the level of service for our clients in Western Australia, so plans are in place to move our existing facilities at Wangara to larger premises at Balcatta in Perth.

Q: So how does 2010 look for Wirtgen Australia?

A: Well! We’re very excited about the future. Over the last 5 years staff numbers have tripled and our revenue has quadrupled so we’re well placed to continue that growth.

2009 was a year of consolidation and a time for forward planning and so we’re ready to capitalise on our new infrastructure and our expanded range of products.

Q: I believe you’ve recently added the name Vogele to your product range can you tell me about Vogele?

A: Vogele is a company in Germany established by Joseph Vogele AG and the company has been building Asphalt Pavers since 1937. Their Pavers are excellent having won European Design Awards and I believe Vogele is now the world’s largest manufacturer of Pavers We sell the new Vision Series with 8ft

Above: Opening of new Australian headquarters at Emu Plains, Sydney by Mr Stephan Wirtgen of WIRTGEN GMBH, Germany, in August 2010

and 10ft Screed Machines as well as the new Dash 2 Super Series.

They all feature electrically heated screeds and the unique ErgoPlus operator control system.

Q: You do have a large range of products on offer how do you keep up with it all?

A: Yes, it can be difficult to keep up, because technology is always improving and the Wirtgen Group is highly innovative so our product range is always expanding. Apart from Wirtgen Road Milling Machines and Stabilisers from the Wirtgen Group of factories there’s not only the Vogele range of Asphalt Pavers but Hamm Rollers and Kleeman Mobile Crushers. The Wirtgen range is always increasing with the introduction of new models. For instance Wirtgen now has over 47 Machine models alone, with the largest now 200 tonnes and 1200 kW.

Foamed Bitumen Stabilisation the Only Solution

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N far North Queensland and in the Nation’s Capital Canberra, it has been decided to recycle the existing failed roads using the latest foam bitumen technology. In both cases alternative methods of reinstating the flood damaged roads in Queensland or the old underdesigned pavement in Canberra were researched extensively.

The Queensland Department of Main Roads had the problem of maintaining road freight access on the main transport routes.

The solution was to block half of the road during the daylight hours then open the whole road at night to allow uninterrupted travel for the trucks and cars. Foamed bitumen stabilisation with the addition of a small percentage of cement allowed a section of road to be excavated, binders added and mixed and relaid in the one operation. After

Wearing course, thin layer asphalt or spray seal Foam bitumen stabilised layer 250-320mm

Existing pavement

compaction the section of the highway was trafficable almost immediately. The final seal was placed every fourth day covering the previous week’s work.

In Canberra the busy London Circuit in the CBD needed complete renewal due to age and the increased traffic loads. The only two alternatives available to minimise traffic disruption by having fast access were deep lift asphalt and foam bitumen stabilisation. Stabilisation was chosen due to its fast one process excavation and laying and its considerable cost savings to give an equivalent pavement to asphalt.

Bitumen binder (optional) Water

Cementitious binder

Above: Bruce Highway

Page 6 - Australian Main Roads Construction News

Q: What are the current equipment trends in paving and is recycling a favoured option?

A: From our perspective there is no doubt that there is a preference towards Wirtgen Cold Milling Machines and Stabilisers. There’s also a further option now with the Wirtgen KMA 220 Mobile Cold Recycling Mixing Plants of 220 tonne per hour capacity. The choice of Streumaster Spreaders for binding applications is a supplement for very accurate addition of hydraulic binders.

STREUMASTER`s cement and lime spreaders are also manufactured in Germany and exclusively distributed by the worldwide Wirtgen Group. In Europe’s largest current road project the A 1 in Poland they are being used in the stabilizing of 20,000,000 tonnes of pavement materials.

You mentioned recycling and there has been a lot of interest lately in recycling and reworking pavements using bitumen in a bitumen and water ‘foam’ mix. The ideal choice there is the Wirtgen WR series of recyclers and we’ve also delivered a number of Wirtgen WLB 10-S Laboratory Testing Machines to soil laboratories.

Q: How about major national road projects, what’s the paving trend there?

A: Wirtgen concrete slip-form paving machines remain in use on major national projects on the Hume and Pacific Highways. These pave up to 12 metres wide here or 16metre widths in major overseas projects.

Also, the first 11.0 tonne SP 150 ‘baby’ of the slip-form range was commissioned last year. There’s also been a lot of interest in the 140 tonne model SP 1600 and 42 tonne SP 500. Both machines operate on a ‘stringless’ control system in conjunction with LEICA Geosystems and we anticipate sales of those machines to increase in 2010.

Q: Is there one particular highlight in paving technology that has or will change the way things are done?

A: Well, it’s not so much changing the way things are done but about doing

it better with technological advances that improve efficiency. For instance we’ve received a number of orders for the new Wirtgen W200 Series Cold Planers. These new 28 tonne 2.0 metre wide cut milling machines with one or two engines replace the W2000 and will be officially released at BAUMA in April 2010.

There’s also been a lot of interest shown for soil and asphalt rollers using HAMM`s “oscillating” technology. A major independent NSW Asphalt contractor for example has taken delivery of a HAMM HDO 75K [R] 1680mm roll width 7.7tonne Combination Oscillating roller.

This machine has a rubber coated oscillating front drum plus 4 x 11.00 by 20 rear tyres. The combination allows static compaction or oscillation for the manipulation of aggregates for thin lift seals without aggregate damage.

Generally the use of oscillating technology has been proven to provide target densities at 30% less passes than conventional vibratory rollers. In some instances even in one or two passes instead of four to six. There’s minimal risk of offsite complaint nor over-rolling damage to the pavement structure or bridge decks. Most major asphalt companies now run these machines on critical projects.

Incidentally, Hamm has been developing rollers since 1911 and in recent years the company has won 11 European design awards.

Mind you, not all Hamm rollers suit Australian conditions and we are careful about which machines we import. European pavements are designed for higher loadings than here, so high energy machines need to be operated appropriately to avoid over-rolling. But Hamm machinery is extremely efficient and the range does accommodate Australian conditions.

Q: What is the philosophy behind the way Wirtgen Australia operates?

A: We believe in an ‘applied technology’ consultative approach to the road industry so we’re always proactively involved. We participate in training programmes and seminars with industry groups like the Asphalt Pavement Association, the Profiling Association, Stabilising Association and the Australia Society for Concrete Pavements. Above all, we want to ensure that the equipment we supply is the right choice and that the technology we offer is safely and correctly applied.

You know, this is our 23rd year in Australia with around 194 machines in the Group portfolio and that represents over 1000 machines in use in Australia and New Zealand , so the future looks good and we are extremely confident going into 2010.

Footnote: Mr A.G. (Geoff) Southwell has been in the road works machine supply, rental or contracting industries since 1971 and often presents at AAPA Training Courses on Compaction, Road Milling and Stabilising. Geoff is based at Wirtgen Australia, Head Office, Emu Plains Sydney NSW. geoff@wirtgen-aust.com.au

FOUR STRONG BRANDS FOR THE CONSTRUCTION INDUSTRY – FROM A SINGLE SOURCE.

ROAD AND MINERAL TECHNOLOGIES

WIRTGEN AUSTRALIA 2-12 Sommerville Circuit · Emu Plains NSW 2750 PO Box 21 Penrith NSW 2751 · Tel.: 02 4735 2699

The market-leading brands Wirtgen, Vögele, Hamm and Kleemann offer strong technologies for road construction and for the mining and processing of mineral raw materials. Wirtgen Australia provides best-in-class, professional consulting and customer services. Clear philosophy, clear benefits for you. www.wirtgen-group.com

Queensland Yatala, Brisbane / Gold Coast Tel.: 07 3382 7593

Victoria & Tasmania Knoxfield, Melbourne Tel.: 03 9800 5268

Western Australia & South Australia Wangara, Perth Tel.: 08 9309 9666

New Zealand Wellington Tel.: 64 2744 26555

Australian Main Roads Construction News - Page 7

ROAD & TRAFFIC CONTROL EQUIPMENT FEATURE Roadliner 2000TM S Series – Approved to 60kph in all States and Territories

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MONG the vast array of successful products produced by Australian manufacturer Barron & Rawson Pty Ltd is the Roadliner 2000TM S Series Road Safety Barrier.

The Roadliner 2000TM S Series is the first Australian designed and manufactured road safety barrier system to comply with AS/NZS 3845:1999, Road Safety Barriers Systems and AS1742.3-2002, Manual of Uniform Traffic Control Devices.

This product represents the premium in portable transportable lightweight polymer safety barrier technology, providing a seamless safety barrier for the protection of site and road work personnel.

Barron & Rawson company spokesperson Mr. David Moore said, “Properly installed, the Roadliner 2000TM S series is capable of providing a safety barrier that on impact by an errant vehicle, can prevent penetration and will bring the impacting vehicle to a controlled stop, or provide a dramatic reduction in speed as well as providing redirection.”

During the testing process, the impact tests provided a pass to all 5 criteria under AS/ NZS 3845:1999.

The system is the first all polymer safety barrier that does not require additional steel frames in the design. The product is available in standard colours of safety orange and yellow and features a unique interlocking ‘S’ design where individual modules are locked together with easy to use swing latches and bolts. Each module incorporates forklift access slots in the base for ease of handling and these slots double to allow for the drainage of rain water.

Each module has a joined together length of 2000mm, a base width of 600mm, a height of 925mm and a dry mass of 50kg. When filled, the water ballasting results in a mass of 630kg.

The pop up water level indicators provide for easy drive-by inspection and when required, the ballast can be drained and reused.

The following Australian Road Authorities have approved Roadliner 2000TM S series for usage within their jurisdictions at 60kph: • Roads and Traffic Authority NSW • Vic Roads - Victoria • Transport SA –South Australia • Main Roads – Queensland • Department of Urban Services – ACT • Main Roads – Western Australia • Department of Transport and Works – Northern Territory • Department of Transport – Tasmania The Roadliner 2000TM S series provides exceptional safety protection for workers and the public, and is a vast improvement on the conventional plastic channalising /delineating devices.

Barron & Rawson Pty Ltd was established in 1947 as a privately owned company based in Sydney and specialising in metal fabrication and toolmaking. During the early years of trading, the company formed some very strong relationships with major manufacturers, and became an integral part of the component supply chain to these companies.

With the evolution of new products and materials, the company later became a pioneer in the new manufacturing process of rotational and vacuum plastic moulding. This has been central to the company’s success

Above and below: Road Safety Barriers in situ and national recognition as Australia’s leader in industrial and consumer rotational moulding.

Through continuing capital investment over the years, the company can today boast possessing some of the most modern moulding machines available.

The stated objective of the company is to design, manufacture and market plastic and hinge products for the Australian and export markets and at all times maintain a quality of service in excess of their customer’s expectations.

Barron & Rawson’s product manufacturing range is extremely large and diverse and includes custom and proprietary products covering a varied group of industries including, Traffic Management, Hazardous Waste Recovery, Industrial Bins, Playground

Equipment and a large selection of sport and recreational equipment.

Barron & Rawson are based at 35-37 Marigold Street Revesby NSW 2212 and can be contacted via Free Call 1800 774 000 or through the details below Tel: 02 9771 6800, Fax: 02 9772 1892 E-mail: info@barronrawson.com.au Website: www.barronrawson.com.au

Above: The Roadliner 2000™ Series Road Safety barriers readying for testing

ROADLINER 2000 S TM

SERIES

Free Call 1800 774 000

Roadliner 2000TM S series

Th Austra e first lian & man designed uf road s afety b actured to com arrier syste m AS/NZ ply with S 3845 :1999

is a lightweight plastic crash tested barrier system which provides a seamless safety barrier for the protection of site and road work personnel.

Barron & Rawson Pty Ltd

Established 1947

Australia’s Leader in Industrial & Consumer Rotational Moulding

E-mail: info@barronrawson.com.au - Website: www.barronrawson.com.au 35-37 Marigold Street Revesby NSW 2212 TEL: 02 9771 6800 FAX: 02 9772 1892

Page 8 - Australian Main Roads Construction News

Successful impact “Patenttest Pending” to AS/NZS 3845:1999

ACS makes traffic problems disappear A

CS Integrated Service Provider is the kind of company that can become your best friend simply because it has the ability to solve those problems that you’d rather not know about or the ones you simply don’t have time or the expertise to deal with.

ACS is a highly professional multi-level, organisation with enough in-house expertise to provide a variety of business support services. The company was established on the Central Coast of New South Wales in 1991 and is rapidly spreading its influence across Australia providing traffic management for the construction sector; security assistance across a range of social and business activities, as well as house-keeping, commercial cleaning and maintenance programmes for developers and property investors.

The company’s growing and impressive list of clients include companies like Coles, Westfield, Colonial First State, ING, WorkCover NSW, Mirvac, Brookfield Multiplex and various City Councils who all subscribe to the variety of support services provided by ACS. So how does ACS Integrated Service Provider work in the field?

As an example, you might be in the construction sector or in Local Government and there’s a crane or an excavator that needs to access your work site. However, the area is subject to a constant flow of traffic and you’re faced with a logistical nightmare if the situation isn’t handled appropriately. You might be a pool installer, a house removalist, a tree surgeon, a builder or an organisation holding an outdoor event or in fact, you could be anyone who is dealing with a project application that has the potential to disrupt traffic flow.

If that’s the case there is an easy solution in the form of ACS and its unique Traffic Management Division. The Division consists of a team of dedicated industry professionals with specialised skills. The members of that team include experienced traffic consultants

who will advise on the best way to solve the traffic problem and ensure your traffic management plans are expeditiously approved

by Council and the relevant State Road Authority. For instance in NSW, it would be the Road Transport Authority (RTA).

On the day itself, ACS will provide signage and qualified traffic controllers who will manage the traffic flow in the area to ensure that the move is executed with the minimum of fuss.

ACS also map out the strategy using state of the art planning software systems to ensure that every aspect of the mission is planned, monitored and managed.

Importantly, whether ACS is providing security, traffic or property management, the company ensures that employees who provide the support services are highly trained. For instance, ACS traffic controllers deal with motorists so they receive not only, traffic management training but customer service and conflict resolution training, regardless of any previous experience. It means that when they are on site they clearly understand the needs of road users and know how to courteously relate to drivers who may be frustrated by any delay.

According to ACS CEO Paul Collins, the company is committed to providing the highest levels of service to clients, whether providing security, retail and commercial cleaning, traffic management or housekeeping.

“We currently service over 4,000,000 square meters of retail, commercial and public precinct space with some of Australia’s most successful blue chip companies. We know our partners, understand their needs and align our service delivery to create strong synergies.

We are directly contactable 24 hours a day.

Simply put, integrity, innovation and resilience underpin our business philosophy.

Importantly, we understand that our staff are our most important asset and heavily invest in training and professional development across

all sectors of activity. We are also committed to applying industry best practice and employ the latest technologies to ensure that we stay ahead of our competitors.”

Strict contract compliance and quality assurance are also key factors in the way ACS

do business. Senior management, including national, regional and site managers as well as a quality assurance team, will conduct regular quality audits relating to safety, risk procedures, OHS and all relevant policies. They will ensure that all contractual requirements are met because the singular aim for ACS is to maximize proficiency and exceed the expectations of all clients on every service contract.

With such a strong company philosophy and strict working ethics, there’s no doubt that ACS Integrated Service Provider is not only a unique support concept, but one which will continue to expand its activities well into the future. If you would like to know more about the range of services that ACS provide then check out www.acsisp.com.au

TRAFFIC CONTROL ACS specialised Traffic Management division is engaged to assist Builders, Pool installers, Tree Surgeons, Crane Operators, Utilities,& Tradesmen where a situation develops where traffic flow is expected to be disrupted.

Our industry experienced traffic consultants will ensure your Traffic Management plans are expeditiously approved by Council and RTA, saving you time and money.

Our state of the art planning software systems ensures every aspect of your project is planned and managed.

As with all of our employees our customer service training is a crucial aspect of the position, ensuring they understand the needs of road users under changed traffic conditions through our customer service and conflict resolution training.

Qualified Traffic Controllers enjoy outside working conditions and the position attracts both genders who are trained not only in traffic control but in client service and courtesy to placate frustrated drivers when journeys are delayed.

CONTACT US NSW - HEAD OFFICE: High Point Building Suite 5, 257-259 Central Coast Highway Erina NSW 2250 T: (02) 43 654420 F: (02) 43 653488

BRISBANE OFFICE: ADELAIDE OFFICE: Suite 4/070b Level 3/ 97 Pirie street, Westfield Garden City, Adelaide S.A 5000 Corner Logan Rd and Kessels Rd P: (08) 7129 4448 Upper Mount Gravatt QLD 4122 M: 0431 041 844 P: (07) 32194667 F: (07) 32194668 www.acsisp.com.au M: 0414 849 418

Australian Main Road Construction News - Page 9

Northern Expressway Project Overview C

ONSTRUCTION of the largest road project in South Australia for more than half a century is ahead of schedule, with advanced progress on bridges the key to rapid progress.

Following extensive consultation with local communities and road user groups the project team committed to an early construction of main overpass bridges to reduce traffic disruption on these important local roads during the ongoing roadway construction.

This strategy has been a benefit for everyday commuters and for agricultural transporters in this important primary produce region of the Northern Adelaide Plains.

In September 2008, construction commenced on the new 23 kilometre Northern Expressway, from Port Wakefield Road to the Gawler Bypass, north of Adelaide.

This project is the result of state and federal government cooperation under the Australian Government’s Nation Building Program.

The Northern Expressway, combined with the upgrade of Port Wakefield Road, is the largest road construction project in South Australia in more than half a century with a total investment of $564 million. The Australian Government is providing $451.2 million towards construction of this project that is due for completion in September 2010.

The project involves: • a new 23 km four-lane, two-way expressway with divided roadway;

Above: Diversion Channel Bridges. The Substructure works are ongoing with the abutments completed and the centre pier Cross heads being poured shortly. Precast T-Roff beams were installed in February

have been six bridges completed to date, five of which have been opened to traffic at March 2010.

Bridges now opened for public use:

Angle Vale bridge / statistics: • • • •

• overpasses and an underpass along the expressway; • changes to the local road network; • a recreational pathway; and

cycle

and

pedestrian

• a 12 km upgrade of the Port Wakefield Road.

The construction contract for the project was awarded in 2008 to consortium the Fulton Hogan York Joint Venture.

Construction commenced on September 1, 2008 at the strategically important Curtis Road and Angle Vale Road interchanges.

The expressway links the recently upgraded Sturt Highway at the Gawler Bypass across to Port Wakefield Road, near Waterloo Corner Road and features a shared use cycling/walking path along its length.

In readiness for the expressway there has been extensive upgrading of Port Wakefield Road near Waterloo Corner to the Salisbury Highway, to cater for increased traffic.

Ten, 55 tonne precast concrete beams 650 m3 of concrete poured 100 tonnes of reinforcing steel 26 x 3.2 tonne precast concrete barriers

Curtis Road bridge / statistics:

• full-speed connection at Gawler, linking with the Gawler Bypass; • entry to the expressway via interchanges along the expressway;

Above: Gawler River Bridges. The Substructure works are ongoing with the 9.5m centre pier columns currently being poured and cross head works commenced. The northern and southern abutments are nearing completion.

Precast T-Roff beams will be installed in March using a 500t Crane.

Above: Smith Creek Culvert. This triple 3mx2.4m culvert 110m long has the base slab completed and headwalls ongoing The benefits of the Northern Expressway include a reduction in travel time of up to 20 minutes between Adelaide and the northern regions, an improvement in traffic conditions for local residents and a safer and a more direct route for people travelling to Adelaide and the Port of Adelaide from the Riverland and Barossa regions.

The expressway will allow for a more direct connection to Port Adelaide for freight traffic, as well as a reduction in the amount of freight being carried on local roads.

This project contributes to the Department’s key objectives of assisting national economic and social development by improving the efficiency, safety and reliability of the National Land Transport Network.

The Northern Expressway is expected to be completed at least three months ahead of schedule and open to traffic by September 2010.

OLYMPIC BORING CONTRACTORS P/L PUMP SALES AND SERVICE Our involvement with Fulton Hogan on the Northern Expressway Project included: • Advising on bore requirements that best suits their needs • Assist with locating old bores • Introduce Fulton Hogan management to the local community • Construct water supply bores for the Expressway • Equip new bores with bore hole pumps • Maintenance on bore hole pumps • Backfill old bores for the Expressway to be built Workshop: Lot 101 Gawler Road, Virginia SA 5120 (PO Box 484 Virginia SA 5120) Tel: (08) 8380 9474 • Fax: (08) 8380 9601 • Email: olympicboring@optusnet.com.au Page 10 - Australian Main Roads Construction News

Bridge Construction program a key to progress The Northern Expressway project alignment includes 15 bridges and one significant culvert structure. Overall there

• Twelve, 58 tonne precast concrete prestressed beams • 750 m3 of concrete poured • 110 tonnes of reinforcing steel • 39 x 3.2 tonne precast concrete barriers • Includes a pedestrian walkway and 3m high throw screen (Continued on next page)

Above: Angle Vale Bridge

PAKTRANS PTY LTD Proud to be associated with Fulton Hogan and the Northern Expressway Project

Our involvement with the project includes the transport of dirt and quarry products from various locations

6/46 Stanbel Road SALISBURY PLAINS SA 5109 PHONE: 0408 080 686 • FAX: (08) 82813277 EMAIL: paktrans@primusonline.com.au

Northern Expressway Project Overview (Continued from previous page)

Heaslip Road bridge / statistics: • Twelve 55 tonne precast super T-Roff beams 30m long • 100 ton of reinforcement • 600 cubic metres of concrete • 44 x 3.2 tonne precast concrete barriers

Two Wells Road bridge / statistics: • Ten, 48 tonne precast concrete prestressed beams • 405 m3 of concrete poured • 80 tonnes of reinforcing steel • 56 x 3.2 tonne precast concrete barriers • 800m2 of reinforced earth wall

Penfield Road bridge / statistics: • Twelve, 59 tonne precast concrete prestressed beams • 702 m3 of concrete poured • 107 tonnes of reinforcing steel • 38 x 3.2 tonne precast concrete barriers • 1200m2 of stone pitching

The five bridges opened to traffic by February 2010 Angle Vale Road: On July 28 2009, the Minister for Infrastructure, Transport, Regional Development and Local Government, Hon Anthony Albanese and SA Premier Mike Rann officially opened the Angle Vale Bridge to traffic. This was a significant milestone on the project and is the first of fifteen bridges to be opened along the Northern Expressway.

The Angle Vale Bridge is a culmination of more than 15,000 hours of labour, and comprises ten 55-tonne concrete beams, 650 cubic metres of concrete, 100 tonnes of reinforcing steel and 26 pre-cast concrete barriers.

The Curtis Road Bridge was opened on 2 October 2009. To mark the completion of the bridge, students from Trinity College Gawler River campus attended the site to learn about plant propagation for the expressway and helped to plant shrubs on the roundabout. Curtis Road is a key route for vehicles travelling to the suburbs of Macdonald Park, Andrews Farm, Davoren Park, Smithfield Plains and Munno Para Downs. The interchange will improve road safety. Construction has involved 17,000 hours of work, including the construction of the pedestrian walkway.

Two Wells Road underpass was opened on 18 December. The Underpass comprises ten 48 tonne pre-cast and pre-stressed concrete beams, 405 cubic metres of poured concrete, 80 tonnes of reinforcing steel; and 56 x 3.2 tonne pre-cast concrete barriers.

Penfield Road bridge was opened to traffic on 22 December, marking the end of 15,000 labour hours. The bridge comprises, twelve 59 tonne Precast Concrete Prestressed Beams, 38 x 3.2 tonne precast concrete barriers, 702 cubic metres of poured concrete, 107 tonnes

of reinforcing steel, 1200 square metres of stone pitching.

Heaslip Road / Womma Road Intersection was opened on 18 February 2010 by the Minister for Transport, Hon Patrick Conlon MP. The intersection is one of the largest on this $564 million dollar project and it includes a five-way roundabout to accommodate significant freight movement in the region, particularly to Edinburgh Park and the future SCT Intermodal site.

Remaining bridges and structures are at various stages of completion at March 2010: • Port Wakefield Road Bridge: This three span, 25m wide bridge deck to handle northbound traffic is due for opening prior to Easter.

• Taylors Road Bridge over ARTC railway lines: The substructure is complete with precast T-Roff beams being installed over the live rail line. Deck works are continuing following this installation.

• Smith Creek Culvert. This triple 3m x 2.4m culvert is 110m long with the base slab completed and headwalls ongoing.

• Gawler River Bridges. The substructure works are ongoing with the 9.5m centre pier columns poured and cross head works commenced. The northern and southern abutments are nearing completion. Precast T-Roff beams will be installed in March using a 500t Crane.

• Diversion Channel Bridges: The substructure works are ongoing with the abutments completed and the centre pier cross heads poured. Precast T-Roff beams now being installed.

• Gawler Underpass Bridge: The substructure is completed awaiting the completion of the final stage of excavation between the contiguous piled walls. The shotcreting for the contiguous piled wall is now completed. Precast T-Roff beams

Above: Heaslip Road Bridge opened on February 18 will be installed with completion of the roadway works.

• Gawler Rail Bridge: The northbound bridge deck is being poured with parapet installation to follow. The southbound bridge abutments are being cast and precast planks due to be installed.

Above: Heaslip Road / Womma Road Intersection was opened in February

Environment at the forefront of construction About 750,000 plants, most grown from locally sourced seed, are being planted around the expressway interchanges.

Plantings on the overpass embankments at the intersections situated near populated areas will help soften and screen the expressway from adjacent residential properties. A range of trees, including river red gums, river boxes and wattles, as well as shrubs, grasses, reeds and sedges will be planted to improve the biodiversity of this important riparian zone.

Environmental and community concerns were addressed during the planning stage of the expressway, to protect the biodiversity of the region and local community interests.

The expressway will cross the Gawler River via two bridge structures, one of which is to allow for the ‘one-in-100 years flood’ mitigation.

Large areas of land associated with the interchange ramps will provide space for the management of stormwater in holding areas and the opportunity to reintroduce native vegetation to the area.

(Continued on next page)

Sovereign Concrete Products proudly associated with Fulton Hogan and York Civil on the NEXY Project

• • • • •

Bridge Parapets Road Barriers Culverts Stormwater Pits J-J Hooks Temporary Barriers 192 Ring Road, WENDOUREE, VIC, 3355 Phone: (03) 5330 7888 Fax: (03) 5339 3328 Email: sales@sovereignconcrete.com.au

A local business proud to be associated with Fulton Hogan and the Northern Expressway Project

Our involvement with this project requires the use of a tandem with trailer for the transportation of soil to various locations 89 Fradd Road, Angle Vale SA 5117 Phone: 0412 386 207 Fax: (08) 8284 8271 Australian Main Roads Construction News - Page 11

Northern Expressway Project Overview (Continued from previous page)

Green transformation now shows on major road upgrade The upgrading of Port Wakefield Road for the Northern Expressway has proved a benefit for local water conservation, even though watering is required for more than 23,000 new plants along this road section.

Recycled water from the City of Salisbury stormwater re-use sites is being used for the irrigation, but science is helping to keep water wastage to a minimum.

As part of the recent landscaping works along Port Wakefield Road, an Irrigation Management and Monitoring System (IMMS) has been installed to sustain these tubestock

plants in the road reserve. A computerised ‘evapo-transpiration / moisture loss’ weather station has been installed on site to measure the climatic conditions that cause moisture loss. A powerful computer program adjusts individual irrigation station run times to match climatic conditions, meaning monitoring and control of the irrigation network can be managed remotely.

The goal this form of irrigation is to gather enough climatic information for each irrigation zone, so that plants receive the exact quantity of water they require to keep them healthy. If rain has replenished a portion of the moisture, the computer system will schedule only enough irrigation to make up the difference.

The result along Port Wakefield Road is now being shown with healthier plants and minimised water waste and run-off.

Project Director Luigi Rossi explained: “As a project of this scale progresses different jobs are created and we quickly recognised that if we wanted to promote these jobs to young people and address skills shortages we needed to be in touch with teachers.”

Workshops conducted with local teachers identified the Premier’s initiative as an opportunity which develops maths and science skills for industry to ensure school students receive an up-to-date and realistic understanding of the application of science and maths within industry.

Targets achieved for employing young and Indigenous Apart from education, emphasis has been placed on local youth and indigenous employment.

Education and employment initiatives on NEXY:

Above: Revegetation contractor Tim Zwiersen adjusts irrigation lines in a field of native windmill grass at the expressway’s purpose-built plant propagation nursery at Penfield near the road corridor

Throughout project construction, the Northern Expressway has placed a high value on education and local community involvement.

More than 2,000 local people have visited and toured the site to lean more about the project. This massive building project has become part of the local community through organised connections with schools, universities, TAFE colleges, engineering groups and many local community and business associations.

In keeping with the Northern Expressway’s growing reputation in the surrounding community as ‘more than a road’, a unique education program is under way to complement this historic project. Four school teachers have been seconded to the project team to develop curriculum units based on real life industry experience and relevant to current curriculum in local schools.

Above: Port Wakefield Road Bridge. This three span, 25m wide bridge deck is currently being completed and is due to be ready for opening in March

Wingfield

Above: Department of Transport Contract Supervisor Ross Rake and Fulton Hogan Project Manager Danny Parkinson helping to plant shrubs at the Curtis Road roundabout on NEXY

Above: Department of Transport Landscape Architect Jordana Wilson, with a tray of seedlings planted at the Curtis Road interchange

The project has a minimum target of 10 per cent employment for young and Indigenous people and is the first project in South Australia to adopt this approach.

During May 2009, a high point was set with young and Indigenous people performing 14 per cent of the labour hours on the job. The expressway project has consistently exceeded its 10 per cent target for these two important demographics.

By 31 December last year, 2,868 people had been employed directly on the NEXY project with around 50 per cent of these residing in suburbs or regions north of Adelaide.

(Continued on next page)

Above: Gawler Underpass Bridges. The substructure is completed awaiting the completion of the final stage of excavation between the contiguous piled walls. The shotcreting for the contiguous piled wall is now completed. Precast T-Roff beams will be installed following completion of the roadway works

Proud to be a part of the Northern Expressway Project Supplying str uctural steel fabrication for the: NEXY Pedestrian Bridge Specialists in heavy and complex steel.

Auslec Wingfield are proud to be associated with Fulton Hogan on the Northern Expressway Project for the supply of Conduits, Pits & associated installation components.

Ph: 08 8359 5744 Fax: 08 8359 8944 Email: auswingfield@auslec.com.au

>PVS <PSME 4VS 8PMVUJPOT Page 12 - Australian Main Roads Construction News

Lot 100, Weber Road, Bowhill, South Australia 5238 Phone: (08) 8570 4208 Facsimile: (08) 8570 4350 BLN: 166 373 ABN: 33 911 388 370 www.boweng.com.au Email: admin@boweng.com.au

Northern Expressway Project Overview (Continued from previous page)

Bridges: Overall there have been 6 bridges completed to date, 5 of which have been opened to traffic. There are 11 bridges that are currently under construction and 1 significant culvert structure.

The remaining bridges and structures are at various stages of completion.

Fulton Hogan NEXY Facts and Figures

T

HE Northern Expressway Project is the construction of a 23 kilometres of dual carriageway linking the Gawler Bypass to Port Wakefield Road and includes the construction of 15 bridges and 5 kilometres of drainage works. To date Fulton Hogan SA has produced a total of 300,000 tonne of asphalt, and laying 2600 tonne on its biggest day. A total of 140,000 tonne is still to be laid before the completion of the Project, most of this being the SMA wearing course and levelling course. There are approximately 40 asphalt employees working onsite, 90% of those being employed and trained locally.

Fulton Hogan SA is operating four paver machines, two shuttle buggies, 8 rollers, and a fleet of 12 trucks, from purpose built semi trailers to truck and dogs.

Based at the Curtis Road project site, Fulton Hogan has an ASTEC Double Drum Asphalt Plant, capable of 200 tn/hr continuous production, fitted with RAP capacity and specialised mix silos. The production plant meets the highest of environmental standards in the world, with a design to reduce emissions and minimise oxidation. The Plant also has a storage capacity of 400 tonne and allows for the storage of mix for a length of up to 4 days.

Also based on site is the Asphalt Laboratory.

This laboratory and its technicians are all NATA certified.

A majority of the aggregate used in production is supplied by the Fulton Hogan Quarry, in Waterloo, and meets the specifications of the Department of Transport and Infrastructure. Materials are stored on site, held in specially built concrete bins that are fitted with sprinkler systems, using stormwater for dust suppression and control. Waste is also recycled and is used in the production of base mixes. The Fulton Hogan plant at Dry Creek also manufactures all polymer modified bitumen materials for the Project, allowing for great control of quality throughout the Project supply chain.

Fast Facts • • • • • • • •

Asphalt 300,000 tonne Crushed Rock (Penrice) 350,000 tonne Crushed Rock (Resourceco) 10,000 tonne Earthworks (shifted) 3,000,000 cubic metres.

Kerb placed 3.5km Fencing 30km Drainage 9.5km Concrete (structural, decks, piers etc) 9500 cubic metres.

Above: Taylors Road bridge. The substructure is complete with Precast T-Roff beams being installed over the ‘live’ ARTC rail line. Deck works are continuing following this installation

Above: Fords Quarry, Kapunda, was re-opened to obtain rock to line the Gawler River and Gawler River Diversion Channel. Material too small to be used for this was used to improve our haul roads

Above: Gawler Rail Bridges. The northbound bridge deck will be poured shortly with parapet installation to follow. The southbound bridge abutments are being cast and precast planks are due to be installed Above: Shoulder paver in action. A shoulder paver is a quick and effective alternative to laying a road shoulder (side tippers and a grader would normally be used)

ABN- 12 709 395 190 Lot 2 Sturt Highway, Nuriootpa Postal address 20 Para Rd, Tanunda SA 5352 Phn 08 8562 2063 Fax 8562 4765 Steve Martin Mob 0412 300 085 Email admin@liftingservices.com.au

ALLTERRAIN offers a portfolio of machines to suit your project including: • 200t, 100t & 95t Allterrain Liebherr mobile cranes with lift height capacity of 108m • Mt 1740 Allterrain elevated work platforms with safe working height of 18m • Prime movers + low loaders for counterweight and machinery transport

Above: Two Wells Road Bridges

Australia wide • 24 hours a day, 7 days a week • Fully self- sufficient lifting company • Computerised lift analysis • A cost effective, modern fleet • Experienced operators, dedicated staff • All plant and machinery are approved and meet all relevant occupational health and safety standards.

ALLTERRAIN offers experienced personnel with a range of skills including: • Crane Operators • EWP + Telescopic Handler Operators • Dogmen • Riggers • Boilermakers • Truck drivers

P h 08 8 5 6 2 2 0 6 3

Australian Main Roads Construction News - Page 13

Federal Updates on Road Infrastructure Projects from the Office of Federal Minister for Infrastructure and Transport, Anthony Albanese Contract awarded for Western Highway overtaking lanes C

Above: Federal Minister for Infrastructure and Transport, Anthony Albanese

New rest areas for Dukes Highway

S

AFETY on the Dukes Highway is to be further improved following the start of construction on four new rest areas and the upgrade of three existing rest areas, part of a $6.6 million project to upgrade conditions on the Dukes highway.

The Tolmer Group of Companies has won the $2.6 million contract to undertake the construction works between Tailem Bend and the Victorian border.

Federal Minister for Infrastructure and Transport Anthony Albanese said the works form part of the wider $80 million Dukes Highway upgrade, funded by the Rudd Labor Government under the Nation Building Program.

“Our primary goal under these works is to improve the safety and efficiency of this important transport corridor,” Mr Albanese said.

“These works will assist in addressing safety issues on the Dukes Highway by providing more opportunities for drivers to stop and rest up then have a safe onward journey.”

This project follows the completion of construction in December 2009 on four overtaking lane extensions on the Dukes Highway and the upgrade of one rest area.

South Australian Minister for Transport Patrick Conlon said fatigue is a significant issue for all drivers, particularly long haul drivers who spend hours at the wheel on our nation’s road network.

“Estimates indicate that fatigue is the main contributing factor in around 25 percent of road crashes that result in serious injury or fatality,” Mr Conlon said.

“Providing new and improved rest areas is one of the ways to address driver fatigue.”

The works are due to be completed by June 2010. A list of works and rest areas are below:

LOCATION West Bound

ONSTRUCTION of two additional overtaking lanes on the Western Highway west of Kanivahas begun, the first major works in a series of improvements on the road between Stawell and the South Australian border.

Federal Infrastructure and Transport Minister Anthony Albanese and Victorian Minister for Roads and Ports Tim Pallas announced the overtaking lane improvements contract had been awarded to Fulton Hogan.

Mr Albanese said Fulton Hogan would build a 1.2 kilometre overtaking lane for motorists travelling towards Adelaide and a one kilometre overtaking lane for traffic heading to Melbourne.

“Importantly, the new dual overtaking lanes are part of a broader plan to give motorists and truck drivers regular, safe opportunities to overtake,” Mr Albanese said.

“Together the Rudd and Brumby Labor Governments are investing $50 million to improve safety and travel times along the Western Highway between Stawell and the South Australian border.”

The Western Highway safety package is a jointly funded initiative, with the Federal Government contributing $40 million and further funding provided by the Victorian Government.

Mr Pallas said it was the stretch of road on the Western Highway between Nhill and the border had seen a large number of fatal crashes, despite relatively low traffic volumes.

“For users of the highway the extra overtaking lanes will mean safer travel and less time travelling behind convoys of slower moving vehicles,” Mr Pallas said.

“Once completed, the overtaking lanes together with a new trailer exchange, decoupling and rest area in Nhill, will make for a safer, less frustrating trip through this spectacular part of Victoria.

“This is another example of the Rudd and Brumby Labor Governments working together to build a better, safer road network for motorists, local residents and businesses in Victoria.”

Future works on the Western Highway project will include upgrading rest areas and bridge strengthening projects.

Work completed on Capricorn Corner upgrade

‘Expressions of Interest’ sought for Kempsey Bypass Bridges

A

multi-million upgrade to a dangerous section of the Barton Highway known as Capricorn Corner, located 28 kilometres north of the Australian Capital Territory, has been completed on time and under budget.

The project has improved safety by realigning the Highway at Capricorn Corner, providing a consistent 100 kilometre speed zone, sealed road shoulders and clearer lines of sight for drivers.

The Barton Highway is an important link between Canberra and the south west of NSW as well as Victoria, with more than 19,000 vehicles a day expected to be using it by 2025.

The Capricorn Corner upgrade is part of the Rudd Labor Government’s $20 million Barton Highway safety package – an investment that will provide a safer road for motorists and truck drivers.

More safety upgrades will continue throughout 2010, with the realignment of the Gounyan Curves to the north of Murrumbateman scheduled to get underway by the middle of this year.

All up, we’re investing $11.6 billion over the next few years to maintain and modernise the road and rail infrastructure of NSW.

WORKS

11km east of Tailem bend New rest area 6km west of Bordertown near Taylors Road New rest area 6km east of KiKi

Upgrade of existing rest area

8km east of Tintinara

Upgrade of existing rest area

East Bound 16.5km east of Tailem Bend, near the Cooke Plains turnoff New rest area West of the entrance to Culburra 13km east of Keith

New rest area Upgrade of existing rest area

Page 14 - Australian Main Roads Construction News

I

N preparation for the start of work on the new Kempsey Bypass, construction companies with expertise in bridge building are being encouraged to register under an ‘expressions of interest’ process being managed by the RTA. The company ultimately selected will partner with the RTA to design and build new bridges over the Macleay River and the nearby floodplain.

Registrations are open and close on Wednesday, 24 March.

At the conclusion of the registration period, a shortlist of applicants will be invited to submit tenders, with a preferred builder expected to be selected shortly thereafter.

The Kempsey Bypass is what the Rudd Labor Government’s Nation Building Program is all about. It will put 450 Australians to work building the road infrastructure vital to our long term economic prosperity.

As well as the new bridges, the project will lay 14.5 kilometres of dual carriageway to the east of Kempsey and Frederickton as well as construct two new interchanges.

The contract for these other aspects of the bypass was awarded in November to a consortium consisting of Leighton Contractors, AECOM and Coffey Geotechnics.

Major road works will start within months, with the erection of bridges due to begin by the middle of next year.

Once completed in mid-2014, this new section of the Pacific Highway will deliver safer driving conditions, cut travel times and take up to 2,000 trucks a day off the local streets of Kempsey.

The existing Highway will be retained as a local road.

Above: Victorian Roads and Ports Minister, Tim Pallas

Safety upgrades on intersections in Renmark SAFETY at intersections in Renmark will be greatly improved using the cost savings realised on other South Australian road projects.

We have reallocated savings of $3.6 million to upgrade intersections on Renmark Avenue, with the 18th Street intersection identified as an immediate priority.

Consultations with the local community will now be undertaken, giving them the opportunity to have their say on which of the other intersections along Renmark Avenue need upgrading – see attached map.

The South Australian Government and Renmark Paringa Council have long advocated the need for action, with the intersections along Renmark Avenue having been the scene of 31 crashes in just the last five years.

Our investment will improve driving conditions and safety for the 6,800 cars and 850 trucks that use Renmark Avenue every day.

We expect construction work to start later this year.

Through our Nation Building Program, the Rudd Labor Government is investing an unprecedented $2.5 billion to upgrade and modernise South Australia’s road and rail infrastructure.

PEAK DOWNS HIGHWAY COMES OF AGE T

HE road begins its journey in Mackay on the Queensland coast and winds its way inland, up and down over hills and creeks for 265km as it heads towards Clermont in the Central West region. Peak Downs Highway started life many years ago when there was not much humanity to see along its route, but since those early days it has seen generations come and go with towns springing to life along the way.

Over the years, what was once a less than travelled route has become far more popular, not least because of the traffic catering for the mines in the surrounding region. In recent times it has become abundantly clear to all who drive on it that the Peak Downs Highway needs to be made safer and more efficient in order to handle the ever increasing flow of vehicles and heavy trucks.

Over 10,000 vehicles a day now travel the highway just on the eastern end near Mackay and with many townships like Eton, Drapers, Walkerston, Alexandra and Nebo standing along its path, it’s no longer a quiet rural road but a major highway with traffic flow increasing by at least 13% every year.

Fortunately, the Queensland Government through its Department of Transport and Main Roads has made a commitment to upgrade Peak Downs Highway. Logistically it won’t be easy as there are many creeks to traverse and the road is extremely hilly with steep inclines at various points along its route. The Department has spent $68.2 million in the past seven years on the Peak Downs Highway with a further $46 million

Above: Concrete truck and pump setting up to pour the reinforced concrete collar for the extension of a 2.25m diameter corrugated steel multi plate pipe culvert Above: Queensland Main Roads Minister, Craig Wallace committed over the next three years.

The Peak Downs Highway upgrade along with other bridge and road construction brings Mackay’s total road funding from the State Government to a record $149 million for the year 2009/10.

Various projects to upgrade the highway have been completed along its route and now it’s the turn of a 4.85 km section located north of Nebo. To be precise, the location being upgraded is between chainages 6.3km and 11.15km north of the township from the

Suttor Road turn-out and Fiery Creek That part of the Highway will be widened to 10m and will be completely bitumen sealed. Already, despite interruptions due to periods of torrential rain, the drainage structure extensions are almost completed with earthworks currently in progress.

This will be followed by paving and the application of the bitumen sealing. The result of the upgrade to that section of road will produce two 3.5m wide traffic lanes with two 1.5m shoulders.

This upgrade alone will cost $6.8 million and according to Queensland Main Roads Minister Craig Wallace, it’s well worth it as the investment will improve safety and travelling conditions on the highway east of the Suttor Development Road intersection.

“This project is further evidence of the Federal and Queensland Government’s

ongoing commitment to improving safety on the Peak Downs Highway, which is a critical link for industry in Central Queensland,” Mr Wallace said.

“The current project also provides a welcomed boost to the local economy, sustaining 69 jobs throughout the duration of the works.”

The project is being conducted by Downer EDI, with completion set for late 2010 and in fairness to all involved, given recent climatic events, weather permitting.

Peak Downs Highway is now a vital link connecting the east coast with the Central West and the huge investment made by the Queensland Government will, not only preserve this road’s historic past, it will also safeguard the future wellbeing of all who travel on this mighty highway.

CMB Farleigh QLD 4741

Phone 07 4959 8624 Fax 07 4959 9198 Email: admin@vellascivil.com.au

Above: Concrete base slab and apron for the extension of a 4 x 2.1m x 1.8m Reinforced Concrete Culvert

VELLA’S CIVIL CONSTRUCTION is a family owned company, specialising in Civil Construction Projects, Machinery Hire and Gravel Sales within the Mackay and Bowen Basin district.

Our management team has a combined 20 years experience in the civil construction industry. We currently employ 40 staff with varying degrees of experience and qualifications.

Vellas Civil Construction pride’s ourselves on our professional service no matter whether the job is big or small.

Vellas Civil Construction

can help you with: • Earth Moving • Residential and Industrial subdivision • Road works • Rural Works including Dam Construction • Supply & Delivery of Gravel Materials • Hourly Machine Hire • Float Moves

Above: Excavation to widen an existing cutting to allow for the road formation widening to increase the formation from 8.4m to 10.0m (2 x 3.5m traffic lanes with 2 x 1.5m sealed shoulders)

Australian Main Roads Construction News - Page 15

THE MACMAHON SOLUTION

A proven formula for the Bunbury Port Access Project HEN Macmahon was awarded the $40.9 million contract to construct the Bunbury Port Access Road and Bridge 232A over the Collie River, it served as further confirmation of the excellent and ongoing relationship between Main Roads Western Australia (MRWA) and Macmahon Holdings.

Macmahon had already successfully completed the Mitchell Freeway project and had recently been awarded the Reid Highway project in Perth on behalf of MRWA, so it was understandable that the responsibility for the complex Bunbury Port Access Road project would be shouldered

by Macmahon.

Mind you, Macmahon Holdings is no stranger to major infrastructure projects.

The company was founded by Adelaide Civil Engineer, Brian Macmahon, back in 1963 and by 1967 it had secured its first mining contract from Nobles Nob Gold Mine at Tennant Creek in the Northern Territory. But that was just one facet of its business enterprise. Since then Macmahon has quietly spread its influence throughout its two key but separate business units.

The company’s abilities are a potent formula enabling Macmahon to target its considerable resources and expertise within two growth sectors; Construction and Mining.

Macmahon’s construction division undertakes key infrastructure projects including roads, bridges, railroads, ports and dams, whilst the mining division provides a total service for open cut and underground operations, managing mines for major customers not only in Australia but internationally.

W

Above: Sheetpiling

Above: Pilecap works for bridge

However even in the early years, apart from forging ahead with mining projects, the strength of the company’s construction capabilities were evident and it was clearly diverse. On the one hand, Macmahon completed projects on major roads like the Stuart Highway in the Northern Territory and on National Highway One in South Australia, while on the other hand the company constructed the Alice Springs to Tarcoola Railway in 1978.

By 1983 Macmahon Holdings had grown

Above: Bridge 232A erly piling and abutment works

considerably and with a 1000-strong workforce and revenue of $77 million, it was listed on the Australian Stock Exchange.

But on reaching that significant landmark there was only time for a brief pause in the life of a rapidly growing company intent on making its mark.

Macmahon is a highly disciplined corporation, one that has always operated under the guidance of a strict set of Corporate Principles. It’s a philosophy and a rule book that ensures that the conduct

and integrity of the company is diligently reflected both within its corporate corridors and beyond. These principles affect every aspect of operation whether providing benefits for shareholders and employees or relating to clients and business partners.

It even extends to local communities and the environment, right at the heart of those project locations where Macmahon conducts its affairs.

It is no surprise therefore, that since 1983 Macmahon has grown considerably, expanding its influence beyond Australia to New Zealand, Asia and recently even in Africa. Over the years Macmahon has quietly built not only a reputation for reliability and excellence but a portfolio of highly significant completed projects and a workforce which has grown to over 3000 employees.

The Bunbury Port Access Road (BPAR) project, funded jointly by the Federal and WA State Governments is important to the local community. Local roads have

(Continued on next page)

Above: Bridge 232A launch

Proud to be associated with Macmahon Contractors on the Bunbury Port Access Project

MJB Ind ust of concrries tendered t Concrete ete pipes and he job for the ground pipes were reqancillary produsupply (manufcaonditions in a uired for aggrects. m ctured s s pecificaallrine environmsive en y for this project)t .

43 Ditchingham Place AUSTRALIND 6233 Phone: (08) 9797 0999 Fax: (08) 9797 0900 Page 16 - Australian Main Roads Construction News

Steelpipe Australia congratulates JJ and the team at Macmahon on the successful completion of the Bunbury Port Access Road.

Steelpipe Australia was delighted to be able to supply Spiral Welded Steel piles manufactured locally in WA to a Western Australian Project.

We look forward to working with Macmahon again on future projects.

Steelpipe Australia 395 Mandurah Road, East Rockingham WA 6168 Contact Ian Hutchens Mobile 0400 099 851

Tel : (08) 9439 7700 Fac: (08) 9439 6477 Email ian@steelpipe.com.au

THE MACMAHON SOLUTION

A proven formula for the Bunbury Port Access Project (Continued from previous page) suffered under the extra congestion caused by heavy vehicles on route to and from the busy Bunbury Inner Harbour. The Access Road will provide a direct link to the Inner Harbour for heavy vehicles and free up the local roads for ordinary traffic.

The BPAR project was awarded to Macmahon in December 2008, with

works commencing in late January 2009.

But the project was not just simply about constructing a 4.5km dual-lane access road to Bunbury Inner Harbour.

The Bunbury Port Access Road portion of the works included the construction of approximately 4.5km of new road alignment from Estuary Drive through

Above: Australind Bypass Bridges

Above: Willenge Drive earthworks

Above: Bridges over Willenge Drive

Above: Willenge Drive

to South-West Highway in Picton. In addition, approximately 4km of intersection construction and upgrade works at three major intersections at Estuary Drive, Australind Bypass and South West Highway have been completed. Two of those intersections also required a traffic light, signalling system and the 4-way, South West Highway intersection required a new signalised, railway crossing.

The project also included the construction of two new road bridges to allow traffic to flow underneath the Australind Bypass and another two pre-existing road bridges over the rail line had to be widened, whilst traffic flows on the busy Australind Bypass had to be maintained A significant part of the project is the construction of a bridge over the Collie River (Bridge 232A). Bridges can be complex affairs but again with typical Macmahon construction versatility it’s all in a day’s work. The bridge consists of a 130m long, 5-span launch bridge with piled foundations, both on the abutments and in the river. The deck was launched over two piers each requiring four in-situ pilecap supports. Despite some initial piling complications the project has progressed well through the launching stages, delivering one launch deck section per week.

The construction of new road ramps to allow traffic access to and from the new bridge to the Old Coast Road are currently in progress, with all facets of the bridge expected to be completed by the end of March 2010.

The Bunbury Port Access Road portion was officially handed over to MRWA when the ‘ribbon was cut’ during a ceremony on 05 February 2010. The remainder of the works related to the road are on schedule for completion at the end of February.

The MRWA contract with Macmahon was subject to federal requirements as part of the funding arrangements, and was successfully audited by both the Federal Safety Commission and the Australian Building and Construction Commission of Australia.

Macmahon carefully plans all of its projects to ensure that high standards of efficiency always prevail. Such foresight has meant that an excellent safety record has also been maintained throughout the life of this contract, with a zero LTI rate for the project to date. The project has also maintained a zero TRIFR (Total Recordable Injury Frequency Rate).

In keeping with their own Corporate Principles, Macmahon exceeded their normal “buy local” commitment as a result of competitive pricing from local suppliers and subcontractors. This meant that the company was able to source and use local products without compromising safety and quality standards. During the construction process Macmahon established excellent relationships with the various stakeholders in the Bunbury area and this ensured that the local economy was boosted by the project whenever possible.

There is no doubt that Macmahon’s involvement in the Bunbury project has again demonstrated the company’s commitment to construction excellence.

It’s a well worn tradition and as the company approaches its 47th birthday the Macmahon Solution will continue to be sought by those involved in the mining and construction sectors, both here and abroad. After all, the Macmahon Solution is the proven formula for success.

Australian Main Roads Construction News - Page 17

‘Southern Gateway Alliance (SGA) dream team’ S

GA was formed to design, construct and deliver the New Perth Bunbury Highway (NPBH) and is comprised of three industry leaders; Leighton Contractors, WA Limestone and GHD, working in conjunction with Main Roads Western Australia (Main Roads).

Not only did this 71 km road project finish under budget, three months ahead of schedule and without one Lost Time Injury over its three year duration, SGA is now constructing the 6.5 km Mandurah Entrance Road for Main Roads WA.

Bridge over the Serpentine River

Alliancing innovation In a first for the construction industry, the Alliance introduced the concept of having a material supply company as part of the head Alliance Agreement (WA Limestone).

This was in recognition that one of the key success factors for the NPBH project depended on the ability to source and transport large quantities of raw materials in a very short time period.

Project team relationships The Southern Gateway Alliance combined the strengths of all the partners and recognised that a project of this size required leadership to take it ‘beyond the bitumen’ and leave a positive legacy of enduring social benefit.

With total commitment from each of the Alliance partner parent companies, a team of the highest calibre was established within the Alliance and considerable time and effort was invested in relationship training and team building to ensure that staff from all of the different partners developed a united Alliance culture. Through this leadership, SGA has been able to set new standards that have gone well beyond the standard ‘safety, time and cost’ measures and has built the community an outstanding project.

Working safer Safety was the project’s highest priority and a fully integrated safety strategy was implemented to achieve the project’s outstanding safety achievements.

Achieving a Worksafe Platinum Certificate of Achievement award for the 3.8 million man hours worked did not come easily. The Alliance delivered a Lost Time Injury (LTI) free project and the most senior project staff demonstrated they were committed to leading by example. This was illustrated by either the Construction Manager or the Safety Manager personally visiting the site whenever a safety incident occurred.

Work in the area would be suspended until the incident and its implications were fully investigated and lessons learnt reports were distributed to the whole team.

Environment The project had numerous environmental challenges, including restricted use of bores, ‘Bush Forever’ sites, State Forests, dieback, Indigenous heritage issues, Declared Rare Flora (DRF), Acid

Page 18 - Australian Main Roads Construction News

and Potential Acid Sulphate Soils (ASS & PASS) and waterways management.

The project excelled in meeting all these challenges with outstanding outcomes.

Stakeholder Satisfaction The main alignment had more than 250 adjacent residents over a frontage of 140 kilometres spanning four local government areas. SGA developed a proactive community relations management plan which encompassed stakeholder identification and profiling, establishing community forums, creating community response and communication protocols.

The project was able to turn detractors into advocates.

Future of Alliancing The project met or exceeded all project objectives and minimum conditions of satisfaction, achieving outstanding results and glowing endorsements from the major stakeholders.

The Southern Gateway Alliance is now committed to raising the performance bar in delivering client expectations for the Mandurah Entrance Road project, currently under construction.

This team of stars is a true demonstration of the benefits of using the Alliance model to achieve excellence in delivering major infrastructure projects.

Kwinana Freeway Extension - Forrest Highway S

OUTHERN Gateway Alliance (SGA) comprising Leighton Contractors, WA Limestone, GHD and Main Roads, was formed in September 2006 to design, construct and deliver the Kwinana Freeway extension and Forrest Highway - one of Western Australia’s most significant infrastructure projects.

Construction commenced in December 2006 and the road was opened to traffic on 20 September 2009, some three months ahead of schedule.

Funded by both the Commonwealth and State Government of Western Australia, the project doubled the length of the existing freeway network and now provides a high standard inter-regional road link, improving transport connectivity and road safety.

The new road connects Perth with the South West, bypassing the heavily populated areas in Mandurah and avoiding inland communities on the existing highway.

The result – reducing travel time for road users by around 30 minutes.

The project was both dynamic and challenging, including 70.5 kilometres of dual carriageway from Safety Bay Road in Baldivis to Old Coast Road in Lake Clifton.

The freeway extension comprises 32 kilometres of freeway standard road from Safety Bay Road in Baldivis to South Yunderup Road, South Yunderup. The remainder of the route, the Forrest Highway, is a rural highway with the ability to be upgraded in the future as traffic demands increase. The entire route is continuous dual carriageway, with two lanes in either direction.

Six grade-separated interchanges are provided at Safety Bay Road, Karnup Road, Paganoni Road, Lymon Road, Lakes Road and Pinjarra Road. With the exception of the Pinjarra Road interchange, these were constructed as diamond interchanges, allowing for movements in all directions. The Pinjarra Road interchange was constructed as a Parclo interchange, where all the on and off ramps are provided on the northern side due to the proximity of the Murray River.

Ten intersections are provided on the Forrest Highway and have the capacity to be upgraded to interchanges in the future.

They are located at Beacham Road, Greenlands Road, Paull Road, Mills Road, Birchmont Road, Herron Point Road, Old Bunbury Road, Dorsett Road, Old Coast Road and Peppermint Grove Road.

In total, 19 bridges were constructed to grade separate the interchanges and extend the Kwinana Freeway extension over the Serpentine River, Nambeelup Brook, Murray River/Pinjarra Road, and the Forrest Highway over South Yunderup Road, Harvey River and the Mayfield Drain.

At the project’s peak, the haulage operations involved a fleet of approximately 200 trucks, hauling some 50,000 tonnes per day and travelling a combined distance of 50,000 kilometres per day. There was also approximately 800 pieces of plant and machinery approved to operate on site.

Approximately 13.5 million tonnes of sand and limestone, which was sourced from various borrow pits near the alignment, was imported to the site and provided the 250mm foundation for the road surface.

The Forrest Highway comprises approximately 300,000 tonnes of Crushed Rockbase (CRB) with a bitumen seal, while the freeway extension features a CRB and asphalt seal combination, as well as a 15

Above: In total, 19 bridges were constructed

Above: Cutting the ribbon are L-R: Premier of WA, the Hon. Colin Barnett MLA, Senator the Hon. Christopher Evans, Commissioner Main Roads Menno Henneveld, and Federal Member for Canning the Hon. Don Randall MP kilometre thick lift asphalt section at the northernmost end, where traffic volumes are the highest.

All of this material was imported and placed by wireless machine guidance technology, which historically would have taken an extensive team of surveyors to peg and guide on site. SGA used a unique combination of machine control systems and a wireless communications network to fast track construction and efficiently manage any issues surrounding the highway’s evolving design.

The Alliance also employed the use of innovative machinery to enhance the efficiency of paving operations, including two German manufactured paving machines, which were the only two of their kind in Australia and could lay the entire width of the 11.7m carriageway in one pass.

Toward the end of paving operations, the crews averaged almost 900m of dual lane carriageway each day, almost double the earlier predicted amount.

SGA was extremely conscious of the community and environment throughout the project and implemented a number of measures to minimise their impact.

Some of the environmental measures included an extensive landscaping program, which revegetated and rehabilitated more than 240 hectares of land within the project site; creation of a 24 hectare artificial wetland in Karnup; installation of “Cockatubes”, which provide new nesting habitat for cockatoos; and relocation of around 400 native grass tress.

The Alliance worked with the community to achieve three major design modifications including the relocation of the carriageway at both Murray Lakes and through the Paganoni Reserve, and also the relocation of the Red Road bridge. The Alliance also created several legacies for the community

Above left: Pinjarra Road Interchange before and after

including walk trails and the restoration of the Harvey River in Lake Clifton; as well as ochre and crib hut contributions to the local indigenous community.

In addition to this, SGA awarded 375 contracts to complete the project with 36 percent to local companies representing a $101 million injection into the local economy.

The project team worked a total of approximately 3.8 million man hours without a lost time injury to construct the road and in doing so, was awarded a Platinum Certificate of Achievement from WorkSafe Australia. A selection of other accolades the project has received is below:

2009 Asia Pacific Spatial Excellence Awards - Construction and Infrastructure Award for Excellence - Overall Award for Excellence

2009 WA Engineers Australia Excellence Awards

Above: 24 hectares of artificial wetlands

NPBH PROJECT QUICK FACTS • • • • • •

- Management of Engineering Award - Infrastructure and Building Award

2009 Surveying and Spatial Science Institute of WA Awards

• •

- Construction and Infrastructure Award for Excellence - Overall Award for Excellence

•

2008 Institute of Quarrying Australia

•

- Bradken Gold Hard Hat Award for Bulk Haulage Safety Southern Gateway Alliance is currently constructing the Mandurah Entrance Road (MER), which is a 6.5 kilometre route connecting the Kwinana Freeway extension with Mandurah. Construction on the MER commenced in September 2009 and is expected to be complete by December 2010.

• • • • • • • • • • • • • • • •

70.5 kilometres of dual carriageway 6 interchanges 10 intersections 19 bridges 32 kilometres of principal shared path for pedestrians and cyclists 7 pedestrian underpasses at the Safety Bay Road, Karnup Road, Paganoni Road, future Mandurah Entrance Road, Lakes Road and Pinjarra Road interchanges 12 fauna underpasses more than 40 kilometres of fauna fencing the use of 5 borrow pits to source sand and limestone over 12 million tonnes of sand, 1.3 million of limestone and almost 1 million of crushed rock/gravel almost 27,000 cubic metres of concrete 821 piles and 146 beams for the bridges over 22 kilometres of drainage around 21 kilometres of noise walls public artwork on each interchange bridge iconic artwork in South Yunderup a 24 hectare artificial wetland 260,000 cubic metres of both mulch and topsoil 300,000 native seedlings 240 hectares revegetated 71 permits for construction activity more than 2000 people inducted to site 375 contracts awarded, with $101 million injected into the local economy 3.8 million man hours worked 116 community bus tours 8 major awards to-date

Above left: Safety Bay Interchange before and after Australian Main Roads Construction News - Page 19

Great Northern Highway – Kimberley Project B

GC Contracting and Laing O’Rourke Australia in a joint venture operating as Team Savannah with AECOM providing the structural design, road and drainage design and environmental management services have completed work on the Great Northern Highway near Warmun in Western Australia. The project was delivered under an ECI (Early Contractor Involvement) model, which is a 2-stage delivery model to expedite this $105M federally funded project, and a first for Main Roads WA. Works were completed over two construction seasons around the Kimberley wet season, and included 3 new bridges and over 23km of realigned highway. The project achieved a number of outstanding achievements including zero Lost-time Injuries (LTIs), innovations in design, and a number of lasting legacies to the community.

The project was officially opened on 9 December, 2009 by the Hon Gary Gray AO MP, Parliamentary Secretary for Western and Northern Australia at a ceremony at Telegraph Creek which included members of the local Gija people and Team Savannah’s project team.

The remote site, spread over 200km of the highway, required the establishment and management of a 165-person construction camp near Warmun. The proximity to this ‘closed’ aboriginal community presented both challenges and opportunities for the project which the team embraced.

Tony Petrusma, Operations Manager at BGC and Team Savannah’s Project Director said “This project was an extraordinary example of what can be achieved when the local Indigenous community is involved from the start.”

“We met with the community during the tendering phase to fully understand how the construction works and our local presence could present opportunities for the community. We negotiated potential contract work, employment and training but just as importantly we talked about impacts and strategies to manage our workforce’s interaction with the community,” he said.

“When we were awarded the contract we moved quickly to implement our commitments and this built a strong foundation for the two year project.”

Rob Yates, Senior Project Leader at Laing O’Rourke and Team Savannah’s Project Manager said “At the start of the project we committed to 7% local Indigenous employment and we maintained 15% throughout the project. We helped new businesses to tender for work and maintained a proactive approach to community involvement.”

“One of our proudest achievements was being awarded the Outstanding Contribution to Employment and Training of Aboriginal People at the East Kimberley Aboriginal Achievement Awards in 2009” says Rob. “We worked hard to ensure

our local trainees and their mentors were supported and this often included talking to family members to fully understand how outside influences were affecting their ability to work. Our local employees stayed in the camp and this assisted their work focus and productivity.”

Tony and Rob both agree that this project set a new benchmark for Indigenous engagement in road construction and look forward to applying this knowledge to future projects.

Tony says “The team was also committed to innovation in the design, construction and activity with stakeholders and generated so many ideas that we needed a robust process to assess them. We developed a database program we called SMART (Sustainability

Above: Official opening of the Great Northern Highway Kimberley Project on 9 December, 2009 by the Hon Gary Gray AO MP (4th from left), together with senior representatives from Main Roads WA, Team Savannah, and the local Gija people from Warmun

Above: Graduation of Team Savannah Trainees

Above: Bridge construction works in progress at Telegraph Creek, the site of the 750 year old boab tree transplanted to Kings Park Perth in July 2008

Above: Dawn on the newly constructed Bow River section.

Adjacent cleared zone is the old alignment

Page 20 - Australian Main Roads Construction News

Measurement Assessment and Recording Tool) to examine each idea for better than business as usual outcomes and then assess it against sustainability goals for the project.”

“The SMART program enabled us to understand the economic benefit of social outcomes and lead to exceptional outcomes for the local community. Our workforce reported a greater sense of satisfaction due to their community involvement and this lead to an extremely low workforce turnover.”

“The process also supported our risk assessment process as mitigation strategies were assessed against the same criteria. One identified risk that eventuated was damage to precast bridge beams during transport.

Our strategy was to standardise the beams across the three bridges so that they were interchangeable. This innovation averted potential down time during critical path work,“ said Rob. Tony says “The SMART process proved to be a valuable inclusion in our planning and management. Without it, managers would have made decisions in their respective areas of responsibility. These would have been based on discussions at project meetings and their own experience. The SMART process takes everything into consideration including the client’s goals and objectives, global environmental best practice, community expectations and commercial viability. Each idea takes less than 5 minutes to assess and the report is easily understood by all parties.”

The innovations developed during the ECI Phase and priced into the project generated significant savings to Main Roads, and provided a sizeable Innovation Bonus to Team Savannah.

BGC Contracting, Laing O’Rourke and AECOM plan to continue to use this tool in other projects and Main Roads WA promotes its use to other contractors. Tony concludes “We are proud of this legacy from the Project and of our determination to develop an innovative process that assessed opportunities against sustainability goals and project objectives.”

Above: Big Mabel Creek Bridge