AMRCN April 2012

ACN 132 670 261

VOL. 4 NO. 15 - April 2012

ABN 52 132 670 261

PRINT POST NO. PP424022/2324

ALL ENQUIRIES PHONE: (07) 5478 9432 EMAIL ENQUIRIES: admin@amrcn.com.au www.amrcn.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

ABIGROUP FORGE AHEAD WITH HUNTER EXPANSION STORY PAGES 4-6

14th International Flexible Pavements Conference For Full Wrap Up See Pages 4-6 Above: Sergio Cinerari (AAPA Chairman also COO Downer Australia), Michael Bushby Chief Executive of the NSW RTA (opened the Conference); Dr Helen Murphy (Director of Sustainability in VicRoads and key note speaker); John Lambert

Bruce Highway Upgrade: New Gin Gin Overtking Lane

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EGULAR users of the Bruce Highway north of Gin Gin near Cabbage Tree Creek can soon expect safer, less frustrating driving conditions, with construction of a new fully-Federally funded southbound overtaking lane on track to be completed by the end of July, weather permitting.

Once completed, the new $5 million, 1.2 kilometre overtaking lane will give the 3,000 motorists and 800 truck drivers which use this stretch of highway everyday an additional opportunity to safely pass slower moving vehicles.

While this project is underway and work teams are onsite, I would urge all drivers

to slow down, obey the signs and follow the instructions of traffic controllers.

The upgrade is being delivered by VEC Civil Engineering.

All up, we’re building 50 new overtaking lanes on the Bruce Highway as part of Federal Labor’s unprecedented $2.8 billion investment in this vital part of the national road network.

Nonetheless we appreciate that the State’s growing population and rapidly expanding resources sector is placing added pressure on this road. That’s why it will always be a priority for Federal Labor and a beneficiary of the extra infrastructure funding which will flow from our new mining tax.

Renmark Avenue Upgrade Builder Selected

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

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

For All General Enquiries - (07) 5478 9432 Email: admin@amrcn.com.au All Advertising Enquiries - Phone: (07) 5499 4441 Email: advertise@amrcn.com.au

Head Office: 14 Merriman Court, PALMWOODS QLD 4555

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OLMER ROADWORKS has secured the contract to upgrade key intersections along Renmark Avenue in the South Australian town of Renmark, with work on this $5.46 million project expected to start shortly.

Renmark Avenue forms part of the Sturt Highway, named in honour of one of Australia’s original explorers Captain Charles Sturt who was the first European to pass through the area now occupied by the town of Renmark. The Highway is part of the main inland route connecting Adelaide to Sydney.

Once fully completed in September 2012, the improvements will deliver smoother, more efficient driving conditions for about 10,200 motorists and truck drivers who pass through the town every day, as well as better safety for local pedestrians.

The Federal Labor Government is contributing funding to the project through its Nation Building Program.

Upgrades in Renmark Avenue include: • Building a roundabout at the intersection with Eighteenth Street.

• Installing a “seagull island” treatment in the medium strip at Twentieth Street intersection and a new right turn only lane into Industry Road.

• Widening the central median strip at the intersection with Twenty-First Street as well as realigning its southbound lane - measures which will improve safety for turning traffic and give drivers a better line of sight.

• Closing the right turn into and out of Twenty-Third Street.

This project is one of many now underway around South Australia as a result of Federal Labor’s unprecedented $2.7 billion investment in the State’s road, rail and public transport infrastructure.

Tom Cook

Postal Address: PO Box 1176, MOOLOOLABA QLD 4557 Facsimile: (07) 5445 9431

To view our latest issues or to subscribe FREE OF CHARGE, visit us online at www.amrcn.com.au ©All content featured within, including all advertising and written material created by Australian Main Roads Construction News for this publication is protected by copyright and cannot be used or reprinted without the express permission of Australian Main Roads Construction News Pty Ltd

We also publishe Australia’s Leading Power Industry Newspaper

Editorial Contributions Civil Engineering, Local Government Councils including all State Road Authorities are invited to submit editorial, photo input on any intermediate or major road infrastructure projects that they are involved with or are nearing completion, to appear in a future issue of the Australian Main Roads Construction News, free of charge to allow and inform our national readership of the many diverse road infrastructure projects currently being undertaken throughout Australia.

In the first instance, please contact the publisher, Tom Cook for further details on: (07) 5478 9432 or email: admin@amrcn.com.au Web: www.amrcn.com.au Page 2 - Australian Main Roads Construction News

Web: www.amrcn.com.au

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In this issue: • Manage your water with Polymer

Innovations Page 3 • Abigroup forge ahead with Hunter expansion Page 4-6 • Federal Updtae on Road Infrastructure Projects Page 7 • 3M Award rewards new road safety initiatives Pages 8-10 • AAPA urges a cost effective approach to paving Pages 11-17 • M80 Ring Road to get Smarter and Safer Wheels in motion for the M80 Ring Road Page 18 • Visionstream provides a fully integrated managed freeway solution to VicRoads Page 19 • Excavators and Attachments Feature Pages 20-24 • Federal Update on Road Infrastructure Projects Page 25 • National Precast heralds a new era in Precast Concrete Pages 26-28

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Manage your water with Polymer Innovations P

olymer Innovations works closely with industries to help them maintain safe working environments that assist with the health and safety of workers, their families and local residents.

Many of these heavy industries such as mining and construction are located in remote locations and utilise dirt or unsealed roads constantly.

Due to the huge amounts of stress these roads regularly receive they soon lose stability and erode.

Spilling and leaching toxic dirt, mud and water pollution into nearby land and waterways affects employees, residents and the local environment.

Road stabilisation is important in maintaining our landscapes integrity by stopping the leaching of water based and airborne pollution, preventing hard panning and increased salt content of soils, protect native land and increase the strength of roads and embankments.

Road stabilisation, soil erosion and dust pollution problems are dealt with quickly

by Polymer Innovations specific polymer products. These products are easy to apply, are cost effective, biodegradable, non-toxic and environmentally friendly.

Water$ave Flobind is a polymer that is used for soil erosion control, road stablisation, dust suppression, dam sealing and hydroseeding.

Water$ave Flobind is extremely versatile and can assist with all water and pollution issues.

It flocculates suspended fine soil particles and stabilises existing soil structure. Flobind is also ideal for smaller applications where powder or emulsion dosing systems are not practical.

This polymer gives us an even greater ability to customise a solution for your water and pollution problems. Whether it is used on its own or mixed with other blends our ability to cater a solution for you is assured.

Suppressing dust and light soil in the air is important in many ways. Such as keeping people and animals free from allergies and asthma, reducing soil erosion, ecological damage and

airborne pollution. Also, reducing wear and tear on nearby expensive equipment.

Finding ways to effectively control dust and air born pollution in a simple and cost effective manner is beneficial for everyone. Polymer Innovations meets this demand with a specific and extremely cost effective polymer blend for dust pollution control Water$ave DS Dust Suppression.

Water$ave DS is an effective dust stabilising agent for soil waste and mineral dumps; civil and commercial construction sites; open cut and underground mines; coal stock pile management; quarries and landfills; unpaved roads; parking lots and open areas; dirt roads; airstrips and other dust prone areas.

Water$ave DS offers a quick, safe and cost effective solution that reduces the amount and the frequency of cart watering. No matter the scale Polymer Innovations staff will provide the best dust suppressant solution to keep your environment clear and it’s inhabitants breathing easier.

Polymer Innovations develops specific polymer blends that address the unique requirements of industries exposed to hazardous

or toxic slimes and sludges. Toxic water slurries that are too thick to pump or too watery to shovel up, can be thickened quickly by adding SAP, allowing for fast and easy removal.

Our SAP Range absorb large quantities of toxins in water and hold them stable for removal for mining, construction and governments roadways; dredging and other industrial waste water affected areas. Water ingress issues are dealt with quickly by our SAP polymer blends.

SAP reduces damage to the surrounding environment and removes hazardous material from the work area that can be caused by water and mud slurries. This ability to cater to the unique requirements of our clients allows us to control water based pollution from some of Australia’s most pristine environments and productive industries.

Polymer Innovations Water$ave PT Plantation is effective in the revegetation and reforestation of roadside trees, bushes, tube stock and saplings. Water$ave PT can reduce the mortality rate caused by transplant shock and enhance root development, encouraging more rapid growth and production. Water$ave PT reduces the leaching of any introduced fertilizer, minimising evaporation from the soil whilst improving porosity and aeration.

Hydroseeding is used to seed grass on commercial sites, highways or motorways, parks and golf courses, heavily damaged or burnt land, lawns and areas too large, inaccessible or unsuitable for conventional methods. Once it is applied to the soil, it enhances growth by providing an ideal environment for seed germination.

Water$ave HY Hydro can be efficiently applied for hydroseeding operations in

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mountainous areas or road embankments. It maximises plant establishment and holds the components together preventing loss of material through wind and water erosion.

Water$ave HY Hydro prevents cellulose mulch from becoming hardpan during a dry spell. The mulch remains aerated allowing the seeds to sprout quickly. Water$ave HY also reduces the amount of mulch needed. Polymer Innovations Water$ave HY Hydro is highly effective in the young regrowth of trees, shrubs, bushes and saplings to assist in revegetation and reforestation.

Water$ave TF Turf - is a special polymer formulation that can be used throughout the growth cycle of lawns and sods, ensuring good germination and fast root development for the even growth of lawns.

The rooting of the sod is faster, increasing growth efficiency. Water$ave TF polymers reduces labour and water costs, as well as providing relief for difficult growth areas and hot spots that are vulnerable to drying out and going brown.

TF is widely used in turf landscaping for decorative lawns, golf courses, bowling greens, parks and gardens.

Water$ave PL Plug is the best polymer based reservoir sealant that is 100% customisable to your specific environment via our specific dam sealing blends Plug, Seep and Bomb. Whether the leak is in the base, wall, through rock or in any soil type we have the specific Water$ave PL dam sealant to put an end to your water loss.

Water$ave PL locates the leak and seals it.

Even if you don’t know exactly where the leak is our polymers will locate the outflow and stop it!

Polymer Innovations sales and support staff will tailor the best solution for your road stabilisation projects.

For more information please visit the website: www.polymerinnovations.com.au or call 02 6571 5177.

Australian Main Roads Construction News - Page 3

Hunter Expressway Feature

Abigroup forge ahead with Hunter expansion The Hunter Expressway in New South Wales is an important link within the national road network and its strategic location at the junction of two major freight and transport corridors makes it a logical choice for expansion.

The F3 Freeway and the New England Highway already play their part in the critical north/south transport route between Sydney and Brisbane and Abigroup’s design and construction of the western section of the Hunter Expressway will contribute to a far more efficient east-west link.

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HE HUNTER Expressway project is the largest single road infrastructure project currently underway in NSW as part of a Federal and State Government program to improve the efficiency and safety of this important transport corridor. The $1.7 billion project will result in a four-lane link road between the F3 Freeway near Seahampton and the New England Highway, west of Branxton.

The new 40 kilometre expressway, a $1.7 billion project, is being constructed under two contracts. The Australian Government will contribute $1.5 billion to the project with the NSW State Government providing up to $200 million. Weather permitting, completion is anticipated by the end of 2013 and the Hunter Expressway will not only enhance the travelling experience for all motorists, but will also dramatically improve connectivity between Newcastle and the growing urban areas throughout the Lower Hunter region.

The 27 kilometre western section of the Hunter Expressway is being completed under a design and construct contract for Roads & Maritime Services (RMS), which replaced the Roads and Traffic Authority of NSW (RTA).

An SKM/SMEC Joint Venture has designed this

section and Abigroup commenced construction of the expressway link in April 2011.

The route of the new four-lane expressway between Kurri Kurri and Branxton traverses an eclectic mix of landscapes, moving through both industrial and picturesque rural settings including vineyards and natural forests.

The Barrington Tops and Mount Sugarloaf provide more distant highlights for motorists and the design of the expressway has served to capitalise on the natural scenic vistas that prevail in the area.

For that reason the design of the new road optimises both horizontal and vertical curvature, while minimising its footprint and its impact on the sensitive areas surrounding the project. In effect, the design also provides motorists with something to look at which is an important safety element on a rural highway, as it reduces the potential for fatigue, boredom and complacency when travelling long distances.

In a further initiative to stimulate the travelling experience, bridges will not feature central piers and the bridge structures will form key signature markers along the route.

In effect, this will create viewing portals which will enhance the overall visual experience for drivers and passengers.

Bridge deck pour – Camp Road Bridge

However, for the Abigroup project team there are many challenges to be faced in the construction process and in some ways regardless of any pre-planning it can become a voyage of further discovery.

The expressway is being constructed in areas subject to mine subsidence and in the presence of acid sulphate soils, with each presenting the need for sensitive and specific solutions. There are a number of old, disused mines in and around the construction site and Abigroup is conducting its own mine void filling programme around the communities of Greta and Kurri Kurri.

As part of this process and in a unique exercise in sustainability, the project team are using a grout mixture incorporating fly ash from local power stations. Although not always used, fly ash and bottom ash produced by coal-fired power generation is an accepted engineered fill and concreting ingredient within the construction industry. Filling the mine voids in Greta and Kurri Kurri is a huge task which requires the pumping of about 45,000m3 and 35,000m3 of grout respectively.

Mine fill work at Greta has been continuing with the activity in that area now almost completed. Abigroup has also established a grout plant to facilitate the mine voids treatment in Kurri Kurri.

Abigroup also expects to start mainline paving in May 2012 and it has an economic and logistical advantage having set up its own onsite concrete facility to batch the concrete required for the paving.

CONFINED WORKSITE PROVIDES EXTRA CHALLENGES

Girder Lift at Tuckers Lane

The constraints of the work site area, along with significant environmental considerations, provide numerous challenges. In minimising the expressway’s footprint, the project incorporates very strict clearing limits which in turn impacts on the space normally required for stockpiling of materials, plant and equipment used on the project as well as the construction of sedimentation basins and the locating of ancillary facilities such as site compounds. www.amrcn.com.au

Abigroup’s project team has responded with some innovative solutions to overcome the logistical problems associated with such a confined site area. This has involved changing designs; working with close neighbours to undertake work outside the road corridor; and consultation with aboriginal stakeholders.

Work is now well underway and at the time of writing the project team has already moved around 2,000,000m3 in earthworks. This represents around two thirds of the extensive earthworks that are required in the western section which includes 28 cuttings and 28 fills. The largest cutting is 380,000m3 with the largest fill requiring 615,000m3.

Primarily, Abigroup will construct approximately 27km of two-lane dual carriageways as well as four interchanges including associated entry and exit ramps.

The four grade-separated interchanges will be located at Kurri Kurri, Loxford, Allandale and Branxton.

The western section is a comprehensive project and Abigroup will construct 22 bridges including five main carriageway twin bridges, with twin bridges over the Main Northern Railway, plus eight transverse bridges over the expressway.

The interchange at Kurri Kurri and Branxton will be full interchanges allowing traffic movements in all directions and will both feature twin bridges over the expressway.

When completed, the new interchange at Branxton will divert traffic onto the Hunter Expressway and this will dramatically reduce the weight of traffic that normally would have travelled through Branxton on the New England Highway.

The interchanges at Loxford and Allandale will be half interchanges with east facing ramps, allowing traffic coming from or travelling to the east to access the expressway with both featuring one bridge across the expressway.

Road bridge crossings will be a feature at McLeod Road at Kurri Kurri, Old Maitland Road at Sawyers Gully, Camp Road at Greta, Tuckers Lane at Greta and Wine Country Drive at Branxton.

Continued page 6

Australian Main Roads Construction News - Page 4

Hunter Expressway Feature

Hunter Expressway Design and Construct Project B

ORAL CEMENT has been awarded the contract to supply Shrinkage Limited Cement and Fine Grade Fly Ash to Abigroup on the Hunter Expressway Project. The venture commenced in early 2011 and will entail delivering significant volumes of cement and fly ash to site batch plants over a period of 2 years.

Above: Scrapers at work on Old Stanford Road, Stanford Merthyr

Boral Cement has successfully supplied product to Abigroup on other high profile projects including the Coolac Bypass, Southern Hume Alliance and Hume Highway Woomargama Alliance in NSW. The strong working relationship that has resulted between the two companies gave Abigroup peace of mind when selecting Boral Cement as Supplier on the Hunter Expressway project.

Asked about Boral Cement’s commitment to a project, Jamie Egan, Pavements Manager, Engineering Services at Abigroup Contractors commented, “Boral Cement’s Sales, Distribution & Technical support to the recent Hume Alliances was first-rate which gave us the assurance that the quality

and delivery of their products would not be compromised.”

In recognition of the significant supply task to the Hunter Expressway project, Boral Cement has assembled a project team to manage supply including Project Manager and appropriately skilled sales, distribution and logistics staff.

A range of planning is implemented together with fortnightly meetings to monitor progress against business KPI’s. Monthly operational reviews held on site with the client ensure tasks are meeting or exceeding their expectations.

Boral Cement has access to a number of distribution hubs - and for this project in particular the Kooragang facility near Newcastle provided the high level of support and service necessary for this and other critical timeline projects that have limited facilities due to their mobile nature.

Co-ordinated road and rail transport is utilised on a daily basis to manage supply and meet project demands.

As part of the supply planning process, additional site storage has been identified

as necessary to safeguard against unforseen issues that may threaten supply continuity.

In addition, Boral Cement is providing 3 Super tankers varying from 120t to 220t capacity to the site to ensure adequate stocks are always on hand for production. Nightshift deliveries are also integral to the supply plan.

These allow product to be delivered whilst the site is closed, reducing congestion and truck movements through the plant during busy production periods.

Amongst many other projects, The Hunter Expressway demonstrates Boral Cement’s capability and experience in supplying major infrastructure projects.

Our knowledge, fleet capacity, site storage, extensive depot network and position as one of the foremost building materials group in Australia ensures that supply to projects such as the Hunter Expressway are completed safely and client expectations are met and ideally exceeded.

Below: Old Maitland Road, Sawyers Gully

Boral Cement Boral Cement is a leading Australian producer and marketer of cement, flyash and lime with manufacturing operations on the eastern seaboard.

Through an integrated supply chain of strategically located mineral deposits, manufacturing facilities and an extensive distribution network, we are able to provide a reliable supply of quality products, in combination with an active innovation program adding further value to our customers.

NSW 02 9033 4000 VIC 1800 673 570 www.boral.com.au/cement BBC 10912 04.12

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Australian Main Roads Construction News - Page 5

Hunter Expressway Feature Continued from page 4

The project team will also construct underpasses, access roads and drainage structures as well as fauna fences, noise attenuation structures, rest areas and the team will also make necessary property adjustments to accommodate the new expressway.

22 BRIDGES UNDER SIMULTANEOUS CONSTRUCTION Bridge construction is moving at full speed and in February the pouring of the first bridge decks occurred at both Camp Road and Anvil Creek. This was a major milestone for the western section and with a very tight construction timeframe the bridges are being built concurrently to maximise the use of resources and to ensure that construction remains on schedule.

Minimising costs whilst retaining quality is paramount and Australian Precast Solutions, a wholly owned subsidiary of Abigroup Limited, is supplying the precast concrete beams which are a major component in the construction of the 22 bridges in the western section.

Although the twin bridge over the main northern railway line at Branxton is being constructed with a composite closed steel box girder beam and concrete slab deck, many of the other bridges are being built using precast beams up to 1.8 metres deep and 39 metres in length.

The largest bridge is almost 114m in length and has four spans that are 28.2 metres in length and 11.5 metres wide. The twin bridges at the Kurri Kurri and Branxton interchanges will be cast-in-situ due to the curved nature of their design.

Over the last few months Abigroup has continued to work on the bridges including completing column pours and abutments at the McLeod Road, Tuckers Lane, Allandale Interchange and Wine Country Drive bridges.

Girders have also been erected at

Above: Cut 23 – looking south toward Tuckers Ln over Grout plant.

Old Maitland Road and decks poured at the Camp Road and Anvil Creek bridges.

Work is also progressing on the two full interchanges with piling, columns and abutments finished at Kurri Kurri interchange and piling and columns in progress at the Branxton interchange.

The size of the workforce employed on the western section is considerable and

currently there are around 600 people working on this section of the Hunter Expressway between Kurri Kurri and Branxton. The project has now entered the peak construction period with bulk earthworks and bridges well underway, and mainline paving about to commence.

When completed this new arterial route will not only significantly improve the efficiency

of the national road network, but will relieve traffic congestion between Newcastle and Branxton by increasing capacity, safety and efficiency.

The new expressway will provide much needed support for local transport around the Upper and Lower Hunter region. It will also improve connectivity and should provide greater benefits for the local economy.

CZL do the hard yards on Hunter Project C

ZL GROUP Pty Ltd is a dynamic, privately owned company, located at Rutherford in the NSW Hunter Valley, and apart from other in-house talents, it’s a company that knows all there is to know about crushing rocks. So who better to call when earthworks are an important feature within a major project and it doesn’t get much bigger than the construction of the new Hunter Expressway.

www.czlgroup.com.au

• Crushing & Screening • Civil Works • Plant Hire • Truck Hire • Contract & Hourly

Phone: 02 4931 9224 Sales: rob@czlgroup.com.au Page 6 - Australian Main Roads Construction News

48 Mustang Drive Rutherford NSW 2320

The Hunter Expressway is the largest single road infrastructure project currently underway in NSW. It’s a $1.7 billion construction project that will result in a 40 kilometre four-lane expressway connecting the F3 Freeway at Seahampton with the New England Highway, west of Branxton. It’s such a big project that to ensure its scheduled delivery it has been divided into two sections and is being constructed under two separate contracts for Roads and Maritime Services (RMS) which replaced the Roads and Traffic Authority of NSW (RTA).

Funded by both the Australian Government ($1.5 billion) and the NSW State Government ($200 million) the eastern section (F3 Freeway to Kurri Kurri) is being built by Thiess Pty Ltd, Parsons Brinckerhoff and Hyder Consulting, under an alliance contract with RMS. The western section, which will take the expressway from Kurri Kurri to Branxton is being built under a design and construct contract with Abigroup Contractors Pty Ltd. However, both sections are being built concurrently and CZL is conducting earthwork related operations for both sections. The company has around 20 personnel employed across the two sites with its teams mainly involved in mobile rock crushing. Work on the eastern section

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commenced in August 2010, while work began on the western section in April 2011.

It’s anticipated, weather permitting, that both sections will be completed and open for traffic at the end of 2013.

Established in 2005, CZL has rapidly gained a reputation for excellence in its field of endeavor with a long list of completed projects to its credit. Mobile crushing and screening are its specialties and the company has a relatively large fleet of earthmoving machines and equipment to support its operational strength.

From its strategically located headquarters in the Hunter Valley, CZL provides operators and earthmoving plant for specific projects and its regularly maintained, modern fleet is also available for hire. The company’s operational reach extends into the Newcastle and Central Coast regions, throughout the Hunter Valley and beyond, taking in the North West corridors as well as both North and South Coast Regions of New South Wales.

CZL’s highly experienced personnel are fully equipped to provide quality earthmoving services for highway construction, mining services, rail construction, private sector projects as well as federal, state and local government projects. The company’s inhouse expertise in conjunction with its extensive, earthmoving fleet allows the company to target specific projects with the right solutions to ensure efficiency and a cost effective result.

CZL’s growth is exceptional and it’s certainly a company to watch as it continues to add more clients to what is already a very impressive list of satisfied customers.

For more information about CZL’s range of services and plant hire visit; www.czlgroup.com.au

Federal Updates on Road Infrastructure Projects from the Office of Federal Minister for Infrastructure and Transport, Anthony Albanese Works begin on Esperance Port Access Corridor

Above: Federal Minister for Infrastructure and Transport, Anthony Albanese

Bruce Highway upgrade: Final contract awarded on Mackay Southern Approach Project BMD Constructions has been selected to deliver the third and final stage in the upgrade of the Bruce Highway through Mackay’s southern suburbs, with construction expected to begin as early as April.

The latest multi-million dollar contract is for the duplication of the Highway between Temples Lane and Farrelly’s Road, and will complement the upgrades to the nearby intersections (nearing completion) as well as the widening of the road between Farrelly’s Road and Boundary Road (completed).

The project’s final stage will also upgrade Connors Road on behalf of the local council, erect traffic lights at the Temples Lane intersection and install a roundabout at the Stockroute Road intersection – see attached map.

Work on this fully-Federally funded project has entered the home straight, news which will no doubt be welcomed by local residents as well as the 15,000 motorists and truck drivers which use this stretch of highway each day.

Once fully completed towards the end of next year, the upgrade will ease localised congestion and deliver smoother, safer driving conditions.

Importantly, this project is just one of many now occurring up and down the Bruce Highway as a direct result of the unprecedented $2.7 billion investment we’re making in this road. Indeed compared to the former Howard Government, Federal Labor is spending more than twice as much in about half the time.

Right now there are hundreds of construction workers on site upgrading 158 kilometres of highway. Unlike LNP politicians who talk a lot about the Bruce when in opposition but quickly ignore it when they get into office, Labor governments have consistently stepped up and taken on the task of building a better, safer Bruce Highway.

As well as upgrading the Bruce Highway through its southern suburbs, Federal Labor investment in Mackay hasn’t stopped there. It also includes a record $7.2 million to assist the council maintain its local roads, safety works at the intersection between Gordon and Tennyson streets, installation of boom gates at three high risk level crossings and a multi-million committed to the redevelop of the City’s sports stadium.

Above: First sod turning at the $120 million project for Esperance Port Access Corridor

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ECENTLY the Federal Minster for Infrastructure and Transport, Anthony Albanese joined WA Transport Minister Troy Buswell onsite in Esperance to turn the first sod of a $120 million project which will improve access to its rapidly expanding port as well as announce Federal funding to advance the ambitious PortLink proposal to the next stage.

The Esperance Port Access Corridor project will untangle the road and rail connections to the Port by realigning Harbour Road and replacing two existing level crossings with overpasses.

Once completed in late 2013, this work will improve the movement of goods and freight into and out of the Port as well as make it easier for locals to get around their town, particularly when trains are passing through.

With one of the deepest harbours in southern Australia, Esperance Port is critical to the national economy. Each year more than 200 ships pass through it carrying over 11 million tonnes of nickel, iron ore and grain exports as well as imports of fuel and fertilisers – volumes which are only expected to grow in

the years ahead.

The project is being delivered by John Holland Pty Ltd with funding from both the Federal Labor Government ($60 million) and the WA Government ($60 million).

As well as addressing Australia’s more immediate infrastructure needs, Federal Labor is also planning for the nation’s future, not just for the next three years but for the next three decades.

That’s why we’ve agreed to allocate $2 million to the PortLink Inland Freight Corridor Plan, a long-talked about proposal with the potential to transform the region and open up access to the vast wealth which lies beneath the ground across this remote part of the country.

If given the final go ahead, the project would establish Kalgoorlie as a hub linking together the ports of Port Hedland, Freemantle, Esperance, Geraldton and the proposed Oakajee facility.

The funding I’m announcing today will go towards the planning and scoping study which will assess the possible road and rail alignment options, undertake the necessary economic and financial modelling as well as determine the operational and technical feasibility of an intermodal facility.

Given the proposal’s complexity and the amount investment that ultimately would be required, we are determined to do our homework and to getting the planning right from the very outset.

$85 million contract for Yeppen North upgrade awarded THE $85 million Yeppen North project will be constructed by Fulton Hogan, Premier Anna Bligh and Federal Infrastructure and Transport MinisterAnthonyAlbanese announced recently.

Ms Bligh said the project was scheduled to begin within months for completion in early 2014, weather permitting.

“With the appointment of Fulton Hogan, we are now one step closer to improving safety and helping ease the congestion at the Yeppen roundabout every morning and afternoon,” said Ms Bligh.

“This project will deliver significant upgrades over a two kilometre stretch including a second Yeppen Bridge, new lanes on the Yeppen Roundabout and intersection upgrades at Jellicoe Street and Port Curtis Road.

“Once completed, the project will deliver

improved safety and better traffic flow.

“Construction is set to start mid-year and the upgraded infrastructure should be open to traffic early 2014, weather permitting.”

Mr Albanese said the Federal Labor Government had contributed $68 million to the project with the State Government providing $17 million.

“With projects such as the Yeppen North upgrade and Calliope Crossroads west of Gladstone to start in the next few months, the region is now seeing the much needed investment and improvements to the national highway,” said Mr Albanese.

The Yeppen North project will deliver: • A new slip lane for traffic entering Rockhampton from Gracemere, addressing congestion and delays at the roundabout; • Speed reduction curves at all roundabout approaches to reduce the likelihood of accidents and heavy vehicle roll-over on

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some roundabout approaches; • Expansion of the roundabout to two lanes between the Yeppen Bridge entry and Capricorn Highway exit to increase capacity and reduce travel times; • A new 420 m Yeppen Bridge downstream of the existing structure. The new twolane bridge will be dedicated to outbound traffic and will be approximately three metres higher than the existing Yeppen Lagoon Bridge; • Both lanes of the existing bridge will be dedicated for inbound traffic; • Upper Dawson Road and Jellicoe Street intersection upgraded to traffic signals and expanded to cater for oversize loads, cyclists and pedestrians; • Reconfiguration of Port Curtis Road intersection to be left-in-left-out to directly address safety and visibility concerns at this location.

Australian Main Roads Construction News - Page 7

3M-ACRS DIAMOND ROAD SAFETY AWARD

3M Award rewards new road safety initiatives Across Australia, state government road authorities and construction companies continue in their combined efforts to design and build safer roads. It’s an important and much needed contribution to road safety particularly when it’s estimated that the collateral cost of road trauma in Australia is around $18 billion annually. There is no doubt whatsoever that road design plays a critical role in improving the safety of the environment in which motorists travel.

However, when you have such a costly burden on taxpayers, which is the equivalent of Australia’s defence budget, it’s obvious that more solutions are needed if we are to break this costly cycle of mayhem on our roads. Of course, that cost does not take into account the emotional and economic toll on a family when dealing with the loss or the injury of a loved one.

F

ORTUNATELY, improving road safety is a mission that 3M have embraced and the company believes that solutions can be found by taking a holistic approach. With that aim in mind 3M, in conjunction with the Australasian College of Road Safety (ACRS), launched the Diamond Road Safety Award in 2011.

The purpose of the annual award is to encourage and share best practice by motivating a much broader community response to the issue of road trauma. The Diamond Road Safety Award seeks new, cost effective and practical initiatives from individuals or groups involved in road safety.

Through the award, 3M and ACRS want to foster ideas that go beyond existing normal practice to ultimately deliver significant improvements in road safety for the general community.

Last year’s inaugural winner was Michael Musumeci, a member of the Queensland Police Service stationed in Ravenshoe, a regional town located on the Atherton Tableland in Far North Queensland.

Michael led a local community group that developed the RAPTOR project. RAPTOR (Reduce Accidents, Prevent Tragedy & Achieve Results) was a new initiative for the Ravenshoe area and involved the whole community.

The project took into account national, state and police plans, analysis of local data and in particular, engagement of all stakeholders. These included owners of licensed premises, council road specialists, state government officials as well as local community and business leaders. Through the analysis of extensive research and various discussions a number of relevant road safety issues were considered and a number of ideas were implemented.

According to ACRS President Lachlan McIntosh, who presented the award to Michael, “Not only were behavioural issues researched and addressed by reducing hours of sale of alcohol and realistic targeting of enforcement, but similar realistic targeting of cost effective road infrastructure maintenance and hazard reduction was identified and completed.”

For his part, Michael Musumeci has just returned from a trip to America which was part of his prize as leader of the group.

While in America, Michael attended the American Traffic Safety Services (ATSSA) Conference in Florida USA, during which he presented his award winning entry to the convention delegates. He then travelled north

Page 8 - Australian Main Roads Construction News

to visit the 3M Customer Technology Center and the company’s headquarters in St Paul Minnesota.

Such was the huge response to the inaugural Diamond Safety Award that the judges decided to present two extra ‘highly commendable’ awards. The first was awarded to Sandra Cook and Kerry Sunderland for their community support website; ‘Journey Beyond Trauma’.

The second highly commended award went to John Quee, an independent inventor who designed a valve that can be installed on car engines to significantly reduce the risk of a petrol fire after a collision.

Both 3M and ACRS deserve congratulations for establishing the Diamond Road Safety Award because it encourages a broader community response on the issue of road safety. It serves to remind people that we are all individually responsible for our actions when driving and it calls for our participation in finding answers.

For many years ‘speed’ has been the main focus in the fight against road trauma and obviously, while it is a factor it is not the sole cause of road accidents. Unfortunately, it appears that there will always be a section of the community who will continue to ignore the notion that excessive speed kills.

However, for the rest of us the causes of road trauma can range from inattention and attitude to simply a lack of driving skill. In any event there’s no doubt that new ideas that serve to identify and respond to the full cycle of reasons why accidents happen on our roads are worthy of much greater consideration.

The Diamond Road Safety Award is a step in the right direction and the efforts of 3M and ACRS should be commended.

Primarily, the award criteria seeks to find new initiatives that deal with four main road safety elements and these are; infrastructure, vehicle safety, enforcement, licensing and education. Clearly they are all fundamental in the quest to find and ultimately implement Continued page 10

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Above: Lauchlan McIntosh opens the award ceremony.

Below: Michael Musumeci proudly accepts his Winner Award.

EN OP 012 IES l 2 TR ri EN st Ap 1

3M–ACRS

Diamond Road Safety

Award 2012

Keeping people safer through innovative best practice DIAMOND AWARD

ENTER & GET RECOGNISED! Have you or a colleague recently developed a road safety treatment/initiative that stands out beyond traditional activities and delivered improved road safety? You could be the winner!

We are looking for entries from any road safety practitioner who works within the Australian private or public sector who fits this criteria. Don’t miss out on your chance to win and be recognised!

s An

individual Team Leader from the winning project will RECEIVE a trip to the USA to attend the 43rd ATSSA Annual Convention & Traffic Expo in 2013 and to 3M Global Headquarters in the USA. This individual will also present on their winning entry and international trip at the following ACRS Road Safety Conference in 2013 winning entry will be announced at the ACRS Road Safety Conference Dinner on 9 August 2012 where all eligible members of the winning project will be presented with the 3M-ACRS Diamond Road Safety Award

s The

WHO WILL JUDGE ENTRIES All entries will be judged by an independent committee of industry representatives, established by the ACRS specifically for this award.

TO ENTER & MORE INFORMATION, VISIT

www.acrs.org.au/award Entries open 1 April 2012 and close 5pm (EST), 15 June 2012 3M is a trademark of 3M Company. © 3M 2012. All rights reserved.

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Australian Main Roads Construction News - Page 9

3M-ACRS DIAMOND ROAD SAFETY AWARD Continued from page 8

better solutions. In commenting on the success of the 2011 awards, Lachlan McIntosh confirmed that the response was up to the task.

“Individuals, partnerships, community groups, local and state government agencies submitted real programs that are all making a contribution to reducing crashes and reducing death and injury. Some specifically targeted a particular problem, while others offered support for victims to encourage better understanding of the many issues around improving road safety results.”

Road safety is familiar territory for 3M, a company that has been involved in that issue for over 70 years. It all began in the 1930’s when 3M introduced the first retroreflective traffic sign and since then the company has continued to invest in research and development to improve a number of technologies that in turn have provided greater safety benefits for road users worldwide. So in establishing the Diamond Road Safety Award it’s a natural progression for the company and sits comfortably on its overall philosophy to reduce road trauma.

As Andrew King, Division Manager of 3M Australia’s Traffic Safety Systems Division stated when the award was first launched.

“3M’s sponsorship of this award is part of our commitment to our employees, customers and the community, to contribute to the objectives of reducing road trauma.”

DIAMOND ROAD SAFETY AWARD 2012 The 2012 3M-ACRS Diamond Road Safety Award is now underway and entries will be received up until 5pm (EST), Friday, 15 June 2012. It’s a great opportunity for road safety practitioners from the public or private sectors including road engineers, contractors, road safety officers, road safety equipment manufacturers, asset managers and town planners Australia-wide to submit highly innovative, cost-effective road safety initiatives or programmes.

All entries will be judged by an independent committee of industry representatives selected by the ACRS specifically for this award.

An individual Team Leader from the winning project will receive a trip to the USA to attend the 43rd ATSSA Annual Convention & Traffic Expo in San Diego, California in February 2013. They will then travel to 3M Company Headquarters in St Paul, Minnesota to learn more about 3M’s incredible technologies and innovative solutions.

The winning entry will be announced at the ACRS Road Safety Conference Dinner in Sydney on 9th August 2012. All eligible members of the winning project will be presented with the award.

To enter simply visit www.acrs.org.au/ award and download an Entry Form.

For more information, visit the official award site at: www.acrs.org.au/award, or contact the Australasian College of Road Safety on (02) 6290 2509 or by email: eo@acrs.org.au

3M DARE TO DREAM, INNOVATE AND IMPLEMENT Founded in 1902 by five businessmen in Minnesota, 3M has enjoyed an extraordinary one hundred year history, highlighted by numerous landmark achievements.

Even in its infancy the company was already turning heads when it created the world’s first waterproof sandpaper in the early 1920’s. At the time, it changed the automotive production environment for the better, by reducing airborne dusts created during manufacturing.

Many of us have grown up using ‘Scotch tape’ as a colloquial term to describe any sticky tape but the actual Scotch brand first saw the light of day in 1925 when Richard G. Drew, a young 3M laboratory assistant invented masking tape which was the first tape to bear the Scotch brand and led to a wide range of pressure sensitive tapes that were to follow including the familiar, Scotch® Cellophane Tape.

During and following the war years in the 1940’s, necessity proved to be the mother of invention and 3M were responsible for the creation of a range of new and much needed products including Scotchlite™ Reflective Sheeting for highway markings, magnetic sound recording tape and filament adhesive tape. That period also saw the start of 3M’s long involvement in the graphic arts with offset printing plates.

Through the 1950’s, 3M continued to introduce new and innovative products including the Thermo-Fax copying process, ‘Scotchgard’ fabric protector, videotape, Scotch-Brite® Cleaning Pads and several new electro-mechanical products.

Over the last 50 years the journey has continued at a frantic pace and the number of new products and technology introduced by 3M has continued to expand. Although far too many to mention here, the range of 3M product now covers Healthcare, Dental, Industrial, Safety, Security, Electronics, Consumer, Graphics and of course, Road Safety.

There’s no doubt, given 3M’s unquestionable innovative approach, supported by a proven 100 year old winning philosophy, that the Diamond Road Safety Award may well lead to a range of new solutions in the way we respond to the issue of road safety.

Page 10 - Australian Main Roads Construction News

Above: Michael Musumeci says a few words about his winning project.

Below left: Lauchlan McIntosh announces the winning project.

Below right: John Quee accepts his Highly Commended Award.

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AUSTRALIAN ASPHALT PAVEMENT ASSOCIATION

Asphalt & Bituminous Surfacing Feature

AAPA urges a cost effective approach to Paving The Australian Asphalt Paving Association (AAPA) believes that significant savings and benefits can be achieved in the long term by both taxpayers and motorists in the way our transport network is maintained. There’s no doubt that in this turbulent economic climate any spending on civil infrastructure should be approached with priority given to maximizing the value of every dollar spent.

T

HIS MEANS ensuring that expenditure addresses both the need for ongoing maintenance of Australia’s existing transport asset as well as the construction of new infrastructure. Building new transport infrastructure is critical to the ongoing development of our growing society. New infrastructure to reduce congestion and facilitate the movement of goods and services is obviously a priority.

However, it is equally, if not more important to maintain our current infrastructure.

According to AAPA’s CEO John Lambert, it is well known that the longer road infrastructure is allowed to deteriorate, the more expensive it will be to eventually maintain that road. This is highlighted in a report produced by the American Association of State Highway and Transportation Officials (AASHTO) entitled; Rough Roads Ahead; ‘Fix Them Now or Pay for it Later’ and John believes that the report has relevance for Australia.

“Like America, our roads have to cover long distances and at the very least, logistically building roads is a costly business. However, the report highlights things that we can do to make our roads more sustainable, lessen their impact on the environment and even reduce emissions through fuel savings that can be achieved under the right road conditions.”

The AASHTO report highlighted the fact that one third of major roads in America are in poor or mediocre condition. Alarmingly, it also noted that roads in urban areas are in even worse shape and these are roads that carry 66% of that nation’s traffic.

Such is their condition that ultimately, should those roads be brought up to standard, the American community will end up paying for them twice. Although that picture relates to America the cost factor scenario is relevant to Australia, particularly when you take a closer look at the report’s findings.

The expanding cost of those ‘rough roads’ to the community is borne through additional vehicle operating costs and higher road repair and reconstruction costs. It has also been estimated that a vehicle travelling along a rough road will use at least 4% more fuel than it would on a smooth pavement. Of course, this leads to increased energy usage and higher emissions.

In the US they estimated that the average driver using rough roads will add $US335 annually to a typical vehicle operating cost.

In urban areas, with high concentrations of poorly maintained roads that figure almost doubles to $US746 annually. Obviously, longer travel times endured by heavy vehicles carrying goods and services increases that cost.

The AASTHO report also found that sustaining a deteriorating road over a

Laying Aggregate at an Austroads/AAPA trial of Polymer Modified Binders near Cooma, NSW.

25 year period will cost three times more than it would, had the road been maintained on a regular basis.

Further details of that report can be found at AAPA’s website; http://www.aapa.asn.au and at the AASTHO website; http://roughroads. transportation.org where you can check all the facts and figures. But in conclusion the report spokesperson said; “There is no more fundamental transport capital investment than system preservation; keeping existing infrastructure in good condition.

If preservation is deferred, costs increase dramatically, leading to the saying; ‘pay me now or pay me more - lots more - later.’

A report produced by the US Asphalt Pavement Alliance titled “Smoothness Matters” also highlights the potential fuel (and emissions) costs of not maintaining a road surface. This can be obtained from

the Asphalt Pavement Alliance website: h t t p : / / a s p h a l t r o a d s . o rg / w h y - a s p h a l t / smoothness-matters.html Meanwhile here in Australia, one can only imagine that if all roads were regularly maintained that in the long term taxpayers would save money on reconstruction; motorists would spend less money on fuel; the transport of goods by road would be far more efficient and with less fuel being used, a real reduction in emissions could be achieved.

In John Lambert’s vision of the future, the investment made in maintaining a major road is seen as valuable as the construction of a new road.

PERPETUAL PAVEMENTS SAVE MONEY IN THE LONG TERM Apart from regular maintenance of existing roads to reduce costs in the long term, the design of roads should also optimise the use of construction materials.

In the case of a major road surface this means designing it to last in perpetuity with just occasional maintenance on the top wearing course. With this in mind AAPA is undertaking a major study to apply the perpetual pavement design approach in Australia. This uses the fatigue endurance limit of pavement material to ensure that pavement thickness is optimised. That is, by designing the pavement so that the endurance limit is not exceeded at the pavement base ensuring that the pavement will not fail from the bottom up.

This means that there is a maximum thickness for pavements regardless of the load. This differs from the current design approach used in Australia which continues to increase the pavement thickness as the load increases. This results in some unnecessarily thick pavements in some situations. Current pavement designs in Australia may be too conservative resulting in some pavements that are over 500mm thick.

Perpetual pavement designs are used in the US and in Europe and it has been estimated that they can result in up to 18% savings in the cost of surfacing a major road.

For its part, AAPA has been extremely proactive in introducing the concept of perpetual pavements, investing $340,000 in its efforts to show that perpetual pavement designs should be used in Australia. This requires undertaking detailed studies of

Laying Warm Mix Asphalt for the Warm Mix Validation Project.

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Australian Main Roads Construction News - Page 11

AUSTRALIAN ASPHALT PAVEMENT ASSOCIATION

Asphalt & Bituminous Surfacing Feature

AAPA urges a cost effective approach to Paving

Reclaimed Asphalt Pavement (RAP), 100% recyclable back into new asphalt.

Continued from page 11

Australian asphalt mixes and comparing them to US mixes.

John Lambert explains. “We believe that roads built using the Perpetual Pavements Fatigue Endurance Limit is the key to optimising the use of pavement materials and maximising the sustainability of the road. When combined with appropriate maintenance of the top wearing courses these pavements will last in perpetuity.”

In conducting this study AAPA is working closely with state road authorities and industry. This includes having industry and State road authorities represented on the AAPA project team. In this way it is expected that this will lead to future amendments to Austroad’s pavement guidelines to include perpetual pavement designs.

AAPA GAINS INCREASING SUPPORT FOR WARM MIX ASPHALT In 2010, in its proactive efforts to have Warm Mix Asphalt (WMA) validated as a suitable alternative to Hot Mix Asphalt (HMA), AAPA in conjunction with Austroads and with generous assistance from VicRoads conducted a project to validate the hypothesis that WMA performed at least the same as HMA. The project then had a range of different WMA samples laid on a section of the Hume Highway in Broadmeadows in Victoria.

This site was provided by VicRoads and the samples were provided by three major asphalt producers; Boral Asphalt, Downer EDI Works and Fulton Hogan. These companies provided 18 different WMA samples including some with different proportions of reclaimed asphalt pavement (RAP). Three HMA sections were also laid as controls for comparison.

The results of the validation tests held over two summers and on pavements enduring normal traffic conditions showed that WMA and HMA performed equally.

Although the final report is still being prepared the success of the validation project has supported the decision by the NSW Roads and Maritime Services (RMS formerly the RTA) to amend its road mix specifications to include warm mix asphalt. VicRoads is also currently developing specifications to allow WMA. In the US it is generally accepted that

that is associated with bitumen and asphalt.

This card is double sided with one side describing the first aid response and the other providing information to guide the ambulance para-medics and the emergency ward hospital staff.

Should a bitumen burn result the first aid response should be followed immediately.

This includes cooling the burn with water and calling an ambulance. The card should also be pinned to the injured person’s shirt so that in the ambulance and in the hospital casualty area, medical staff, who are generally not experienced in the treatment of a bitumen burn, can refer to the card and provide the appropriate response.

Importantly this includes not attempting to remove the bitumen unless instructed by a burns specialist. Many doctors first response would be to remove the bitumen. However, this can also remove the skin and as the bitumen is generally a sterile material, opens the wound to possible infection.

The card also recommends that a colleague of the injured worker attend the hospital to ensure that the card’s instructions do not go unnoticed.

As well as the burns card, AAPA has produced a small burns card which can be carried in people’s wallets or purses. This credit card sized card contains first aid information and refers to the larger burns card. This card was developed in cooperation with VicRoads and it is recommended that everyone involved in the asphalt industry carry one of these cards in their wallet or purse.

Copies of both the large burns card and smaller first aid burns cards are available from AAPA. The large card costs $1 to cover the cost of producing high quality water proof cards. The first aid a card is available from AAPA at no cost. c In another initiative to protect its workers by creating a safer working w environment, AAPA has embarked on a e study which particularly focuses on the s speed of traffic around temporary road sp maintenance sites. m Traffic management around new road construction sites can be coordinated co over a longer period of time and ov motorists become used to slowing down m and an negotiating detours. However, in the case ca of short term works, there may only be temporary barriers such as witches’ hats ha separating workers from passing traffi tra c. Also motorists may be less aware of the need to slow down.

As A part of the study, AAPA is seeking to appoint a Senior Traffic Manager from a one of the State Road Authorities for a three month period. That person will work with AAPA members and others involved in temporary traffic worksites to firstly identify the actual risks associated with these temporary worksites and then identify measures that will make working on roads that are in use at the time, much safer.

WMA will soon become the standard way asphalt is made in the near future. Many in Australia also believe that this will also apply in this country as well.

This is great news because the production of WMA has many benefits including lower greenhouse emissions, no fuming and it is safer and much easier for workers to handle.

It is also able to be more readily compacted than traditional HMA. In simple terms the asphalt binder used in the production of HMA has to be heated to around 160 degrees centigrade to decrease its viscosity. Then the asphalt has to be applied to the road surface while it is still hot to ensure that it can be compacted to attain the appropriate consistency to provide a smooth surface.

On the other hand WMA, which can provide the same smooth surface, can be produced and applied at much lower temperatures (about 40 degrees less). It will make working conditions a lot more comfortable; it can be applied in colder months; can be hauled to the site over longer distances; it cools quicker and so roads can be driven on a lot sooner, reducing disruption for motorists. WMA also allows for a greater use of RAP. Although asphalt pavements already have the lowest carbon footprint of any pavement surface and can be fully recycled, WMA takes that next step and further reduces the environmental impact.

AAPA INTRODUCES SMART CARD RESPONSE TO BITUMEN BURNS Bitumen, the binder used in asphalt and in sprayed seals, is liquid at high temperatures and has the potential to inflict very severe burns if not handled safely. In its response AAPA offers Safe Handling of Bitumen training courses around Australia. The aim of these courses and indeed the aim of all AAPA members handling bitumen is zero harm.

Despite this AAPA is fully aware that burns can and occasionally do occur.

When a burn does occur it is critical that there is an appropriate first aid response. It is also important that a person is taken to hospital to be appropriately treated.

In recognising this, AAPA obtained agreement from one of its members, Downer Australia, to reproduce a bitumen burns card to be carried in every vehicle and first aid kit

Page 12 - Australian Main Roads Construction News

AAPA ACTIONS WORTHY OF WIDER APPRECIATION

AAPA Bitumen Burns Card to be carried in every first aid kit and vehicle associated with bitumen, asphalt and sprayed sealing.

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It could be said that it is not in the Australian Asphalt Paving Association’s best economic interests to promote a less costly approach to paving on behalf of its members, nor to reduce the need for normal asphalt paving demand by employing Perpetual Pavement technology. The Association and its members are therefore worthy of strong praise for the proactive approach they take in reducing road construction costs by making asphalt pavement more cost effective, more sustainable and minimising its impact on our environment.

AUSTRALIAN ASPHALT PAVEMENT ASSOCIATION

Asphalt & Bituminous Surfacing Feature

:

VOGELE opens new factory J

oseph Vögele AG leads the world market for pavers and their technology. One reason for this leadership lies in the top quality of its products and services, quality that is based on the company’s new factory.

For Vögele, the new factory in Ludwigshafen is an opportunity to scrutinize and improve existing processes. Logistic workflows, for instance, have been optimized with an eye to the value-added and the flow of material. Ultramodern machines and superbly trained employees are further hallmarks of the new factory.

Short distances and the principle of flow assembly with continuous production lines allow the Vögele staff to work with full concentration and without any unnecessary interruptions. The materials are stored right there where they are needed.

What’s more, the individual components are also preassembled precisely where they are to be installed in the machine. The mechanical production area is a prime example of highprecision work.

During production of the telescoping tubes, honing machines eliminate microscopic irregularities that are up to 20 times finer than human hair. Thanks to this precision, the telescoping tubes of the extending screeds move in and out with perfect ease. Despite this, however, all lubes are additionally ground. This precision produces sturdy extending screeds with zero flexing.

Before the machines leave the factory, they are put through a series of exhaustive tests.

Can the paver be driven, steered and braked as intended? Do the lights, indicators and displays work? Are all the speeds, pressures, filling levels and heat outputs correct? Have all the customer’s special wishes been met?

All in all, paver and screed undergo 200 tests and inspections before being approved and released with a detailed assembly and acceptance record.

The customer is not abandoned even after the machine has been delivered. Highly trained

and experienced after-sales staff can reach every site anywhere in the world in next to no time.

They help the paving team when working with new products for the first time, obtain replacement parts and assist the repair shop during maintenance or when upgrading older machines with new components.

This total service is based on a global network of 55 sales and service companies and more than 100 Wirtgen Group dealers. © www.voegele.info

VÖGELE SUPER 1300-2:

COMPACT–SIZE AND POWERFUL!

AUTOMATED PROCESSES In the steel working shop and the mechanical production area, robots are used in a number of fundamental work sequences to ensure that quality remains at a consistently high level.

For instance, Vögele uses what is known as a flexible welding system with welding robots to automate the production of welds. This system is programmed just once and then works more or less independently.

A total of four welding cells are constantly supplied with the required workpiece pallets from an automated high-bay warehouse. An orbital positioning device holds and moves the workpiece while it is being welded by the robot. This ensures consistently high quality of a standard unattainable when welding is done manually.

A production team is responsible for compliance with and further development of the quality standards jointly developed in accordance with the continual improvement process (CIP). This process is made up of small continuous steps serving to improve the quality of products, processes and service.

Orderliness and cleanliness are factors of paramount importance. For example: only the tools actually needed for an assembly step are located at the workstation. Tools which are frequently needed must be within the worker’s direct reach. The appropriate supply systems are provided by Vögele, If workers find individual solutions for a particular task, such as a holder for glues or a storage device for cable lies, these are investigated and then standardized if applicable.

MODERN, ENVIRONMENTALLY FRIENDLY PROCESSES The powder coating facility with two booths for different colours was the biggest single investment in machinery for the new Vögele factory. Hardness, elasticity, adhesive strength and the resistance to light and corrosion of powder-coated surfaces are considerably better than those of conventionally painted coatings.

This also makes them particularly durable and strong.

What’s more, the powder coating facility proves that quality, cost-efficiency and environmental protection can go hand In hand. The heat produced when baking the powder coating, for example, is used to dry the components after cleaning or to heat the factory halls in winter.

ROAD AND MINERAL TECHNOLOGIES

www.wirtgen-aust.com.au www.wirtgen-group.com/soilstabilization

WIRTGEN AUSTRALIA 2-12 Sommerville Circuit, Emu Plains NSW 2750 PO Box 21 Penrith NSW 2751 Tel: +61 2 4735 2699

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

www.amrcn.com.au

Victoria & Tasmania Knoxfield, Melbourne Tel: 03 9800 5268

Western Australia & South Australia Balcatta, Perth Tel: 08 9240 1611

New Zealand Wellington Tel: 64 2744 26555

Australian Main Roads Construction News - Page 13

AUSTRALIAN ASPHALT PAVEMENT ASSOCIATION

Asphalt & Bituminous Surfacing Feature

A new generation of CA rollers with unique features!

the work area and surroundings. A spin-around seat and steering module allows movement of up to 180 degrees without stress to the neck or body. This arrangement, combined with the short machine length and excellent turning radius, makes maneuvering easy in the most difficult conditions.

Safety functions include Electronic Drive Control with a “quick brake” function, which shortens braking distances if lever is moved very fast, and a tilt indicator. Loss of traction, even in the toughest conditions, is swiftly counteracted by an easy-to-use toggling gear shifting system, or with an optional antispin system.

Launching in Australia this year, is Dynapac’s fifth generation of CA single drum vibratory rollers. The CA5000, CA6000 and CA6500 rollers are yet another example of Dynapac’s innovative thinking.

The first of their type with crossmounted engines, the new CA rollers represent a major revolution in terms of serviceability.

Two other unique time and money saving features are optimised amplitude for superior compaction performance and Active Bouncing Control (ABC) that prevents damage to the machine and over-compaction.

The advantages don’t end there. Add even higher operator comfort, greater maneuverability and drastically reduced noise levels and fuel consumption, and the result is a line of state-of-the art single drum soil compactors that will make a major contribution to cutting costs and raising productivity for customers worldwide.

Lower cost per compacted cubic metre The three new CA rollers have static linear loads of 50, 60 and 65 kg/cm, respectively.

A high amplitude of 2.1 mm enables rockfill to be compacted in almost 2 m thick layers and the rock size can be up to 1 m in diameter.

The better depth effect results in higher volume capacity and less passes to reach compaction specifications, thus saving fuel and reducing the cost per compacted cubic meter. Environmental impact is also lower.

Mission control!

Dynapac’s advanced process control and systems make it possible to raise productivity by gaining control over the entire “rolling mission” in three clear steps. Preparation: planning the task with Dynapac CompBase software is the first. Second is performance: performing the work using the Compaction Meter and analyzer on the roller. Thirdly is protocol: analyzing the results afterwards using the Dynapac Compaction Analyzer (DCA). These systems answer the questions - What should I do? What am I doing?

What have I done?

Top: Dynapac’s fifth generation CA series single drum vibratory rollers provide owners with lower costs per compacted metre Above: A cross-mounted engine in the new CA series has low noise levels and is easily accessible for servicing Left: Dynapac’s new CA series rollers are shorter in length, lower in noise emissions and offer greater compacted depths than previous models

Dynapac’s CostCtrl software on the web and an extended warranty for CA rollers enable customers to gain full control over life-cycle costs and maximize machine availability. The company’s international service network offers full support and assistance with all parts and service needs.

Lower fuel consumption The new CA rollers are available with four cylinder Cummins or six cylinder Deutz engines.. They can be used with a mix of biodiesel and fossil diesel fuel, some can be run on 10% biodiesel.

The “best-point” fuel saving system minimizes fuel consumption and CO2 emissions

Page 14 - Australian Main Roads Construction News

by ensuring that the roller does not consume more power than needed at any time. This, together with higher compaction parameters and other improvements, has resulted in a drastic reduction in fuel consumption compared to the previous generation.

The CA6000D can be equipped with a Sustainability Package featuring an rpm management system, biodegradable fill-for-life hydraulic fluid, 50 hours service kit, electrical engine block heater and working lights with LED lamps.

Comfortable, safe and easy to maneuver The ergonomically designed, air-conditioned cabs on the new generation offer a high level of operator comfort and good visibility over

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Bouncing guard prevents component damage – easy as ABC Automatic Bouncing Control (ABC) prevents damage and prolongs the lifetime of the roller by eliminating drum double jump, or over-compacting – an action that can destroy components in any rooler. The CA6000D also features a speed limiter to avoid compacting at too high speed, which saves money in the long term.

A new level of serviceability A service interval alert in the instrumentation display indicates when service is required and what action to take. The cross-mounted engine at the rear offers excellent access for all service and maintenance needs. The engine hood is easy to open for quick maintenance and the hydraulic pumps are in line with the engine and fully accessible for service.

The cross-mounted engine is easily accessible and gives both optimal weight distribution and ease of transportation as it keeps down machine length. Also, the noise level is very low, since the combustion air intake is placed at the top of the hood with the outlet down the sides, combined with the ejector exhaust outlet.

This has the advantage of keeping the inlet air is as clean as possible, an important factor in the dusty environments in which these rollers operate.

A wide range of models and options The new CA rollers are available in standard models with a long list of different specifications that can be selected and an extensive choice of optional extras.

Customers are invited to “build” their own machines or choose from a number of packages, just visit the Dynapac website: www.dynapac.com.au

www.amrcn.com.au

Australian Main Roads Construction News - Page 15

AUSTRALIAN ASPHALT PAVEMENT ASSOCIATION

Asphalt & Bituminous Surfacing Feature

Smooth Paving Paving job goes perfectly in preparation for America’s Cup

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HE Portuguese village of Cascais has enough attractions—including magnificent views of the Atlantic Ocean— to make it a tourist destination. The historic hotels and winding roads that nearly touch the ocean also have been the backdrops of movies, including a “James Bond” film.

In addition, the city has a rich racing history, having hosted the FI Portugal Grand Prix and numerous motorcycle events.

The attention was even greater this year with the arrival of one of the world’s premiere sailing races, the America’s Cup, in August.

With a busy summer ahead, Cascais municipality realized it had to make improvements to Avenida Marginal, the waterfront thoroughfare that leads to the village and the main attractions.

The main issue with the road was its drainage.

“In times of heavy rainfall, stormwater tributaries accumulate, forming a river and making it dangerous to cars and pedestrian circulation,” an engineer for the village of Cascais wrote in a report.

The importance of the street meant that the work had to be completed before the America’s Cup crowd arrived. Yet the seasonal tourists also meant the road had to remain open while the work took place.

Sanestradas, a respected paving contractor, was chosen for the job based on the time requirements and the need for high quality.

THE PROJECT Cascais municipality’s project involved a 1 km (0.62 mile) section of Avenida Marginal.

Much of the road’s surface was in good shape, with the exception of about 65 m (213’). That section of road had been damaged during a building construction project. The 65 m (213’) also would be the location for a new drainage system, with rainfall channeled to it via curbs along the remainder of that 1 km (0.62 mile) section.

Directing the water to those drains created another challenge. About 300 m (984’) of the road was so level that water did not flow.

A simple solution would have been placing a new surface lift with a slightly steeper grade.

Yet that choice was dismissed because of low curbs—an average of only 100 mm (4”).

Applying a new bituminous layer to create the grade would have simply caused rain to run over the curbs. The flooding would have continued.

Cascais municipal officials came up with a strategy. First, they proceeded with the new drainage system. The 65 m (213’) of existing curb was removed, and the ditch floor area replaced with two 200 mm (7.8”) layers of crushed, aggregate base of extensive granulometry. That base featured irrigation fluidized MC70 bitumen at an impregnation rate of 1kg/m2.

A binder layer with a thickness of 11 cm (4.3”) was placed on top, followed by the wear layer with an average thickness of 6 cm (2.3”).

The remainder of the road did not need new base layers or improvements. Therefore, milling crews removed 6 cm (2.3”) of material.

The paving crew then placed an AC 14 Surf 35/50 (BB) wear layer over both the rebuilt and milled portions of the project.

TIGHT SCHEDULE Crews were given just two weeks to complete the work, but the time was actually considerably less because work was only allowed at night.

Crews began work at 8pm or 9pm and continued until about 7am the following morning.

In addition, Avenida Marginal had to remain open to traffic with no limitations on Fridays, Saturdays and Sundays to allow tourists to come and go unimpeded. That meant the two weeks was in actuality eight days.

Further complicating the project was the requirement to keep traffic circulating, though in a limited manner. This led to a process of milling one lane for two nights, then tandem paving and compacting for the next night. At that point, the lane was completed.

MILLING A Cat® PM102 Cold Planer removed the 6 cm (2.3”) of asphalt in the required areas.

The PM102, smaller than the Cat PM200, was chosen because its size made it a better fit for the narrow road. Yet the machine delivered the required productivity, too, as it had to mill a lane in only two nights.

The tight timeframe left no margin for error.

Because of this, two service technicians from STET, the Cat Dealer in Portugal, remained on the jobsite throughout the night in case they were needed. Fortunately, there were no problems.

PAVING When an entire lane was milled, tandem pavers went to work. Delivery trucks enddumped the material into the pavers.

Sanestradas chose the new Cat AP555E with an AS4252C Screed. Working just a few meters ahead of it was the tried-and-tested Cat AP655D. Pedro Santos, project chief for Sanestradas, was pleased with both pavers. One key reason: Their productivity enabled the job to be completed in a short timeframe. “With the two pavers working in tandem we succeeded in finishing the job much faster than expected, and with excellent smoothness results,” said Sr. Santos.

Caterpillar had a technician specialized in handling pavers on hand to ensure smooth integration of the new AP555E. He closely followed both the performance of the machine and the crew and offered suggestions for improvement.

COMPACTION Three Cat compactors—the CB434D, PS300B and CB34—easily kept pace with the two pavers, and met density specifications.

The PS300B worked in breakdown mode, and was right behind the second paver, the AP555E. The longitudinal joint was done “hot,” and easily compacted, because the first paver worked only a few dozen meters ahead of the second.

Top: The importance of the Cascais street meant it had to remain open while the work was done.

Left: Tandem pavers helped crews meet the tight deadlines.

Page 16 - Australian Main Roads Construction News

www.amrcn.com.au

The compactors worked at a distance that enabled compaction and kept pace with the paving train. The number of passes depended on the pace of the paver and the delivery trucks.

The compactors treated the two freshly placed mats as if they were one and worked across the entire width of the lane.

COMPLETION Mr. Santos and other Sanestradas representatives were pleased with the performance of the Cat cold planers, pavers and compactors—and the Caterpillar dealer. Many officials from both Caterpillar and STET were on-site to ensure the highly complex project was a success.

No spectators were more important than Cascais Municipality authorities, who also kept a close watch on the jobsite. They saw machines making quick work of the milling, paving and compaction and were pleased the road was completed in time for the America’s Cup— while serving all the tourists so crucial to the village’s economy.

VERSATILITY DEFINED

The new Cat® AP555E Asphalt Paver — Big Capability in a New Portable Size.

Caterpillar customers demand high productivity– that’s a given. They also want a paver that is transportable, highly manoeuvrable and has the mobility and traction to handle a wide variety of work. Done.

The new Cat AP555E Asphalt Paver delivers in all these areas and many more too.

Paving All Day. Every Day. www.cat.com.au/paving

CONTACT YOUR LOCAL CAT DEALER NSW/ACT - WesTrac: 1300 881 064 VIC - William Adams: (03) 9566 0666 QLD/NT - Hastings Deering: 131 228 NZ - Goughs: (03) 983 2333 P.N.G & Solomon Islands - Hastings Deering: 675 300 8300

WA - WesTrac: 1300 881 064 TAS - William Adams: (03) 6326 6366 SA - Cavpower: (08) 8343 1600 New Caledonia - Caltrac: 687 438 181

© 2012 Caterpillar Inc. All Rights Reserved. CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the POWER EDGE trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

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Australian Main Roads Construction News - Page 17

M80 - VISIONSTREAM FEATURE

M80 Ring Road to get Smarter and Safer T

HE M80 Ring Road is set to get an intelligence boost following the awarding of a $62.5 million contract to equip it with technology that will help prevent congestion while giving motorists the information they need to better plan their journeys.

Federal Infrastructure and Transport Minister Anthony Albanese said Visionstream Australia will install an electronic freeway management system along what is one of Melbourne’s busiest roads, providing VicRoads the tools to better manage traffic flows as well as respond quickly to accidents and breakdowns.

“It’s all about getting the most out of the infrastructure we already have, which over time is a far smarter and cheaper option than simply building more and bigger roads,” said Mr Albanese.

is part of the $2.25 billion M80 Ring Road Upgrade being jointly funded by the Federal ($900m) and Victorian ($300m) governments, with the remainder to be sought in future budgets.

Victorian Roads Minister Terry Mulder said once fully in place, the system will use sensors built into the surface of the road to monitor the flow of traffic and prevent congestion by automatically reducing the number of vehicles entering the freeway via

the on-ramps and varying the speed limits along it.

“What’s more, strategically placed electronic message boards will provide motorists with real time information on the traffic conditions which may lie ahead, not only along the M80 but also on key connecting roads,” said Mr Mulder.

“Together with the Federal Government we are rebuilding the M80 into a modern piece of road infrastructure able to support

Melbourne’s continued growth and development in the decades ahead.

“While the upgrade will deliver more traffic lanes, it is the electronic freeway management system which will make sure that over the longer term we get the most out of this multi-billion investment including fewer accidents and quicker, more reliability travel times.”

For more details on the M80 Upgrade: www.vicroads.vic.gov.au/m80upgrade.

JOINT MEDIA STATEMENT

“... sensors built into the surface of the road to monitor the flow of traffic and prevent congestion ...”

“As well as being good for taxpayers, this technology will deliver faster, safer and less frustrating driving conditions for the 142,000 motorists and truck drivers who use this vital part of Melbourne’s road network every day.

“Indeed if applied nationwide, electronic freeway management systems have the potential to greatly reduce congestion and save Australian families and businesses more than $500 million a year. That’s why in last year’s Budget we set aside funds to assist the states retrofit their existing motorways with the technology.”

Installation of the electronic freeway management system between the Princes Freeway and the Greensborough Highway

Wheels in motion for the M80 Ring Road D

RIVERS in Melbourne’s north are set to benefit as the next section of the $2.25 billion M80 Ring Road Upgrade got underway today between Edgars Road, Thomastown and Plenty Road, Bundoora.

Victorian Minister for Roads, Terry Mulder, and Federal Member for McEwen, Rob Mitchell, were on site at Thomastown today to get work started on this six kilometre stretch.

Minister Mulder said the latest works add to the 16 kilometres of construction already underway between the Western Highway and Sunshine Avenue, and from the Calder Freeway to Sydney Road.

“As Victoria’s biggest road project on the ground, the M80 Upgrade is providing a much needed boost to the state’s economy, directly supporting up to 6500 jobs over the life of the project, with thousands of other flow on jobs for services and suppliers,” Mr Mulder said.

“When completed, the improved freeway with extra lanes and better access will help ease congestion, and reduce travel times and costs for commuters, and importantly for road freight industry, with 20,000 trucks currently using the Ring Road each day.

“With works now underway between Edgars Road and Plenty Road, around 60 per cent of the Ring Road is now being improved.

“When completed in mid 2014, this section will have three lanes in each direction to significantly reduce congestion and improve safety.”

“Between interchanges there will also be an additional lane in each direction to minimise the congestion impacts of vehicles entering and exiting the freeway from adjacent interchanges.”

Mr Mitchell said more than 140,000 drivers use the M80 Ring Road every day, making it Melbourne’s second busiest freeway.

“That’s why the Gillard Labor Government

Page 18 - Australian Main Roads Construction News

Minister Mulder said the works were has invested $900 million in the upgrade to date, along with $300 million from the being planned and delivered to minimise the impact on drivers and the community.

Victorian Government,” Mr Mitchell said.

“Drivers travelling through this new “Across the 38 kilometre corridor, the upgrade will also improvements to key work zone can expect changed traffic interchanges and a state-of-the-art electronic conditions including temporary lower speed limits and narrowed freeway management lanes,” Mr Mulder said. system.

“When completed “The safety of all “As someone who uses in mid 2014, this road users and workers the Ring Road regularly, I section will have is paramount so we ask understand how people in drivers take extra care our communities rely on the three lanes in through construction Ring Road to get to work or each direction to areas and be alert to these into the city and travel to see significantly reduce changes.” family and take the kids to congestion and The M80 Ring Road sports. improve safety.”

Upgrade is a $2.25 billion “So the start of these latest project jointly funded works as part of the overall by the Australian and M80 upgrade will no doubt Victorian Governments, and is a vital part be welcome news.

“There is further good news in store for of the Australian Government’s Nation drivers, with new lanes due to open on other Building Program. sections later this year.”

JOINT MEDIA STATEMENT

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M80 - VISIONSTREAM FEATURE

Visionstream provides a fully integrated managed freeway solution to VicRoads

V

ISIONSTREAM has been awarded a $62.5 million contract by VicRoads to deliver the Intelligent Transport System (ITS) to the M80 Ring Road, increasing the route’s safety and efficiency.

The installation of this electronic freeway management system along 38kms of road from Laverton North to Greensborough will provide VicRoads with the ability to manage traffic flow, minimise accidents and other incidents and prevent congestion on the M80 and its main connecting roads.

The estimated 150,000 Victorian motorists that use the M80 daily will enjoy the benefits of the ITS, making the M80 the safest, most efficient and sustainable freeway in Australia.

Allan Bradford, General Manager of Visionstream, said “Visionstream is pleased to provide the technology, expertise and project management skills to modernise this critical part of Melbourne’s road network.”

“Securing this project against international competition reinforces Visionstream’s position as Australia’s leading Intelligent Transport System provider” said Mr Bradford.

The M80 Ring Road Upgrade is more than just a freeway widening project. Forming a significant part of a fully integrated managed

motorway system, it will allow VicRoads to deploy and manage the latest physical and electronic measures across the metropolitan area and potentially the state.

It will include a range of communication network systems, from road sensors to monitor traffic flows, automatic control of vehicle entry onto the M80 and the dynamic management of the freeway’s speed limits, as well as electronic message boards with real time information on traffic conditions, travel time and general freeway information.

The information provided by the electronic freeway management system will, allow faster response times to unexpected traffic conditions, improve management of road works and closures, which will significantlyimprove the driving conditions experienced by road users on the M80.

Not only will the project deliver ITS technologies seen in many modernised motorways, it will also provide an opportunity for new vehicle-to-infrastructure (V2I) technologies to be deployed and tested.

Visionstream and VicRoads are actively supporting the development of these new technologies through initiatives with ITS Australia and the AusDSRC group, and various trials, including rail safety initiatives.

Above: Visionstream erecting a Gantry and VMS over 10 lanes on MCW. Below: Erecting a VMS on MCW

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Visionstream will use its experience to select the most robust components in its design. This includes CCTV, freeway management dynamic signage, field cabinets and power systems.

These devices will be integrated back into the existing VicRoads network to provide an end to end managed network allowing monitoring and control of the whole road network.

Visionstream’s systems architecture is designed to be scalable and flexible, allowing integration of future services to support “any-to-any”, as opposed to “point-to-point”, communications.

This provides an ITS environment which enables sharing of intelligence available on one system to others, thereby optimising freeway management and supporting other information services.

Visionstream’s ITS project experience is extensive and our current project portfolio includes ITS design, construction and commissioning projects as well as operation and maintenance contracts. As well as the successful installation of ITS devices and systems for the iconic Monash-CityLink-West Gate Upgrade project, Visionstream also has constructed ITS devices and networks on the M2 and M5 in NSW, and maintains VicRoads’ current M1 ITS network.

The M80 Ring Road Upgrade is jointly funded by the state and Commonwealth governments and is expected to take five years to complete. Under the contract, Visionstream will design, supply, construct, commission and maintain the ITS network.

“We are thrilled to be working with the Federal and Victorian governments to assist VicRoads in delivering an intelligence boost to the M80 Ring Road Upgrade,” said Mr Bradford.

Australian Main Roads Construction News - Page 19

Digga is a name synonymous with a high quality, world class product so when the company creates a road profiler you know it’s going to be something special. Digga is a company that has been doing what they do best since 1981 and since then has established an award winning reputation for the design and manufacture of earthmoving machinery attachments.

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IGGA was founded in 1981 by Stewart Wright in Queensland and initially supplied wear-parts and repairs for local machine operators, prior to establishing a small factory in Tingalpa. This was the beginning of a period of steady growth and expansion as the company began manufacturing a range of machinery including fulfilling a growing demand for drilling augers.

By 1989 Digga had moved its manufacturing process into the computer age with software controlled machining and robotic welding and shortly after, due to extraordinary demand for its products, advanced steel cutting equipment was installed at the company’s factory.

The Digga Profile Range is perfect for planing (mill) rock, concrete and asphalt.

Digga takes Road Profiling to a New Level What followed was an incredible period of success for the company as Digga established itself as a leader in the manufacture and supply of a broad range of quality, cost effective, earthmoving attachments.

In 2006 the market demand for its products was so big that the company acquired a new purpose built, 12,500sq/m manufacturing facility at Yatala located mid-way between Brisbane and the Gold Coast.

Today, Digga has three facilities across Australia and its manufacturing base is pure state of the art. It features15 CNC multiaxis machines, 15 gear cutting and spindling machines, 8 robotic welders and an endless array of leading edge equipment including 3D analysis and modeling software.

Amongst the company’s 200 plus personnel is a dedicated team of technical staff including 12 highly qualified engineers.

It’s their job to keep Digga ahead of the rest with the design of new cutting edge products and an ongoing programme of performance optimization of its own product technology.

Digga is now Australia’s largest manufacturer of planetary gearboxes, the quality of which is world class and the company now supplies its gearboxes to, not only Australian companies, but many of the world’s leading earthmoving companies.

Digga also manufactures over 70 different machinery attachments as well as extensive wear-parts, spare parts and complete servicing. The company exports its products to over 50 countries around the globe and recently, Digga launched its new range of road profilers, marketing the brand as ‘Road Profila’ throughout Australia.

Profila with features that now make life a lot easier for the road profiling operator.

Not least are Road Profila’s size options which start at 300mm to suit standard flow skid steers with the range including 450mm, 600mm, 750mm and 1metre profilers to suit high flow skid steers. However, the 300mm Road Profila has a very unique advantage.

Traditionally, you couldn’t use a profiler unless you had a high flow skid steer but now Digga’s 300mm profiler has changed the game completely and can be used with a standard flow machine.

Digga’s profilers also provide the option of 3 different motors which allows them to be custom fitted to suit the parent machine’s

hydraulic flow. This insures that the drum speed and torque produced are optimised for every skid steer. Its wheel planetary piston drive motor is the key and you can choose a cold planer specifically matched to meet the skid loader’s flow specification. You can also achieve higher torque which makes cutting through asphalt easier once you’ve made the correct motor choice.

Importantly, unlike the $3K to $5K replacement costs for a direct drive motor, replacing Digga’s wheel planetary piston drive motor is far cheaper at around $500 to $1000 and can be custom fitted efficiently to reduce down time should replacement be required.

ROAD PROFILA RESPONDS TO SPECIFIC INDUSTRY NEEDS Yet again the company, through its policy of responding directly to construction needs has excelled in the development of the Road Page 20 - Australian Main Roads Construction News

Digga’s Open Face bucket broom can clean out a profiled cut and also allows debris to be swept right up against walls, gutters, barriers or any obstruction. www.amrcn.com.au

Unlike most other profilers that use in-line cylinders, the Road Profila has independently operating cylinders which, apart from providing greater control over the potential for drift during operation, are also positioned to avoid impact from spoil debris. The wheels on the Road Profila are surrounded by a steel cover which not only protects them from damage but also serves to push spoil out of the way. The wheels can be easily removed to allow planing next to curbs and other obstructions.

The weight of the Digga attachment is heavier than other types and this provides much greater stability for smoother cuts and with minimum vibration it reduces wear on loader arms. The Road Profila is far less likely to bounce or ride up out of cuts and with a heavier main frame and attachment plate it provides a strong working platform so that consistency and maximum work performance can be achieved.

The Road Profila’s combination of a skid and wheel base provides much greater flexibility which broadens the opportunities for contractors as it’s ideal for a variety of applications and allows the contractor to either roll on the pavement or to skid.

In conjunction with the Road Profila is another recent and valuable addition to the Digga ranks. The Open Face Bucket Broom attachment is ideal for road clean-ups and perfectly suited to clean out a profiled cut.

It’s primarily a bucket broom with the broom exposed to allow debris to be swept right up against structures such as walls, gutters and barriers.

Digga continues to innovate, creating a range of attachments designed to support world’s best practice in the construction frontline. Most importantly they reflect the results of extensive research throughout the construction sector and provide a range of solutions to overcome the logistical problems faced at a practical operational level.

For more information about the extensive range call Digga on 07 3807 3330 or check out; www.digga.com

ROAD WORK ATTACHMENTS

QLD / NT 07 3807 3330

NSW / ACT 02 4647 1400

VIC / SA / TAS 03 9706 6171

WA 08 9457 1544

www.amrcn.com.au

Australian Main Roads Construction News - Page 21

Case launches smarter, faster CX-C Series excavators Case Construction Equipment’s new CX300C and CX350C heavy excavators are the first in Australia to feature Tier 4 Interim compliant engines as well as the exclusive Case Intelligent Hydraulic System.

C

ASE Construction Equipment’s brand new CX300C and CX350C heavy excavators are cleaner, stronger and more efficient and cheaper to run. They’re also the first heavy excavators in the Australian market to be launched with Tier 4 Interim compliant low emission engines.

“The CX300C and CX350C offer an eight per cent increase in cycle times, a five per cent increase in lift capacity and fine controllability – all in a package that is both fuel efficient and cost effective to run.”

“The Case Intelligent Hydraulic System includes a number of functions designed to ensure that the hydraulic flow and engine load is perfectly matched to the task at hand, which means that any operator can get maximum results with minimum fuel use,” said Case Product Manager, Scott O’Hare.

There are five new energy saving systems within the overall Case Intelligent Hydraulic System.

These include: - Boom Economy Control (BEC), which senses and controls engine load and fuel consumption during boom down and swing operation.

- Idle Management System (IMS) manages engine rpm, lowering engine revs after five seconds of inactivity and shutting down after three minutes of inactivity.

- Swing Relief Control (SWC) regulates hydraulic flow at the start of the swing operation to optimise performance while minimising fuel consumption.

- Auto Economy Control (AEC) improves fuel efficiency whenever the joysticks are in the neutral position.

- Spool Stroke Control (SSC) senses pressure during the digging operation to further optimise the hydraulic pressure requirements for fuel efficient operation.

Page 22 - Australian Main Roads Construction News

Like all Case excavators, the new CX300C and CX350C offer a spacious cab with generous legroom and storage space with a best-in-class operator environment delivering ultra-low noise and vibration.

A seven-inch full colour LED monitor with easy to operate controls includes camera views for increased visibility around the machine along with machine data for increased visibility into the machine’s performance.

Safety is assured with ROPS compliant cabs and hose burst control valves as standard, along with an air suspension seat for additional comfort.

“Case’s efficient Tier 4 interim diesel engines feature Cooled Exhaust Gas Recirculation (CEGR) and a diesel particulate diffusor (DPD) to reduce emissions without the added expense and complexity of additional diesel exhaust fluids,” said Scott.

“The automatic self-regeneration of the DPD ensures no loss of productivity while the low engine rpm, improved hydraulic pump control and additional

www.amrcn.com.au

energy saving systems boost fuel economy, with no operator input required. You can also activate a ‘green economy’ gauge in the cab to help you choose the most economical settings for the machine and view fuel consumption in real time – which is a huge benefit to operators keen to reduce fuel costs.

“We have already seen strong customer interest in these new Tier 4 Interim compliant heavy excavators and anticipate a very positive response from customers who want to reduce their fuel bill and from customers who want to minimise their impact on the environment, while still maintaining full productivity,” said Scott.

Smarter, Faster & up to10% Less Fuel!

TIER 4 CERTIFIED

40

Used 37% More

35

Used 20% More

Litres of Fuel per Hour

30

Increased fuel efficiency during boom operation.

Improved fuel efficiency when joysticks are in neutral.

25

Automatic pressure adjustments save fuel during digging and levelling operations.

20

Auto Idle and Idle Shutdown provides additional fuel savings.

15

10

3 BEC – BOOM ECONOMY CONTROL 3 AEC – AUTOMATIC ECONOMY CONTROL 3 SSC – SPOOL STROKE CONTROL 3 IMS – IDLE MANAGEMENT SYSTEM 3 SWC – SWING RELIEF CONTROL

Case CX300C

Cat 325DL

Komatsu PC270LC-8

Manages the hydraulic power distribution for most efficient flow and pressure while slewing.

CLASS-LEADING ECONOMY

Call your local dealer on 1300 99 CASE SUPERIOR | RELIABILITY FUEL EFFICIENCY OPERATOR ENVIRONMENT SERVICEABILITY

www.caseconstruction.com.au

Testing conducted in USA by independent operators. Consistent operations were used for all tests; machines were operated at full load and full fuel for each test; operation duration 30 minutes to pre-determined depth for each testing machine. Calculated CX300C fuel savings in comparison to CX290B.

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Australian Main Roads Construction News - Page 23

C.I.T.S deliver practical ready for work skills

C.I.T.S Excavator training in progress.

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HE dynamic and highly competitive nature of the Australian construction sector, particularly in the area of civil infrastructure, demands that a company’s workforce is highly skilled. Ideally, new entrants to that workforce need to be job-ready, able to take up their position on the frontline with a minimum of fuss.

Although certificate level qualifications will always be relevant, it is within the practical application of their training where candidates, when given that opportunity to exercise their skill on the worksite, can succeed or fail.

It is from this simple but realistic perspective that C.I.T.S Training Australia applies its training programmes and it’s a strategy that has ensured that the company has successfully delivered qualified hands-on ready recruits for the last 20 years.

As a family owned and run business, its strength and endurance is partly due to an inherited and disciplined work ethic. This is reinforced by an effective in-house training philosophy that obviously runs deep throughout the broad range of services provided by the company.

C.I.T.S Training was established in 1990 by husband and wife, Les and Lenie Jennings at Dunkeld in Victoria’s western district. Today, together with their daughters and an expanded qualified training team, the company is now well established in Hamilton with training centres located in Ballarat and Horsham.

However, the company’s reach now extends well beyond regional Victoria and according to Les Jennings there are a number of reasons why C.I.T.S training courses are in demand.

“We believe that skill training has to go much further than simply providing people

C.I.T.S Dozer courses available.

with the ability to pass a test. It must also deal with the practical application of that skill on the worksite and so we concentrate on ensuring that anyone we train has the confidence and the ability to apply their skill in a real workplace situation.“ Les went on to say, “Our trainers and assessors are all fully accredited and we run smaller course groups so this means we can provide far more one on one time with each client. This particularly applies in the field of heavy machinery and heavy vehicles and it allows us to concentrate on those broader issues that can confront the client under workplace conditions.

We can cover issues like operational safety and awareness of normal worksite conditions

Page 24 - Australian Main Roads Construction News

so that the client not only attains certificate qualification but is prepared, as much as possible to respond to the expectations of the employer.”

C.I.T.S offers a broad range of training and testing related to the construction sector and can even provide onsite training in most parts of Australia. Government funding is available for eligible applicants under the Victorian Training Guarantee and other government subsidies may apply.

Some of the courses conducted by accredited trainers and assessors include: • Heavy Vehicle Training and testing from Light Rigid through to Multi Combination • Civil Construction Training and testing including Front end loader, excavator, backhoe, skid steer, roller, grader, dozer and dump truck • High Risk Work Training and testing including forklifts, elevated work platform, Dogging, Rigging and cranes (vehicle mounted, slewing, non-slewing)

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• 4WD and ATV’s • Construction Induction Card • Traineeships – up to Cert IV level in Road Transport, Civil Construction and Transport and logistics Across Australia, from both government and the private sector there are continued calls to increase the skill level of the current and future Australian workforce and C.I.T.S Training Australia has clearly established leadership in meeting those objectives.

The company’s one shop approach to industry training, combined with its attention to the practical application of that new skill provides an advantage for its clients.

For the uninitiated, the worksite can be an awkward place if a certificate of qualification does not provide the ability to apply that new skill with confidence in the frontline. It’s to the credit of C.I.T.S that it recognises the reality of the workplace and with its training methodology it strives to provide a much needed remedy.

Federal Updates on Road Infrastructure Projects from the Office of Federal Minister for Infrastructure and Transport, Anthony Albanese

Above: Federal Minister for Infrastructure and Transport, Anthony Albanese

Opening of the Ocean Reef Road Extension

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LL road users will benefit from a safer road, reduced congestion and decreased travel time and distance thanks to the Ocean Reef Road extension which opened to traffic in December.

Federal Infrastructure and Transport Minister Anthony Albanese, represented recently at the official celebrations by Senator Louise Pratt,

said the increased capacity was necessary to meet the demands of traffic growth in the region.

“It is predicted that by 2021 over 30,000 vehicles will travel on the Ocean Reef Road each week-day – double the 2009 figure,” said Mr Albanese.

“Federal Labor has got on with the job with its significant contribution towards this muchneeded extension.”

Senator Pratt said the $16.7 million Ocean Reef Road extension would allow roads in the region to be better connected.

“The completion of the Ocean Reef Road extension means that motorists now have a direct route to the Swan region, the East Wanneroo region, the Great Northern Highway, the Mitchell freeway and commercial and industrial areas in the City of Swan, shortening travel time and distance for commuters,” said Senator Pratt.

The Federal Labor Government committed over $7 million towards the 4.1 kilometre Ocean Reef Road Extension and the City of Wanneroo a further $9.7 million.

Works included clearing, earthworks, stormwater drainage and construction of the asphalt sealed four-lane dual carriageway, as well as a 2.5 metre-wide dual use concrete path, street lighting and pavement marking.

The Ocean Reef Road Extension project generated 18 jobs, providing vital economic opportunities to Western Australians.

The Gillard Labor Government is investing a record $3.7 billion in land transport infrastructure in Western Australia over the six year period to 2013-14.

Upgrade delivers a safer, less congested F5

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ESIDENTS of Campbelltown and Sydney’s south west who regularly commute to and from work along the F5 are now experiencing quicker, less frustrating driving conditions following the upgrade and widening of the section between Brooks and Narellan roads.

Federal Infrastructure and Transport Minister Anthony Albanese was onsite to officially mark the completion of the $116 million project ontime and within budget.

“The upgrade, which complements earlier widening work between Camden Valley Way and Brooks Road, is already delivering real benefits for the 80,000 motorists and truck drivers which use the F5 every day,” said Mr Albanese.

“Equally, the money we’ve invested will go a long way to making sure this vital part of the City’s road network is able to cope with future demand. Put simply, in partnership with the NSW Government, Federal Labor is building the infrastructure that will support Sydney’s continued growth in decades ahead.

“Indeed, the widening of the F5 is just one a number of Federally-funded road and rail projects designed to help keep Australia’s biggest city moving.

Already, we have committed $3.7 billion to this task, more than 10 times what our predecessors spent during their 12 years in office.”

The F5 Widening was a jointly funded project, with the Federal Government contributing $93 million and the NSW Government a further $23 million. Over the life of the project some 135 construction jobs were created.

NSW Roads Minister Duncan Gay said the multi-million project, delivered in three stages, involved widening the Freeway from four to eight lanes between Raby and Brooks roads, and to six lanes from Raby Road to Narellan

Above: Anthony Albanese and Chris Patterson, State member for Camden at the completion of the F5 widening

Road.

“In addition, these sections of freeway were re-surfaced and a new on-ramp built to make it easier and safer for motorists coming along Raby Road to join the F5,” said Mr Gay. “As part of the forward thinking and planning that went into this project, the builders took the opportunity to install the sensors and cabling which will form the backbone of a future electronic management system, new technology which can prevent congestion and give motorists real-time traffic information.

“Lastly, nearby residents weren’t forgotten either. Not only have additional sound barriers been installed, but a new pedestrian/cycle bridge connecting the suburbs of Claymore and Woodbine was erected over the F5.”

Work on the project kicked off in February 2009 and was completed in March.

Above: Senator Louise Pratt (Left) and Tracey Roberts, Mayor, City of Wanneroo at the official celebrations

Construction starts on the McLaren Vale Overpass RESIDENTS of McLaren Vale and the Fleurieu Peninsula, as well as visitors to the region, will soon enjoy quicker, safer journeys to and from Adelaide following the start of work on replacing the existing T-intersection between Victor Harbor and Main Roads with a new overpass.

Representing Federal Infrastructure and road, rail and public transport infrastructure.”

Transport Minister Anthony Albanese, Construction of the new overpass is being Kingston MP Amanda Rishworth recently jointly funded by the Federal Labor ($14.4 joined South Australian Transport Minister million) and State Labor ($3.6 million) Patrick Conlon onsite to turn the first sod of governments. At the peak of construction the multimillion dollar project which will there will be some 124 workers on site. elevate Main Road over Victor Harbor Road.

Mr Conlon said the final design of the “Once completed in 2013, the new overpass was settled following extensive overpass will significantly improve safety for consultations with the local community and the almost 28,000 motorists and truck drivers will not only cut travel times but also save who pass through this junction each day,” lives at what is currently one of the State’s said Ms Rishworth. most notorious intersections.

“The overpass will be particularly “Between 2002 and 2009, over 38 crashes beneficial for regular users of Main Road as it occurred at this intersection, including one will make it easier for them to get on and off which resulted in multiple fatalities,” said Mr Victor Harbor Road.

Conlon.

“Importantly, this project is just one of many “This is unacceptable, and in partnership now occurring around the State as a direct with the Federal Labor Government we are result of the Federal Labor Government’s going to fix it once and for all.” unprecedented $2.4 billion investment in its www.amrcn.com.au

Australian Main Roads Construction News - Page 25

National Precast heralds a new era in Precast Concrete It’s no wonder that precast concrete has broadened the horizons within the construction sector. Now with a much wider capability, precast concrete has a multitude of applications and most importantly it’s cost effective and sustainable.

The National Precast Concrete Association Australia (National Precast) has played and will continue to play an integral role in ensuring the expansion of both its own industry and the environmental advantages of precast concrete within the building industry.

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hen you talk to Sarah Bachmann, the Association’s Executive Officer, it’s clear that Sarah is extremely passionate about her industry with a fervent desire to maximise all of the opportunities available to the Association’s membership.

“It’s an exciting time in the world of precast concrete. We are always striving to stay ahead of the times, to be proactive in establishing solutions that are both sustainable and cost effective. The construction sector is providing us with opportunities by demanding increased flexibility as well as products which are consistently needed on time and which are always of high quality. The work that the Association does to assist our Members and encourage continued product improvement places us as an industry in an ideal position to capitalise on those opportunities. We can see the future and we are up to the task.”

Historically, the use of precast concrete dates back to Ancient Rome when builders poured concrete into moulds to construct their vast array of aqueducts, culverts and tunnels. In Australia the use of precast concrete has been around since the early 1900’s when a rat plague in Sydney was quelled, in part due to a precast sea-wall. The smooth surface of the sea-wall made a trip from ship to shore extremely difficult for enterprising rats who wanted to explore the land down under.

Back then in the world of precast concrete and thanks in part to the seafaring rats, the journey had just begun and the development of a variety of precast components used throughout Australia soon followed. Furthermore, the pace in the advancement of the precast product was about to shift up a gear in 1990 when National Precast was established by a small group of precast manufacturers. Today, it’s a far more sophisticated Association and the industry’s products are finely tuned to the needs of the construction sector and the environment.

Although National Precast may have had humble beginnings, membership has grown dramatically over the last twenty years and today it represents a wealth of combined talent. Members include not just precast manufacturers and those who supply the industry, but architects, engineers, builders lawyers and accountants as well as affiliated organisations and international associations.

It’s a formidable array of expertise available to an Association dedicated to raising production standards, ensuring world’s best practice across the industry and maximizing the variety of applications available to its members. Most importantly National Precast is now a strong voice effectively representing the precast concrete industry to ensure its ongoing growth.

Above: An example of the sophistication of moulds used by the precast industry: segments for the Gold Coast Desalination Project were manufactured with a dimensional accuracy of +/- 0.3mm.

The Precast Concrete Handbook (available in hard copy or on disk) is one of the several publications produced by National Precast.

PRECAST CONCRETE COMES OF AGE Today, most modern precast factories have all their processes documented with many having independent third party accreditation. There is now a National Code of Practice governing the use of precast on construction sites. These two examples typify the due diligence exercised

by National Precast in reforming its industry practices throughout Australia.

This uniformity has introduced a consistency

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of quality across the industry and over the last decade or so, the Association has participated in a number of initiatives that have transformed the way precast concrete products are produced and installed.

Through its publications, education programmes and forums National Precast has developed a formidable and credible reputation.

The Association is now recognized by various important bodies including Standards Australia, Safe Work Australia and the various State roads’ authorities. National Precast also

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regularly communicates and is represented on many allied industry group committees. There is no doubt that through its disciplined actions, National Precast has influenced much change within the precast concrete industry.

From an industry and manufacturing perspective, the advances made within the precast moulding process over the last ten years have provided a far more accurate and sophisticated response in meeting elaborate demands by the building sector. For example, the increase in the use of large precast trough girders can require expensive and complex mould fabrications and the precast industry has been able to rise to the occasion and respond with appropriate and more cost effective solutions.

Concrete technology continues to evolve such as the use of self-compacting concrete or super flow concrete and the precast manufacturing process has remained abreast of these developments and is well placed to apply these new techniques along with the product advantages that follow.

The precast concrete industry’s continued growth is partly due to a growth in the size and demand for much larger precast components.

On today’s building site it’s not uncommon to find large mobile cranes, including 300 tonne cranes which are capable of erecting much bigger precast elements.

Technology has also played its part in improving the quality of manufacturing and expanding the range of precast elements available. The use of 3D drafting software allows much faster design preparation along with greater flexibility, scope and accuracy.

It also provides documentation to show the Continued on page 28

Innovative cast-in lifting solution sets the standard for M80 A

S ambitious road projects continue to dominate Australia’s infrastructure landscape, organisations tasked with their delivery face ever increasing pressure to find new and innovative solutions to overcome the challenges inherent in such large projects.

The M80 Ring Road Upgrade is one such ambitious project - a $2.25 Billion investment to be constructed across 7 interconnecting segments within a 5 year time frame.

The M80 Ring Road & Ballarat Road interchange, designed by Aecom and currently being constructed by Leighton Contractors, connects the Princess Freeway and Western Highway segments of this M80 project. This interchange required 15 prestressed precast T-Roff Girders, 2m deep and up to 45m long, to be built and lifted into place. A beam lift of this size has never been done in Australia before, presenting Leighton, Aecom & the precast concrete manufacturer Westkon Precast with a problem - how to lift a long, 105 tonne concrete T-Roff Girder safely and efficiently.

To solve this problem, the team consulted with RUD who have long had a strong reputation for lifting and lashing expertise in Australia and New Zealand. RUD have recently expanded their extensive product range by becoming the sole Australian distributors for the PHILIPP Group’s precast concrete products. The PHILIPP Group is a Germanbased world leading supplier of connecting,

anchoring and lifting systems for prefabricated concrete industry.

The RUD/ PHILIPP Engineering team worked with the M80 team to design and validate a solution that would meet site safety requirements and set a new benchmark in Australia for heavy lifting of concrete units.

The design incorporated 4 PHILIPP 37t Castin Lifting Hoops into each of the concrete T-Roff Girders to enable a four point lift from the precast yard to their final resting place onsite. Andrew Steer, Westkon’s project Manager explained “the PHILIPP hoop system is a suitable solution for cases like this where 32t foot anchors can’t be used”.

Installing T-Roff Girders is one of the highest risk activities on a road construction site, so it was critical that the RUD/ PHILIPP recommended solution not only solved the lifting dilemma for the 105 tonne T-Roff Girder, but provided safety guarantees throughout the lift as well.

The PHILIPP Cast-in Lifting Hoops have been proven in similar applications throughout Europe for over 20 years. They consist of flexible high strength fibre core wire rope hoops which are cast into the concrete elements to align with the direction of pull. They require no special tools to install or special lifting devices – they simply connect to a hook or shackle. They are suitable for axial and diagonal loading, and allow the rigger to work free of cumbersome lifting clutches that

are heavy and have numerous pinch-points and potential for back and crush injuries.

The PHILIPP Cast-in lifting Hoop is a safer and more cost effective method to lift prefabricated units as it alleviates the need for anchors, recess formers and lifting clutches which need to be tested once a year to ensure their continuing integrity. Brent Young from Metcalf Cranes performed the M80 Ring Road & Ballarat Road interchange lifts and said they would be “suggesting to future contractors that they too use the PHILIPP Group’s T-Roff Girders from now on.” Leighton’s Andrew Harrap was equally impressed with the newto-Australia technology, saying he would be “recommending this solution through to our design managers to potentially be implemented on our other projects.”

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It is a tense time for Australian infrastructure project owners and contractors alike when their targets require they implement methods they have never employed before. The RUD/ PHILIPP team was proud to share their extensive experience to alleviate the potential risk of this heavy lift requirement for the M80 team. Stephen Broomfield, RUD/ PHILIPP Product Manager for Precast Concrete Solutions commented that “the 37t Cast-in Lifting Hoops used on the project are but one of the many innovative cast-in lifting solutions that make up the PHILIPP Group’s comprehensive connecting, anchoring and lifting system range, and with the new lifting benchmark now set, RUD/ PHILIPP looks forward to providing similar safety and performance guarantees for other high performing infrastructure teams.”

Australian Main Roads Construction News - Page 27

Continued from page 26

history in the development of any product which can then be used as a starting point for future designs.

Manufacturing efficiency is much improved due to the introduction of state of the art carousel production line technology which has now been adopted in many manufacturing facilities. Gone are the days when precast concrete colours and finishes were limited.

Now both the range of colours and textures has been greatly expanded allowing most colours within the spectrum to be accommodated.

There is now almost no limit to the variety of precast concrete components available for buildings and civil construction. Apart from walling panels, precast flooring, columns and beams, stairs, marine elements, retaining walls, pipes, culverts, noise walls and bridge beams currently available, if there is a demand for a particular product the precast industry will respond.

PRECAST CONCRETE THE SUSTAINABLE ADVANTAGE To the lay person, words like precast concrete and sustainability do not sound compatible with each other and yet the number of cost effective and sustainable qualities of precast concrete is extraordinary. There’s no doubt that the inherent properties of precast concrete along with its practicality and worksite installation simplicity is a good story to tell.

However, look deeper and the environmental, social and economic benefits make it a very smart construction choice in terms of overall sustainability.

Locally sourced precast concrete reduces transport costs. Roads suffer less wear and tear and with less heavy traffic it reduces congestion around and beyond the construction zone and with that comes an obvious reduction in exhaust emissions.

In any event, ready-to-install precast concrete elements are delivered to the site and can be quickly and simply applied to the construction, without the need for other tradespeople that are normally required. This in itself has its own WH&S benefits. Also precast floors can provide a safe immediate working platform for the erection crew.

Manufacture of precast elements is not weather dependent. Production and delivery can be scheduled when elements are needed rather than taking up valuable onsite storage space. During construction there is far less impact on local communities with faster construction times, minimal waste removal required and dramatically reduced transport and environmental costs for waste disposal.

Above: An example of the sophistication of moulds used by the precast industry: segments for the Gold Coast Desalination Project were manufactured with a dimensional accuracy of +/- 0.3mm.

The manufacture of precast concrete products produces minimal waste and any waste that is produced in the controlled factory environment is generally recycled back into the mix. Further, waste products such as slag and fly-ash can be incorporated into the mix and recycled aggregate, steel and water can be used.

Moulds can be re-used which of course reduces costs as well as lessening any potential environmental impact due to the need to manufacture new moulds. Then, at the end of their working lives, precast concrete elements can either be re-used or can be crushed and reused as aggregate for road base or construction fill, providing economic and environmental savings.

Precast concrete’s low water-cement ratio means precast is extremely durable and has a long life expectancy of over 100 years.

Because it’s of a higher quality than insitu concrete, a precast structure is able to contain less concrete and steel. Much like wood it also

absorbs carbon dioxide. Precast structures can be extended and structures do not need to be demolished and can simply be renovated internally conserving resources, reducing waste and landfill. Alternatively, precast elements can be re-used.

There are a number of energy efficient thermal mass benefits associated with precast concrete. Its high thermal mass enables it to absorb, store and later radiate heat. Using precast concrete in passive solar designs allows natural heating in winter and cooling in summer, thereby reducing the need to rely on artificial heating and cooling.

The acoustic performance of precast with its high thermal mass assists with sound insulation to reduce noise and absorb noise impact. Precast concrete noise walls provide an effective sound barrier between roads and residential areas blocking out unwanted urban noises. This allows suburban outdoor and indoor spaces to be a far more peaceful environment.

Anthony’s Cutting in Melbourne’s west (part of the Western Highway Melton West to Bacchus Marsh Realignment Project) shows the growth in demand for much larger precast components.

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Within buildings themselves, the use of precast concrete can neutralise internal diurnal building temperatures. Some precast systems (such as TermoDeck®) can improve indoor air quality, providing fresh air inside the home.

Precast is extremely tough and can withstand wear and tear, requiring minimal repairs. There is minimal maintenance during its life with often, only cleaning being required. It can also be moulded into almost any form and finish.

At a time when floods are prevalent it’s a reminder that precast concrete is flood resistant.

It does not erode or rot and is ideal for river and coastal barriers to protect against high tides and storms. It also gains strength as it ages, won’t shrink, distort or move and will not deteriorate with exposure to climatic change.

As a hardy waterproof construction method, precast concrete underground pipes transport sewerage and clean water across the country.

As a building material it is impact resistant and hard to cut, offering security and protection against terrorist acts.

Precast concrete is non-combustible with fire resistant properties. It does not melt and therefore does not require additional fireproofing applications. It does not emit toxic fumes under fire and can limit smoke spreading in buildings.

As an inert substance which does not emit or give off gases or compounds, its use is therefore a huge relief for allergy sufferers and does not attract mould or mildew. Precast concrete is also termite proof and there is less likelihood of requiring chemical spray to reduce termites and vermin which is safer for the environment.

As landscaping and street furniture features, planters increase biodiversity apart from providing a green environment for birds and a pleasant communal meeting place.

You can understand Sarah Bachmann’s enthusiasm for the precast industry because there’s no doubt that precast concrete is a valued commodity in today’s construction sector and one can only contemplate its evolution into the future.

As Sarah says, “The sustainability of building materials is critical because in terms of infrastructure it leads to a far better outcome and creates an important legacy for future generations in the way we manage our environment. The gains we have made in the precast concrete industry over the last ten years or so have contributed to this legacy and we look forward to the difference our industry and Association can make in ensuring that tomorrow’s world continues to become a much kinder place. Particularly, in the way we can build new infrastructure and still respect the environment in which we live.”