Vol 2. No 7

ACN 132 670 261

VOL. 2 NO. 7 SEPTEMBER 2010

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

Geelong Ring Road - A significant project for south western Victoria Pages 10-14

Paving machine operating on the Ballina Bypass at Cumbalum - Pacific Highway Upgrade Pages 3-7

Work starts on Hunter Expressway

Above: Federal Minister for Infrastructure and Transport, Anthony Albanese

T

HE start of major construction work on the new Hunter Expressway is the culmination of the community’s twenty year campaign for better road infrastructure to support the Hunter’s continued growth, not just for the next three years but for the next three decades.

Infrastructure and Transport Minister Anthony Albanese was recently joined by Premier Kristina Keneally, Federal Labor Member for Hunter, Joel Fitzgibbon and State Member for Cessnock, Kerry Hickey, to turn the first sod on this new road.

“After 18 months of detailed planning, geotechnical investigations and site preparations it’s now full steam ahead with delivering this long awaited new piece of infrastructure,” said Mr Albanese.

“First mooted in 1988, it’s taken a partnership between Federal Labor and State Labor to complete the necessary planning, secure the finances and begin building this road,” said Anthony Albanese.

“Once completed in 2013, the new Expressway will cut travel times between Newcastle and Branxton by half an hour and take up to 30,000 vehicles a day off the New England Highway and away from the towns of Thornton, Maitland and Rutherford.

“This project is part of the unprecedented investment we’ve made in the Hunter over the last three years which also includes the most extensive upgrade of the region’s rail network in generations.”

The new Hunter Expressway will be a 40 kilometre dual carriageway connecting the F3 to the New England Highway and include interchanges at Buchanan, Kurri Kurri, Loxford, Allendale and Branxton.

Its construction is a jointly funded project with $1.45 billion coming from the Federal Government and a further $200 million from the NSW Government.

Ms Keneally said the start of major construction was not only a victory for the local community but would also have significant economic benefits for the region both immediate and longer term.

“Indeed in the short term the delivery of this new Expressway will support over 800 construction jobs and a further 2,400 indirect jobs, underpinning the economic prosperity of the Hunter,” said Ms Keneally.

“This road project – the biggest currently underway anywhere in NSW – is a great example of the Gillard and Keneally Labor governments working together to build the infrastructure our State needs.

“When finished in three years time, the new Expressway will slash travel times and deliver safer driving conditions as well as provide a better link to the Hunter’s everpopular wineries.

The recent sod turning took place at the site of the planned Buchanan Interchange and where in coming months the first stages of the new Expressway will take shape.

Federal Labor Member for the Hunter, Joel Fitzgibbon, said the new road will better support the region’s rapidly growing population and industries.

“For many years now the construction of this road has been our region’s number one infrastructure priority,” said Mr Fitzgibbon.

“That’s why I’m particularly proud to be part of a Government which has stepped up to the mark and provide the funding necessary to get it built, yet further proof only Labor has the vision to build the modern, well planned infrastructure our community expects and our economy needs.

“What’s more, funding for this project was provided as part of our recession-busting, job-creating Economic Stimulus Plan, the very initiative the Federal Coalition voted against early last year and have consistently opposed ever since.

“In fact if Bob Baldwin and his Liberal and National Party colleagues had had their way the celebrations would still be many years away.”

Mr Hickey said the residents and businesses of his Cessnock electorate will welcome the reduction in traffic congestion along the New England Highway that this project will deliver.

“This is a big win for Cessnock and a great day for the Hunter,” said Mr Hickey.

The new Hunter Expressway will be delivered via two contracts: • The 13 kilometre eastern section (F3 Freeway to Kurri Kurri) will be built under an alliance formed between the RTA, Thiess, Parsons Brinckerhoff and Hyder Consulting; and • The 27 kilometre western section (Kurri Kurri to Branxton) will be built under a design and construct contract, with the successful builder to be announced later this year and work to start in early 2011.

Page 2 - Australian Main Roads Construction News

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:

Tom Cook

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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

In this issue: • Pacific Highway Upgrade to Stand the Test of Time Pages 3-7 • AusStab Annual Conference held on Gold Coast Page 8 • Geelong Ring Road - A significant project for south western Victoria Pages 10-14 • Hale Street Link a Landmark Achievement Pages 15-17 • Tiger Brennan Drive Extension Nears Completion Pages 18-21 • Another Landmark Project - Mandurah Entrance Road Pages 22-23 • Precast Concrete Feature Pages 24-25 • NSW Road Services Directory Page 26 • QLD Road Services Directory Page 27 • M80 Ring Road Upgrade will improve 38km Western and Metropolitan Ring Roads Page 28 www.amrcn.com.au

PACIFIC HIGHWAY UPGRADE DESIGNED TO STAND THE TEST OF TIME T

HE Pacific Highway is a vital transport link that connects the cities and towns along the east coast of Australia and in the past it has had its fair share of controversy.

However, following the RTA’s commitment to a massive upgrade programme that has been a work in process since 1996; the highway’s reputation and level of safety has dramatically improved. Jointly funded by the NSW and Federal Governments, the comprehensive upgrade covering the 677km highway between Hexham and the Queensland border is now only a few years away from completion, with work on five major sections now underway.

Three of these important sections will affect the areas of Kempsey, Ballina and Sapphire to Woolgoolga and they are probably the most challenging. Leighton Contractors in conjunction with their alliance and joint venture partners is delivering the three sections and dealing with environmental and logistical challenges is all part of a day’s work for the company’s road construction team.

Brett Smythe is Leighton Contractors’ Roads Business Manager for NSW and the ACT. As a qualified Structural Design Engineer, Brett has accrued a wealth of frontline experience managing major civil infrastructure projects in Australia and in Asia and he and his team at Leighton Contractors are passionate about road building.

Leighton Contractors prides itself on ‘certainty of delivery’ and it’s a phrase that goes well beyond simply delivering a project on time and within budget. Brett measures the successful delivery of every project on its ability to achieve all expectations; a project that overcomes all competing logistical, environmental safety and quality concerns and above all, a project that is engineered and constructed to stand the test of time.

That ‘certainty of delivery’ also includes maintaining the respect of those affected most by the process involved when delivering any project. In this instance, the Pacific Highway serves not only interstate motorists, but the many local communities and businesses along its route. Brett believes that it is paramount that the impact of any major construction project is minimised to allow normal life to continue beyond any unavoidable delays due to road construction.

Brett sees this as an important aspect of the company’s involvement in the upgrade of the highway. So in all projects involving Leighton Contractors, the company participates in an ongoing consultation process with various community groups and the RTA to ensure that these projects deliver on the commitments made.

In tandem with that consultative approach is the need to deliver a long-term result best suited to the particular local environment.

BPE

Above: Paving machine operating on the Ballina Bypass at Cumbalum For instance, as more road upgrades occur within the ‘built’ environment, managing impacts such as noise become critical.

The Leighton Contractors team always pays special attention to the mitigation of significant noise impacts and is currently investigating the reduction of road surface noise as an alternative to costly and imposing noise walls.

SOLUTION DRIVEN As well as its highly skilled and expert design partners, Leighton Contractors has its own Technical Services Department (TSD) that provides innovation and engineering solutions. This is a team of engineers and technicians dedicated to the task of maximising overall road value through pavement and road technology improvements in the areas of noise, maintenance, construction, traffic and materials use.

Apart from constant testing and analysis of paving and concrete products, TSD specialists develop training packages for use in-house and on-site. The training provided covers the various facets involved in the

Contractors

Servicing the Civil Construction Industry since 1988 • Loaders • Side Tippers • Batch Plant • Trailers • Flo-con • Tippers • Aggitators • Water Truck • Low Loader • Excavator Proud to be associated with Leightons – BBA – Ballina Bypass Alliance

Brad Pemberton 0412 325 364 Phone 6655 5026 Fax 6655 3027 bpecontractors@yahoo.com.au

www.amrcn.com.au

construction process including road safety and traffic management.

THE RTA CONNECTION Whilst it might be expected that a contractor would be gracious in its appraisal of the body responsible for issuing a contract, Brett Smythe has expressed genuine appreciation on behalf of Leighton Contractors for the continued input from the RTA and he is extremely pleased with the working relationship that has evolved.

In terms of alliances, Brett talks enthusiastically about the ‘one room’ approach, how the standard of collaboration between all construction partners including the RTA is paramount to the success of these complex and demanding projects.

In particular, Brett sees the willingness of RTA personnel to engage in these projects as a big plus and their on-site support and encouragement is a critical contributor to ‘certainty of delivery’ in line with their own project objectives.

Brett also stresses that it’s very much a team approach and the extent of collaboration between all the alliance partners represents a sharp focus by all concerned to maximise the efficiency of the work process on a daily basis; its impact on the local environment and the quality of the end product. According to Brett such collaboration highlights the benefits of an evolution taking place within the construction sector.

“The relationships that have evolved under alliancing have also given rise to a far more collaborative environment under other contractual delivery models.

This provides enormous opportunity for continually improved performance, which is transforming how contracting occurs.”

THE RTA OBJECTIVE Much of the Pacific Highway has already been dramatically transformed under the governance of the NSW Road and Transport Authority (RTA). By the end of 2009 motorists were able to enjoy a 305km stretch of double lane, divided road going north from Hexham. Since then, significant improvements have also been made to a

number of sections further along the 677km highway.

Since 1996 the RTA’s intention has been to significantly reduce the negative aspects of the Pacific Highway that might contribute to road accidents and injuries. For the most part, this has already been achieved with the work performed to date. Reducing travel times for motorists and freight transport costs were also key objectives and apart from the ongoing construction process in some areas, travel times have certainly been reduced.

It was also important that any changes to the route taken by the upgraded highway were done in consultation and in consideration of the various community interests along its path. A key RTA concern was that all section upgrades would be performed in accordance with Ecologically Sustainable Development (ESD) principles and at the end of the day the whole program would represent value for money.

The Pacific Highway Upgrade Program is one of the largest infrastructure projects in NSW history and $3.6 billion has already been committed to continue the Pacific Highway upgrade between 2009 and 2014. There is no doubt that since 1996 the program has already achieved many of its objectives. By the end of 2014 motorists should only be just a few years away from enjoying a secure and smooth ride either way, from the end of the F3 at Newcastle to the Queensland border.

THE BALLINA BYPASS Leighton Contractors is involved in one of the most important and challenging sections of the Pacific Highway Upgrade Program. In principle, the Ballina bypass involves the construction of an 11.5km four lane, dual carriageway which begins where the Pacific and Bruxner Highways intersect, south of Ballina. The bypass will ultimately extend around the town until it reaches the intersection of Ross Lane at Tintenbar and the Pacific Highway, north of Ballina.

In 2007 the Ballina Bypass Alliance (BBA) was formed to construct the bypass

(Continued on next page c)

Australian Main Roads Construction News - Page 3

PACIFIC HIGHWAY UPGRADE DESIGNED TO STAND THE TEST OF TIME (Continued from previous page) and apart from Leighton Contractors the alliance includes AECOM, SMEC, Coffey Geotechnics and the RTA as owner and participant. The new highway will certainly make the route far more efficient and safer for motorists heading north or south. It will bypass a 19km section of the existing Pacific Highway, negating the need to traverse five roundabouts as well as the traffic lights and 60km speed zones that currently operate in the Ballina urban area.

The Ballina bypass is being constructed in two stages and the first stage is due for completion by the end of this year. When opened, this stage will carry traffic from the Cumbalum interchange to the Ross Lane interchange.

The second stage of the bypass between Bruxner Highway and the Cumbalum interchange is currently under construction and is due to be opened for traffic in mid 2012.

Of course the project is not simply about building an 11.5km four lane, dual highway, nor overcoming the various local, technical and environmental challenges. The bypass also involves the construction of various pieces of significant infrastructure, including 20 new bridges and two major interchanges at Teven Road, Cumbalum and at Ross Lane in Tintenbar.

There’s also 12km of local road works and the project involves more than 1.7 million cubic metres of earth works and will incorporate around 140,000 cubic metres of concrete.

As with many areas along the Pacific Highway, the soil quality in the Ballina area varies dramatically. This meant that the road construction process required various and significant pre-treatments to ensure the long life of the road. Special attention has been paid to the construction of the four multi-span, Super T viaducts and the insitu balanced, cantilever bridge over Emigrant Creek. Due to the deep soft soils in those areas, deep boring and driven pile foundations were required. Other treatments applied to overcome the inadequacies of soft or deep soil along the bypass route include the use of stone columns, dynamic compaction, the use of wick drains and surcharge as well as deep soil mixing and piling.

In all, the experience on the Ballina bypass has provided a wealth of technical knowledge about constructing a motorway in very soft soils which will be invaluable to the RTA on the remaining Pacific Highway projects.

The BBA, including the RTA, has also conducted extensive consultations between all the construction partners and the local community and in particular has paid special attention to all the local environmental concerns such as those in relation to

Above: Resizing of a sediment basin control installation on the Sapphire to Woolgoolga project ‘threatened’ plants and animals.

THE KEMPSEY BYPASS The third major section to be designed and constructed by Leighton Contractors and its alliance partners, AECOM and Coffey Geotechnics, is the Kempsey Bypass which is part of the Kempsey to Eungai project.

In total the whole project will result in the construction of a 40km four-lane divided highway running from south of Kempsey to north of Eungai Rail.

The $618 million bypass itself will be 14.5km in length and consist of a four-lane divided road which will bypass Kempsey and Frederickton. It is expected that the bypass will be open for motorists by June 2014.

This is a highly complex and challenging project and preconstruction activities have been comprehensive to ensure that the ultimate design of the bypass incorporates local community views and all of the environmental concerns. The RTA and the project alliance team have dealt with some unique issues within and around the proposed bypass route. In particular, the area is prone to flooding and so flood mitigation is an important element within the design process.

Some houses located within the floodplain area have been raised and sedimentation fences have been installed. Site access tracks have been developed and fencing erected to

accommodate the building of earth mounds on the Macleay River flood plain. These mounds will provide shelter for livestock should flooding become a problem.

A number of flood mitigation measures have also been implemented to reduce the impact of flooding and to ensure the ongoing welfare of farms and residents within the flood plain area.

A detailed ground survey and a geotechnical investigation have been undertaken and preliminary clearing has been performed on the site. Vigorous community consultation has recently been conducted and construction of the bypass is expected to start shortly.

SAPPHIRE TO WOOLGOOLGA UPGRADE When the design and construction contract was awarded to Leighton Contractors and joint venture partner, Fulton Hogan Pty Ltd in 2010, Mr Peter Handel, General Manager NSW/ACT, Construction Division of Leighton Contractors, remarked on the significance of the contract. “Our experience on other Pacific Highway alliance projects now underway at Ballina and Kempsey means we are ideally placed to work with Fulton Hogan to achieve best value for money and excellent results on the Sapphire to Woolgoolga Upgrade.

Our fully integrated delivery team is

looking forward to working with the RTA, local authorities and the surrounding community as the Sapphire to Woolgoolga Upgrade is rolled out over the next 3 years.”

But since then much has happened including all the required preconstruction work to prepare the site as well as a comprehensive consultation process conducted with the local communities in the area.

In simple terms the $698 million upgrade will feature a 25km section of dual lane, divided carriageways which will extend from Campbell Close, Sapphire, to Arrawarra Beach Road, Arrawarra on the NSW mid north coast. Included in the project is a 15km upgrade of the highway north of Coffs Harbour and a 10km bypass around Woolgoolga.

However, in order to complete the new highway it will require the construction of 30 bridges or bridge sized structures.

These include replacement of bridges over the existing creeks and construction of new bridges as part of the underpasses and overpasses required to accommodate the new interchanges.

There will be five new interchanges and these will be located at; Gaudrons Road/Spilt Solitary Road, Sapphire; Moonee Beach Road/Hoys Road, Moonee Beach; Fiddaman (Continued on next page c)

“Concrete is not hard for us” CONCRETE CUTTING & CORE DRILLING, AUSTRALIA-WIDE • • • • • • • •

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www.arrowconcretecutting.com.au Page 4 - Australian Main Roads Construction News

Above: Construction works, Ballina Bypass www.amrcn.com.au

PACIFIC HIGHWAY UPGRADE DESIGNED TO STAND THE TEST OF TIME (Continued from previous page) Solitary Road, Sapphire; Moonee Beach Road/Hoys Road, Moonee Beach; Fiddaman Road/Graham Drive South, Emerald; Graham Drive North/Hearnes Lake Road, south Woolgoolga; and Arrawarra Beach Road, Arrawarra.

A local road network will also be created to support the local community. This will allow local traffic, including school buses, to travel through the area without having to use the upgraded highway.

This project, in line with the RTA’s ongoing commitment, is yet another big step in the Upgrade Program and when finished within two years, it will bring motorists much closer to the day when they can enjoy an uninterrupted journey up or down the coast, travelling at an efficient and safe speed.

CONCRETE INTEGRITY The quality of concrete used in any project is critical to its long term integrity and Leighton Contractors has a strategy to ensure that high standards are always maintained.

Leighton Contractors has established its own Precast Facility located at Coffs Harbour. It has a production capacity of around 30,000 tonnes per year and while providing complete control over product quality, the facility also ensures surety of supply. The Facility’s primary objective is to produce Super T Girders in all sizes up to 1800mm deep, as well as precast planks and parapets. Considering the demand for numerous bridges and viaducts in the three sections under construction, the company’s Precast Facility represents a huge advantage in ensuring the consistent integrity of the precast concrete used.

THE FORMULA FOR SUCCESS The selection of Leighton Contractors for the delivery of three main sections in the Pacific Highway Upgrade Program reflects the company’s long standing reputation for excellence in project delivery. But it’s a reputation earned over the course of a journey that began in 1949 when soon after, Leighton Contractors first began laying pipes for the historic Snowy Mountains Hydro Electric Scheme. It’s also a journey that features a generation of landmark projects delivered by the company along the way.

Since those early days Leighton Contractors has dramatically expanded both its reach and its accomplishments. The company is now one of the Australia’s leading contracting and project development groups with a huge workforce employing more than 9000 people stretching across Australia and New Zealand.

Leighton Contractors services a ‘bluechip’ client group covering a broad range of industries and sectors including resources, construction, telecommunications, energy and infrastructure as well as facility management. But there’s no secret to the company’s success, it’s due to the application of a well-proven formula and it’s one that drives the company through all activities both internally and externally.

It starts with a strict and disciplined work ethic, an ability to listen, to adapt, to innovate and to deliver. It features an unmatched project versatility powered by a diverse and highly skilled workforce. If that isn’t enough then the very structure that rules Leighton Contractors ensures an edge. Divided into four operating divisions aligned to key industry sectors, each one is in competition with the other because each division wants to be more successful than the other.

It’s a powerful formula and its effectiveness is highly visible amongst the countless landmark infrastructure projects that litter the countryside. The Leighton Contractors’ footprint is clearly evident in NSW on the Eastern Distributor, the M2 and M7 Motorways and on the Hume Highway, to name just a few. In Queensland there’s the Clem 7 Tunnel, the Gateway Bridge and the Inner Northern Busway. Further afield there is the Metrorail in Perth, the Southern Cross Railway Station in Melbourne and the Northern Gateway in Auckland. But there are countless other projects including bridges, roads and tunnels that have become features on a landscape of award winning achievements.

It’s no wonder that Leighton Contractors currently has projects in hand worth over $9 billion. Of course it won’t stop there, the word is out. When Leighton Contractors build something, it’s built to stand the test of time.

Pacific Highway - Sapphire to Woolgoolga Duplication gets underway

A

NTHONY Albanese, Federal Minister for Infrastructure and Transport recently turned the first sod to mark the start of major construction on the $700 million Sapphire to Woolgoolga duplication of the Pacific Highway.

Minister Albanese was on site with Federal Labor Candidate for Cowper, Paul Sekfy and Mayor of Coffs Harbour City Council, Keith Rhoades.

“I was here in January this year to see firsthand the early works at the site, so I am really pleased to be back here to mark the start of construction on this important stretch of the Pacific Highway,” Mr Albanese said.

“The Sapphire to Woolgoolga upgrade is expected to support 500 jobs over the next four years, delivering a boost to the region’s economy.

“It will create 25 kilometres of four lane divided road, making the Sapphire to Woolgoolga section safer for people and cutting travel times for cars and trucks.

“The project will also help improve safety for local motorists in the growing northern suburbs of Coffs Harbour by diverting them from the highway to an upgraded local service road.

“The start of works on Sapphire to Woolgoolga means that, right now, construction is underway or about to commence on about 125 kilometres of the Pacific Highway.

“The Kempsey, Ballina, Glenugie and Bulahdelah bypasses are underway, as is the Banora Point upgrade further north.”

“We are determined to deliver this upgrade as quickly as possible to create jobs and delivering infrastructure into the long term,” Mr Sekfy said.

“I am pleased that this upgrade will make the highway a little bit safer for our local community while making sure that the produce from our farms and the products from our businesses can be transported more efficiently.”

The Sapphire and Woolgoolga upgrade

There are 69km of construction projects underway on the Pacific Highway. This consists of the following projects: • Ballina Bypass • Bulahdelah Bypass • Banora Point • Glenugie Upgrade

Above: Anthony Albanese, Federal Minister for Infrastructure and Transport is a jointly funded project, with the Federal Government contributing $610 million and the NSW Government a further $88.3 million. It is due for completion in 2014, weather permitting.

Key features of the project are: • Twenty-five kilometres of dual carriageway highway.

• Interchanges at: • Gaudrons Road/Split Solitary Road, Sapphire; • Moonee Beach Road/Hoys Road, Moonee Beach; • Fiddaman Road/Graham Drive South, Emerald; • Graham Drive North/Hearnes Lake Road, south Woolgoolga; and • Arrawarra Beach Road, Arrawarra.

• An upgraded local road between Sapphire and Woolgoolga, providing safer access to local properties and an alternative route those not wanting to use the highway.

• Kempsey Bypass • Sapphire to Woolgoolga Upgrade In the next 12 months two projects are expected to commence.

They are: • Herons Creek to Stills Road • Devils Pulpit

Above: Coopernook to Herons Creek Pacific Highway upgrade project

Above: Blast occurring at Glenugie www.amrcn.com.au

Above: A Bebo Arch that has been constructed at Nine Mile Creek, part of the Glenugie project Australian Main Roads Construction News - Page 5

IT’S WHAT’S UNDERNEATH THAT COUNTS T

HOSE in the construction sector are very much aware that earth management is a critical factor because the ground on which they build represents the greatest risk to any structure. It is the foundation on which a road, a tunnel, a bridge or a building will stand so, before anything is built, analysis of soil and rock is mandatory. But it goes way beyond the initial construction process, understanding the secret of the ground beneath will contribute directly to the long term performance of any physical infrastructure.

Our planet’s surface is a combination of soil, rock and water and Coffey Geotechnics is a leading specialist in ground engineering and earth management. Coffey Information is an industry-leading specialist in scientific testing solutions, providing quality and assurance in construction, environment and mining projects.

As a vital part of Coffey International Ltd, a multi-skilled company with over 4,000 people working in 80 countries, Coffey Geotechnics’ and Coffey Information’s skills stand alone and are always on display globally. However, currently they are very much in play closer to home, contributing directly to the long term welfare of the Pacific Highway Upgrade Project.

The Roads and Traffic Authority (RTA) Pacific Highway Upgrade Program consists of upgrading 677 km of the road between Hexham in the south and the Queensland border. It covers a distance that traverses over hills, through valleys, across rivers and creeks and while the scenery is highly visible, it’s what you can’t see that matters most. There are dramatic variations in ground conditions along most of its route and understanding the variation in behaviour of these conditions is critical in ensuring the long term durability of the completed upgrade.

Coffey is currently involved in a number of projects along the Pacific Highway, including seven with unique underground characteristics that are described below.

SOFT SOIL AN ISSUE FOR BALLINA BYPASS The Pacific Highway is part of the National Land Transport Network. The federal and New South Wales governments have been jointly upgrading the Pacific Highway since 1996. Together, $3.6 billion has been committed to continue the upgrade of the highway over the five years to mid 2014. When the Ballina bypass is completed it will provide a 12 km dual carriageway around the town of Ballina on the north coast of NSW. Apart from reducing travel times and making the road far safer, the bypass will eliminate the need for motorists to negotiate five existing roundabouts. It will also allow the Ballina community to remain independent of the highway with improvements to be made to the local roads in that region.

However, soil analysis undertaken by Coffey Geotechnics revealed that the quality of the soil was a concern as the area features some of the deepest and softest patches of soil in Australia.

Embankments have settled up to 6.4m during construction, a record for the Pacific Highway and perhaps Australia. Coffey’s specialist ground engineers conducted comprehensive geotechnical investigations and geological interpretations.

Coffey Geotechnics provided foundation design for 18 bridges, 3 arches and 6 large box culverts and assessed the available options for stabilising soft soil beneath the embankments.

They also assessed potential instability in the design of deep cuttings to mitigate risks as well as advising on the usage of material removed from the cuttings.

Coffey ground engineers then developed cost-effective geotechnical solutions to balance the requirements of the project with respect to time, cost, risk and long term functionality.

They also provided on site design support during construction to manage geotechnical risks and take advantage of opportunities as they arise.

Coffey has introduced a number of emerging ground treatment technologies to overcome the difficult soft ground conditions that occur along the bypass route. One of the innovative solutions is vacuum consolidation, which is a soft soil improvement method being used on road projects in Australia for the first time.

Other soft ground treatment solutions such as

Campbell Close, Sapphire, to Arrawarra Beach Road, Arrawarra, bypassing the town of Woolgoolga. It involves duplication of the existing Pacific Highway for 15 km in the southern section and construction of 10 km of dual carriageway to the west of Woolgoolga. Pre-construction activities have now commenced, including utilities relocation and property acquisitions.

Coffey Geotechnics formed part of the design team for the Leighton - Fulton Hogan Joint Venture. The joint venture successfully tendered for the upgrade, with Coffey now providing geotechnical design services, site contamination assessments, site investigations services and construction stage verifications services.

Specific design tasks for the upgrade include geotechnical pile design, cut and fill embankment stability assessment, retaining wall geotechnical design, foundation assessments for culverts, noise walls and miscellaneous structures.

BANORA POINT UPGRADE Above: Richard Kelly and John Atkinson at the Cumbalum Flood Relief Bridge site, Ballina Bypass

lightweight fill, deep soil mixing, stone columns and dynamic replacement are also being used.

The RTA has formed an alliance with Coffey, Leighton Contractors, AECOM and Snowy Mountains Engineering Corporation (SMEC). Coffey enthusiastically supports a close working relationship with their alliance partners to achieve the best outcomes for the project. The benefits gained by the alliance are numerous and based on the solutions they have adopted; the timetable for the highway is expected to be reduced.

COFFEY CONTRIBUTES TO KEMPSEY BYPASS Much like the Ballina bypass, the Kempsey bypass is one of the major sections under construction within the overall upgrade project.

Coffey Geotechnics and Coffey Information are both playing their part in the alliance team formed to deliver the road works portion of the Kempsey bypass. The RTA has formed an alliance with Coffey, Leighton Contractors and AECOM. The Pacific Highway is vital to the efficient flow of road traffic up and down the east coast of Australia and the Kempsey bypass will dramatically improve the efficiency of this important transport link. When completed, the bypass will provide a14.5 km, four-lane divided highway between Kempsey and Frederickton.

The role played by Coffey Information clearly demonstrates the value of a multiskilled company like Coffey. Whilst Coffey Geotechnics engineers investigate the quality of soil along the bypass route and earmark design solutions, Coffey Information technicians provide an onsite laboratory to analyse ground samples and test those solutions. Both aspects of Coffey are critical and will ensure the long term durability of the new bypass along with the broader contribution made by the alliance team.

Overall, Coffey’s role is to conduct all necessary investigations, undertake detailed design of cuttings and embankments, foundations for bridges and other infrastructure. Coffey Geotechnics provide geotechnical investigation and design while Coffey Information performs materials testing for the project.

The alliance will deliver the main road works and all other activities, including preparation of the site for the bridge contractor. There is 2.2 kilometres of bridging included in the bypass and the main bridging over the Macleay River floodplain will be built under a separate design and construct contract.

COFFEY EXPERTISE FROM COOPERNOOK TO HERONS CREEK The Coopernook to Herons Creek project included the design and construction of a 33 kilometre dual carriageway between Coopernook and Herons Creek.

Pacific Highway soil quality is again an important consideration and Coffey Information was awarded the contract as the sole testing supplier for the project.

Coffey Information established a team of 15 testing personnel based in on-site laboratories

Page 6 - Australian Main Roads Construction News

along the route. This figure increased to around 27 personnel as the project progressed.

Interestingly, a number of technicians were recruited from the local area and trained by Coffey to the appropriate standards required.

It was a great opportunity for those selected to expand their skill levels and they will be supervised by Coffey’s qualified Technical and Management team.

Coffey Information’s team of specialist technicians, scientists and field data collectors worked on the highway carrying out Quality Assurance testing in the form of compaction control, bearing capacity (CBR), Atterberg limits, gradings and concrete testing to ensure the newly constructed road met all design and safety standards.

Due to Coffey’s expertise on soft ground engineering, the Coopernook to Herons Creek Alliance also requested Coffey Geotechnics to conduct an independent review of the ground treatment at two river crossings where soft soils exist beneath the bridge approach embankments.

The alliance adopted rigid inclusions at these locations to control movements of the ground and the pile foundations of the existing adjacent bridges. Coffey’s review added value to the alliance by identifying potential risks associated with ground movement. These may be induced during installation of closely spaced rigid inclusions, so Coffey assisted the alliance designers to develop an appropriate installation sequence to mitigate the risks.

This project was opened to traffic in July 2010.

PREPARING THE WAYWOOLGOOLGA TO BALLINA The actual project delivery mechanism for the Woolgoolga to Ballina section of the Pacific Highway Upgrade Program has yet to be determined however, preliminary planning is already in progress. Coffey Geotechnics has been involved in a front end study on behalf of the RTA to determine, amongst other things, the best strategy in dealing with ground treatment and in the selection of appropriate sites along the proposed route.

Ultimately, the Woolgoolga to Ballina section will provide approximately, a 150 km dual lane highway separated by a median. However, the upgrade alignment extends over alluvial soils which include layers of soft soils that extend to a 20m depth. The current concept design alignment includes embankments up to 16m high over the soft soil areas. These soft soils are required to be treated to ensure that post construction total and differential settlements are within an acceptable performance criteria and will provide an efficient maintenance regime.

Coffey Geotechnics is well aware that soft soil treatment has a significant impact on project cost and the program of delivery, so a major challenge was to develop a strategy to enable early treatment of the soft soils.

DESIGNS FOR SAPPHIRE TO WOOLGOOLGA The Sapphire to Woolgoolga Pacific Highway upgrade extends approximately 25 km from

The RTA has formed an alliance with Abigroup Contractors, Seymour Whyte Constructions and Snowy Mountains Engineering Corporation (SMEC) to design and build the Banora Point upgrade.

Coffey Geotechnics undertook detailed geotechnical investigations for the RTA as part of the project development works for the 2.5 km, 6 lane divided carriage way between Barneys Point Bridge and the Tweed Heeds bypass at Banora Point.

The detailed geotechnical investigations were undertaken to assist the RTA with the detailed design and construction phases of the project.

In addition to providing advice on foundation conditions for a number of bridge structures and a viaduct about 330m long across a central valley area, Coffey Geotechnics used its unrivalled engineering geological skills to develop a geotechnical model for a near vertical cut about 20m deep by 100m wide in variably weathered basalt. This cut at Sexton Hill is to form part of a land bridge to provide a green connection between east and west Banora Point.

To compliment the geotechnical investigations, Coffey Geotechnics also employed a range of specialist geophysical techniques, including Seismic Refraction, Electrical Resistivity Imaging and Site Uniformity Borehole Seismic to further enhance the understanding of ground conditions.

WARRELL CREEK to URUNGA INVESTIGATION COMMENCES The Warrell Creek to Urunga upgrade spans approximately 42 km for a dual carriageway upgrade. The RTA is finalising a submissions report on the recent display of the environmental assessment and will shortly be seeking project approval from the Department of Planning and the Minister for Planning.

Coffey Geotechnics has been awarded the Warrell Creek to Urunga detailed Geotechnical Investigation works and are currently in the planning stage prior to commencement on site.

THE COFFEY RESPONSE TO AN EXPANDING POPULATION As cities expand and the demand for regional infrastructure increases, the quality of the ground beyond the normal suburban boundaries requires much closer scrutiny.

Coffey’s ability to understand and utilize that diminishing surface is invaluable if we are to keep in step with an expanding population.

However, that skill is enhanced by Coffey’s understanding of the risks and constraints faced by their clients. It’s in overcoming the demands of an expanding environment with a cost effective solution where Coffey excels.

Working in multi-discipline teams, Coffey provide the ideal response to onsite earth management. By combining the expertise of skilled ground engineers, technicians, environmental specialists and project managers they provide the full range of services producing solutions from design through to implementation.

It ensures that as far as this planet is concerned, when it’s what’s underneath a project that counts; the construction sector can count on Coffey.

www.amrcn.com.au

SPECIALIST KNOWLEDGE, EXTRAORDINARY OUTCOMES Coffey is proud to be working with the RTA on the Pacific Highway, part of the National Land Transport Network. The federal and New South Wales governments have been jointly upgrading the Pacific Highway since 1996. Together, $3.6 billion has been committed to continue the upgrade of the highway over the five years to mid 2014.

Our specialist ground engineers and technicians provide onsite investigation and analysis to produce onsite solution design and implementation for each step of the project within: • • • • • • •

Ballina Bypass Alliance Banora Point Coopernook to Heron’s Creek Kempsey Bypass Alliance Sapphire to Woolgoolga Warrell Creek to Urunga Woolgoolga to Ballina

Coffey has worked on numerous road infrastructure projects including Airport Link & Northern Busway, Albury Wodonga Hume Freeway, Clem Jones Tunnel (Clem 7), Five Islands Road, Hume Highway, Inner City Bypass, Inner Northern Busway, Ipswich Logan Motorway Interchange Upgrade, Lawrence Hargrave Drive Alliance, Millstream Link Alliance, Northern Access Road (NAR), Northern Hume Alliance and Port of Brisbane Motorway.

Coffey International Limited is a listed company (ASX: COF) with over 4,000 people working on projects in more than 80 countries. Operating for 50 years, we have a range of specialist businesses working in the social and physical infrastructure markets. Collectively, we aim to achieve our vision: to be global specialists solving emerging challenges to improve the lives of communities.

coffey.com www.amrcn.com.au

Australian Main Roads Construction News - Page 7

AUSTAB ANNUAL CONFERENCE HELD ON GOLD COAST

T

HE AustStab Annual Conference was well attended this year with attention focused on the main topic on the agenda sustainability of roads.

A workshop was conducted by Nigel Howard of Edge Environment during which all aspects of pavement sustainability were discussed.

One of the features was an outstanding presentation on the environmental advantages of stabilisation over conventional virgin material construction. Some of the major advantages highlighted included: • Lower carbon emission • Less energy in construction • Greatly reduced truck movements • Minimal landfill

• Minimal depletion of scarce quarry resources • Reduced time of construction • Less disruption to traffic flows • More economical A sustainability working group was also formed, featuring contractors and suppliers from all over Australia. The group’s aim is to work towards quantifying the environmental differences between different forms of construction.

Guest speaker at the conference, Doug Harland from Australian Green Infrastructure Council (AGIC), emphasised the need for the infrastructure industry to consider environmental and sustainable construction methods which would ultimately benefit future generations.

Doug Harland put forward a strong argument to highlight the fact that sustainable construction need not be more expensive. He used the example of how stabilisation was an example of a process

where saving cost and time was a ‘win win’ because the method also greatly benefited the environment. The industry is well aware that the stabilisation industry has developed significantly over the last decade. Much has changed, including the use of vastly improved computer controlled plant and a variety of new, highly specialised binders that produced a high quality pavement.

AUSTSTAB NAME CHANGE AustStab has decided to change its name to Pavement Recycling and Stabilisation Association but will also retain the use of the familiar abbreviation of AustStab. It was felt that with the broadening of the member base and the emphasis on the recycling advantages within the industry, that a change was needed.

In a move to further improve the quality of construction there was a unanimous decision reached by all members at the Conference to proceed with third party accreditation of all member contractors. This will provide the

Allight highlights Australian manufacturing with milestone lighting tower

A

S Allight’s 7000th mobile lighting comes out of production, the Perthbased manufacturer has presented the milestone Australian-made product to national industrial equipment hire group.

Designed, engineered and manufactured in Australia, an EnviroLight MS4K9 Mine Series lighting tower completed in early June was the 7000th tower produced by Allight and will now be transferred to Barrow Island to provide turtle-friendly lighting for the Gorgon Project.

“We’re thrilled that this landmark piece of equipment is destined for local shores, where it’s going to be used as a safe lighting system in a sensitive environment,” said Allight’s Managing Director, Patrick Walsh.

Developed by Allight in response to the pressing need for an environmentally and ecologically-friendly lighting solution, the MS4K9 lighting tower will be one of several units used by Coates Hire to power construction work on the Gorgon project.

According to Walsh, the EnviroLight system functions in a way that significantly reduces the threat to local wildlife without compromising site safety or production efficiency.

The lighting tower was officially presented

by Chairman of Allight’s board, the Hon. Richard Court, AC, to Mr Marcus Geisler, Executive General Manager of Coates Hire West at the special event held in Perth on Friday 11th June.

industry with a benchmark when employing contractors and an assurance that the knowledge, equipment and resources needed for such a highly specialised process are in order.

Scott Young from Downer was elected president for the second year. In his president’s message, Scott highlighted the achievements of the industry over the last twelve months. He was particularly excited about the publication of the “Pavement Recycling and Stabilisation Guide” due in November. The soon to be published guide will feature a complete update and expansion of the Austroads “Guide to Stabilisation in Roadworks” which is no longer in print. The guide will be distributed free of charge to the road design and construction industry, particularly councils, road authorities and consultants.

The Annual Conference was extremely successful and members looked forward to meeting up again in 2011.

Early finish for Northern Expresway T

Above: The milestone tower was officially presented by Chairman of Allight’s board, the Hon. Richard Court, AC, to Mr Marcus Geisler, Executive General Manager of Coates Hire West “The event was much more than a celebration of the milestone. It was an opportunity to celebrate the cutting edge of Australian technology and acknowledge this crucial step forward in delivering much-needed environmental solutions.”

“It was also an opportunity to formally thank Coates Hire for their continued support and officially recognise the

efforts of our local manufacturing team,” concluded Walsh.

Allight began manufacturing mobile lighting towers at a dedicated production facility in Perth over 20 years ago.

Today, the company supplies a range of mobile lighting towers alongside Godwin pumps, Perkins diesel engines, FG Wilson generators and Rotair air compressors.

Above: The EnviroLight’s sodium vapour lights emit a softer yellow glow instead of the usual harsh, white light, which can disorient the endangered flat-head turtles nesting on Barrow Island’s A-class nature reserve Page 8 - Australian Main Roads Construction News

RAFFIC began flowing on the nation’s newest freeway, Adelaide’s $564 million Northern Expressway on Monday, September 13 – three months ahead of schedule thanks to funding brought forward as part of the Federal Labor Government’s Economic Stimulus Plan.

Premier Mike Rann and Federal Minister for Infrastructure, Anthony Albanese made the announcement at the opening of the Port Wakefield Road Bridge – one of 15 bridges along the 23-kilometre Northern Expressway recently.

They were joined by SA Minister for Infrastructure and Transport, Patrick Conlon and Federal Member for Wakefield, Nick Champion.

“The Northern Expressway is one of the largest SA road projects in the past 50 years and I am very pleased that only the finishing touches remain,” Mr Rann said.

“The opening of all lanes of the Port Wakefield Road Bridge heralds the Northern Expressway’s imminent completion which I am delighted to say will see traffic using the brand-new road from September 13.

“That puts us some three months ahead of schedule - which for an undertaking of this magnitude is a wonderful effort by all concerned.

“The Federal Labor Government has provided $451.2 million towards this project, with funding brought forward as part of our Economic Stimulus Plan,” Mr Albanese said.

“Over the past two years, this project has delivered a major economic and social boost in Adelaide’s north and employed more than 3,000 people.

‘This is what the Gillard Labor Government’s economic plan is all about – supporting jobs today while building infrastructure to grow the economy into the long term.

“In contrast, Tony Abbott’s lack of judgement in opposing the Government’s Economic Stimulus Plan means that he is simply not up to being the next Prime Minister of Australia.”

“The Northern Expressway will link the Sturt Highway with Port Wakefield Road, cutting travel times for working families and businesses travelling between Adelaide and the north by up to 20 minutes,” Mr Conlon said.

“The 90-metre Port Wakefield Bridge is one of the last major milestones in the completion of the Northern Expressway project.

“In excess of 3,000 people have been employed on the project – many of whom are residents of nearby communities – and more than 130 local sub-contracting firms have been engaged.

“Ambitious targets have also been set – and consistently exceeded – for the employment of young and Indigenous people, with 14 per cent of workers on-site having been drawn from these backgrounds.”

“This is great news for our local community and for our economy,” Mr Champion said.

“I know the community has been very patient during the project’s construction and the opening of the Port Wakefield Road Bridge means that we are almost there.

“The Northern Expressway will make Adelaide’s north safer for motorists and their families, more productive economically and a better place to work and to live.”

www.amrcn.com.au

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Queensland Yatala, Brisbane / Gold Coast

Victoria & Tasmania Knoxfield, Melbourne

Western Australia & South Australia Balcatta, Perth

Tel.: 07 3382 7593

Tel.: 03 9800 5268

Tel.: 08 9240 1611

New Zealand Wellington Tel.: 64 2744 26555

Australian Main Roads Construction News - Page 9

Geelong Ring Road - A significant project for south western Victoria T

HE Geelong Ring Road opened to traffic through to the Princes Highway in June 2009. It provides a 23km freeway link between Corio and Waurn Ponds, along Geelong’s western outskirts.

Benefits of the Geelong Ring Road include: •Safer driving conditions for freeway users with reduced travel times.

• Removal of trucks and through traffic from the Geelong road network, improving safety and amenity for locals and tourists.

• Improved access between Melbourne to the Surf Coast, Great Ocean Road and south-western Victoria.

• Reduced vehicle running costs, particularly for commercial traffic.

• Enhanced environmental conditions with extensive planning of native trees and grasses.

Section 4A In December 2008 Fulton Hogan was awarded a $62 million contract for the design and construction of Section 4A of Geelong Ring Road. Having completed the twin 200m bridges over the Moorabool River as part of Section 2 of the Ring Road, Fulton Hogan was extremely pleased to continue its involvement in this landmark project for the region.

Section 4A extends the Ring Road

Above: Traffic on the newly open Geelong Ring Road 14/06/2009

2.5km to Anglesea Road via overpasses of Pigdons Road and the Princes Highway, including duplication of Anglesea Road as far as Hams Road.

In addition to the new freeway construction, the project involves local roadworks and construction of a shared

user path for pedestrians and cyclists.

Project Overview The 2.5km section is being constructed as a four-lane freeway which connects the Geelong Ring Road to Anglesea Road, which currently carries around 7,500 vehicles per day, comprised of commuter,

Above: Section 4A - Traffic switched to (east side) new south bound carriageways in Anglesea Road, through a 5 metre cut

tourist and commercial traffic.

Land acquisition was minimised by using the existing carriageway and road reserve.

Features of the project include: • 2 lanes in each direction.

• 5 bridges, including a five span, 200m bridge over the Princes Highway.

• 7.5 km of concrete barriers.

• 2,500 m2 of noise walls.

• 4,500 m2 of soil nail and shotcrete walls.

• 5,000 m2 of retained earth walls.

• Relocation of major services including communications, gas main, water mains (1400mm and 600mm) and high voltage power.

• Electronic Variable Message Sign for driver information.

Architecturally designed noise walls feature along the Ring Road, combining weathering steel with coloured acrylic panels to provide visual continuity with the theme used previously. When combined with the ochre coloured precast retaining walls, the concept is visually bold and dynamic and will complement the surrounding landscape.

Indigenous trees, shrubs and grasses will be planted to enhance the driving experience consistent with the surrounding residential and rural properties.

(Continued on next page c)

Trafficworks - Specialist Traffic Engineering Consultancy Trafficworks is a specialist traffic engineering consultancy prequalified with VicRoads to undertake the following services:

• • • • •

Road Safety Audits Traffic Management Plans Traffic Design Scoping reports for funding bids Research for strategic road safety and policy advice • Traffic analysis of intersections Page 10 - Australian Main Roads Construction News

Postal: PO Box 417 Ivanhoe Vic 3079 Office: Suite 1, 1st Floor 132 Upper Heidelberg Rd Ivanhoe Vic 3079

Tel: 03 9490 5900 Fax: 03 9490 5910 Contact Emmanuel Natalizio or Kate Kennedy on the above numbers or by email emmanuel.natalizio@trafficworks.com.au or kate.kennedy@trafficworks.com.au www.trafficworks.com.au

T

RAFFICWORKS was pleased to provide the following professional services to Fulton Hogan for the Geelong Ring Road Stage 4A project: • Preparation of traffic management plans (including several alignment shifts).

• Road Safety Audits.

• Street lighting design for temporary traffic management arrangements.

• SIDRA intersection analysis.

Trafficworks in conjunction with Fulton Hogan, determined the most suitable and cost effective traffic

management treatments for the sequencing of construction works for the Project with consideration of maximising worker safety and safety for road users, whilst minimising the number of lane closures, detours on surrounding roads, delays and inconvenience to the public.

In addition the traffic management treatments were selected to minimise disruption to affected businesses and properties adjacent to the works, and to minimise the public vehicle interaction with construction vehicles and activities. www.amrcn.com.au

Geelong Ring Road - A significant project for south western Victoria (Continued from previous page)

New shared paths linking with the existing network will be constructed to provide safe access for students between the education precinct, including Deakin University, and Waurn Ponds; and provide alternative routes for those seeking recreational exercise.

Construction Update Major utility services have been relocated including underground and overhead high voltage electrical cables, a gas transmission line and large diameter water mains, allowing Fulton Hogan to focus on works in Anglesea Road.

The use of 40 tonne excavators and tandem trailers to relocate 100,000 cubic metres of cut to fill continues, to create a five metre deep cut along Anglesea Road to accommodate the new freeway.

The installation of 2,400 square metres of precast concrete retained earth panels has been completed with the backfill operation starting to take shape.

Structural work on the Princes Highway overpass, Pigdons Road overpass and the shared user path bridge is progressing well.

Beams have been installed over three of the five spans of Princes Highway bridge. Due to its location, members of the community have been watching with interest as the bridge takes shape, including night works for the launching of the beams.

The existing roundabout at Princes Highway and Anglesea Road will be retained and used as part of the interchange providing access between the new freeway and the Waurn Ponds area.

Key challenges The management of traffic is a major challenge for this project, in particular

Section 4A - View from centre span of bridge over Princes Highway looking up Anglesea Road, just prior to traffic switch

during the holiday period with thousands of additional drivers making their way through Geelong to the Surf Coast, Great Ocean Road and south-western Victoria.

Despite some congestion on a few peak days during the 2009 Christmas period, the open section of the Ring Road to Waurn Ponds has functioned very well. Careful planning through the construction zone was undertaken prior to contractors taking their well deserved Christmas break.

Maintaining traffic flows through the project area has been a major challenge, using extensive safety barriers, reduced speed limits and variable message signs to increase the safety of road workers and all road users.

Management of the surrounding local roads has involved the construction of a new service road on the west side of Anglesea Road to provide and maintain access for residents.

Major milestones

Fulton Hogan completed the realignment of Ghazeepore Road (local road) prior to Christmas 2009. This realignment now connects traffic directly with the Princes Highway and replaces the previously indirect connection via Anglesea Road resulting in a safer and more efficient road network that will serve a growing population in the area.

In August 2010, construction of the south bound lanes along Anglesea Road was completed. Traffic has been shifted to the completed lanes to allow construction of the north bound lanes and the service road to continue.

Community Consultation The Geelong Ring Road is a significant project for south western Victoria and is of great interest to the Geelong community.

Extensive consultation with the community has been undertaken throughout, with the project using existing networks, established relationships and stakeholder groups during the planning and construction of the project.

The Project team has also had direct consultation with affected stakeholders and individual landowners throughout the works.

Regular updates on the VicRoads website, e-bulletins for traffic conditions and major construction activities ensure the community is well informed about the progress of works.

What’s next?

Section 4B of the Geelong Ring Road will provide a 5 km westerly connection from Anglesea Road near Hams Road to the Princes Highway near Draytons Road, through land currently occupied by the Blue Circle Southern Cement quarry.

A contract for the works has been awarded to Cut and Fill Pty Ltd with major construction expected to begin late 2010 with completion in 2012.

Above: Section 4A - Excavation on west side of Anglesea Road preparing for the north bound carriageways www.amrcn.com.au

Australian Main Roads Construction News - Page 11

DIRECTBOR – HARD ROCK EXPERTISE IN DEMAND

W

ISDOM is a priceless commodity and the ‘getting of it’ is only achieved through a journey confronted by years of frontline experience. It comes with the accumulation of problems faced and the knowledge gained by finding solutions through instinct, initiative and the ability to learn everything there is to know about failure and success. It’s that ‘hands-on, know-how’ accrued over time which is vital to every industry.

The construction sector in Australia has its fair share of expertise and we are blessed with a range of large and dynamic companies capable of building anything, anywhere on the world stage. Equally, there are many smaller companies that stand alone or continue to play their part in that amazing success story and one of them is a company called DirectBor. In 1977 Paul Finch used his initiative to start his own backyard business in Geelong, Victoria. Initially he specialised in drilling clay before graduating to rock drilling and underground boring and like any new venture, despite everything he knew, he soon learnt that establishing a new business has its own set of unique demands. But Paul was prepared to do the hard yards and learn by his early mistakes.

But as we know, reputations are earned and then recognized through word of mouth and it wasn’t long before word had spread and DirectBor could stand alone.

Soon, the trickle of jobs became a flow and the journey had begun.

Business flourished and such rapid growth forced DirectBor out of the backyard and into bigger premises in Leopold. Since those earliest of days, Paul Finch hasn’t looked back and he’s been applying his unique earthmoving and drilling talents ever since. Of course the company has grown and it must be a source of pride to Paul Finch that his

Above: Installation of a 100mm power conduit in blue stone on LaTrobe Terrace in Geelong sons, Aaron, James and Mark now stand shoulder to shoulder alongside him in the frontline. Soon, daughter Kara will join the force alongside another six existing and permanent employees.

DirectBor is a specialist company skilled in directional boring for underground conduit and piping installation. The DirectBor team do their job with pinpoint accuracy whether it’s a 300 metre bore, drilling rock or a multi-conduit installation.

Recently, the team were selected for a project by Fulton Hogan Pty Ltd, the company responsible for the construction of the Anglesea Overpass on behalf of the Victorian Government. The new overpass is part of Stage 4A of the Geelong Ring Road project.

Above: Installation of a 350mm water main under Geelong Race Course Page 12 - Australian Main Roads Construction News

In the bigger picture Stage 4A involves the construction of a 2.5km four lane, dual carriageway freeway, from the Geelong Ring Road at Princes Highway to Anglesea Road, terminating at Hams Road. Work will include construction of bridges over Pigdons Road, Princes Highway West and Waurn Ponds Creek.

DirectBor’s role in the project related to the overpass and although a small part to play, it was a critical component. Overhead power lines were impeding the planned location of the overpass and had to be removed. DirectBor’s job was to install underground conduits over a distance of 100m. Fourteen conduits, varying in size from 63mm to 150mm were installed with grouting using the directional boring method. Expertise accrued over time always proves invaluable when dealing with the inconsistencies of underground geology and with typical efficiency, the total project was successfully delivered by DirectBor within 8 working days.

Paul Finch continues to run a non-stop business and his company is always in demand. When drilling through anything to allow for underground installations DirectBor’s reputation is second to none.

The company has a long list of credits including the installation of new conduits in the main street in Lorne in Victoria.

The conduits were required to allow for the existing over head power lines to be placed under ground. DirectBor installed 1.6 km of conduits in a water table via directional drilling. The project was

completed on behalf of Canteri Bros in just three weeks with minimum disturbance to the surrounding residents and businesses in the area.

Recently, DirectBor were called on to complete 1km of rock drilling though blue stone for the Mortlake power station.

The drilling was necessary to assist in the supply of a 180mm water main to the new gas fired power plant. DirectBor also installed a 180mm recycled water main piped from the new power plant to the sewerage plant.

It was a particularly challenging project and the DirectBor team had to drill through insecure rock and fracted grounds at depths of 8m to allow for creek crossings.

The team also had to formulate a special mud program to enable fallen rock, the size of tennis balls, to float out during the drilling process.

The challenges didn’t stop there and DirectBor needed to drill on grade to allow for a steel main to be inserted under Warrnambool Highway. Every bore hole had to be grouted as per the requirement by the principal contractor, Origin Energy.

Overall the project took 6 weeks and DirectBor enjoyed the opportunity to apply what they do best in overcoming the variety of challenges for the Egan’s Group, Bilfinger Berger Services and Origin Energy.

The success of small business in Australia is critical. Small and medium size businesses are integral to the ongoing economic welfare of our nation. For the individual, success always starts with a job and so ideally, a small business will ultimately expand, increasing employment opportunities for others along the way.

At a time when many small businesses have been placed under pressure by elements beyond their control, it is heartening to see the remarkable and enduring capacity of DirectBor. Thirty seven years ago Paul Finch made a decision to put his family’s economic stability and security at risk by establishing a small business. It didn’t happen without the support of his wife Lena and like so many small businesses it’s always been a family affair. The fact that DirectBor has survived the economic turbulence of a generation is to Paul and his family’s great credit.

There is no doubt that the lessons learnt over such a long period will provide an invaluable legacy for his sons. It will be they, who in turn, will continue to ensure that DirectBor survives the next thirty seven years because as we all know; the wisdom of the living years is a priceless commodity and in his line of work, Paul Finch has that in ‘spades’.

Above: Installation of a 63mm power and a 50mm water service under 2 storey units www.amrcn.com.au

Earthmoving & Boring Contractors DirectBor is the number one company in Geelong and surrounding areas that specialise in: • Underground electrical installation • Telecommunications • Gas and Water lines • Horizontal Directional Drilling • Vacuum Excavation (Non-Destructive Digging) • Asset Location • Traffic Management • Trenching • Excavator, Backhoe and Bobcat Hire • Truck Hire – Tip & supper dog, Winch and Low-loader

AUSTRALIA Objectives: • 100% Client satisfaction • High focus on Occupational Health, Safety and Environmental management.

• Completion of projects to the quality requested, on time and within budget.

At DirectBor our main aim is to deliver 100% customer satisfaction. This is achieved through a high focus on project quality, with an impeccable safety record for both our staff and the public.

Each project is completed to the clients standards and restraints, including but not exclusive to; Time, Cost and Quality.

DirectBor is the number one drilling company in Geelong and surrounding areas.

Paul W. Finch Nominees Pty Ltd 110 Clifton Ave, Moolap ABN 67 980 355 212 PO Box 352, LEOPOLD 3224 P: (03) 5250 1673 F: (03) 5250 5418 E: drectbor@bigpond.net.au Aaron Finch: 0432 744 697 Operation/Projects Manager Paul Finch: 0413 315 284 Managing Director

www.amrcn.com.au

Australian Main Roads Construction News - Page 13

Cut & Fill provide the complete package A

LTHOUGH the strength of a company is often measured by its ability to get the job done, the true test of strength can only be measured when a company consistently performs at the highest level.

Such concentrated power requires an energy that goes beyond the work site and it can only be generated by a culture that runs deep within a company’s corridors. It’s a formula that creates a bond between management and employees; a philosophy that recognises employment as a two-way street and provides career advancement through appropriate training, workplace opportunity and reward for effort.

One particular civil engineering company that has always operated under those core principles is Cut & Fill Pty Ltd. It was established over 30 years ago and throughout its growth the company has never failed to deliver and there are good reasons why this is the case. Since its inception, Cut & Fill has made it a priority to cultivate a workforce complete with an extremely broad and diverse range of skills, always ready and equipped to meet any project demand.

Through an employment policy implemented by a highly qualified management team, with over 200 years of combined frontline experience, the company continues to encourage, nurture and foster employee personal growth. This investment in a valued human resource is mutually beneficial. The employee is supported by inhouse training, workplace opportunity and ultimately promotion and in turn Cut & Fill has developed a multi-skilled employee base with a depth of experience across all diverse areas of project criteria.

But there’s more to come because at any one time, amongst its ranks, you will find graduates, student engineers and construction apprentices who are all on their

way to becoming tomorrow’s construction frontline. It’s no wonder that Cut & Fill has forged an enviable reputation throughout the construction sector.

Cut & Fill has always invested strongly in the recruitment, training, and development of its people and the results speak for themselves.

When you look at the extraordinary and extensive scope of projects completed by Cut & Fill it covers all areas and has produced a long list of landmark achievements. From major civil infrastructure and local government improvements to environmental and lifestyle projects, Cut & Fill has constructed major roads, bridges and civil infrastructure. It’s a long list enhanced by urban landscaping projects, waterway and land remediation. All completed with a policy driven respect for the particular local environment and those communities affected.

MAJOR CONTRIBUTOR TO GEELONG RING ROAD Cut & Fill has enjoyed a long association with VicRoads and, apart from completing many other projects on behalf of the Victorian Government it has played a major role in the construction of the important Geelong Ring Road. Having completed Stage 2 in 2009, the company was recently awarded the $70 million, design and construct contract for Section 4B which relates to the Princes Highway/Waurn Ponds connection.

Apart from completing the road section, Cut & Fill will construct 5 bridge structures including a bridge over the Warnabool rail line, two interchange bridges and an access bridge for Boral Cement. A pedestrian underpass will also be built under the Ring Road. The project will also include extensive noise wall construction along the route, in keeping with the previous design and aesthetics of the noise walls constructed by Cut & Fill during Stage 2.

JOIN IN THE SUCCESS Our people are central to our culture and our success.

Over the past 30 years Cut & Fill has steadily grown into a fully diversified civil engineering business. It’s now a business built on a solid foundation with a work force that has earned a reputation as one of the best in the civil construction business.

A career with Cut & Fill provides the opportunity to build just about anything from a major freeway or bridge structure to architecturally designed wetlands and recreational infrastructure.

No matter where you begin, Cut & Fill has a reputation of being an employer of choice in this industry as we provide an environment where our staff are challenged, developed and satisfied.

Each year we take on and train our apprentices (Diesel Mechanics or Civil Construction), appoint Graduate Engineers, QSE Experts, engage Student Engineers and take on experienced Field Supervisors and Engineering Project Managers that meet our ethos of practical hands on civil construction management.

Current works and opportunities exist on our Geelong Ring Road Stage 4B project, Cox’s Bridge Project in Sale and numerous others in NSW and the ACT. If you are interested in a career with us, please send your resume to:

Above: Cut & Fill Stage 2 - Aerial view of the early stages of construction, showing the project’s proximity to residential areas Overall the project will result in a new 5km westerly link from Anglesea Road near Hams Road to the Princes Highway near Draytons Road. It will run through land currently occupied by the Boral quarry. The project is in the planning and design stages and work is expected to start shortly and take approximately two years to complete.

Cut & Fill previously designed and constructed Stage 2 of the Geelong Bypass.

The project included major earthworks and construction of a 4.5km dual carriageway complete with exit and entry ramps and architecturally designed noise walls. With construction being adjacent to built up residential areas, consultation with the local community was an important management aspect and efforts were also made to minimise construction dust and noise.

In addition to the four-lane freeway, a shared bicycle and pedestrian path was also a feature of the project. The shared path stretches from Broderick Road, Corio to Church Street, Hamlyn Heights.

Architecturally-designed noise walls constructed from weathering steel were constructed at specific locations along the Ring Road. Cut & Fill also provided significant landscaping along the route which included planting thousands of native and indigenous trees, shrubs and grasses.

Road safety features were also incorporated.

These included emergency stopping lanes, median safety barriers and Help Phones linked to VicRoads Traffic Management Centre.

The Ring Road has improved safety and accessibility, as well as attracting further tourism to Geelong, the Surf Coast and south western Victoria. Using these sections of the Ring Road, drivers can now bypass up to 16 sets of traffic lights and enjoy significant travel time savings.

The role performed by the company in completing Stage 2 of the Geelong Bypass highlights Cut & Fill’s overall expertise and an ability to perform all aspects of a project from design and construct to landscaping, telecommunications and traffic management.

EQUIPPED TO BE ENVIRONMENTALLY RESPONSIBLE

Apart from the company’s internal, high standard of engineering and design expertise, Cut & Fill also supports its contribution to the civil construction industry with its own unique, in-house Landscaping Team.

Cut & Fill see landscaping and environmental sustainability as an integral part of its approach to all applicable construction projects.

The company’s Landscaping Team expands the reach of its civil engineering ability and serves to enhance project capability for the company’s client roster. The Landscaping Team’s contribution to the greater environment is reflected by the number of carefully selected trees and shrubs which are planted each year. It’s an annual figure which is often in the millions.

The Team is managed by a dedicated and experienced Landscape Manager and landscape crews are well equipped to undertake both hard and soft landscape.

It’s a huge advantage for the company as most projects undertaken by Cut & Fill incorporate a landscaping component. Many of its completed projects have included rock gardens and waterway bridges; escarpment walls; ecological & sustainable landscape gardens and dry river walks.

Cut & Fill also operates its own fully equipped mechanical and engineering workshop for plant maintenance with three diesel mechanics on hand to ensure that all equipment including the construction fleet can be fully utilised at a moment’s notice.

The company’s journey over the last 30 years has many highlights and it has already forged successful project partnerships, not only with governments in Victoria, NSW, ACT, Tasmania and the Northern Territory, but has completed civil infrastructure works for councils and local government entities such as Royal Botanic Gardens, Vic Urban, Parks Victoria and many others.

From the outside looking in, it’s obvious that with a finely tuned workplace culture geared to both employee and diverse project growth, Cut & Fill provide the complete package. It’s the true test of strength and why Cut & Fill is now one of Australia’s leading civil engineering and infrastructure contractors.

Cut & Fill Pty Ltd Sophie Brown, HR Manager 369 High Street, Kew Vic. 3101 E: sbrown@cutandfill.com.au P: (03) 8417 7800 W: www.cutandfill.com.au

Above: Cut & Fill Stage 2 - Noise wall construction and approaches to Twin Bridges over the Moorabool River Page 14 - Australian Main Roads Construction News

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HALE STREET LINK A LANDMARK ACHIEVEMENT B

UILDING any kind of bridge is always a challenge, but building a bridge across a river in the middle of a busy city with all its incumbent transport issues, is a logistical task beyond most normal proportions.

The Hale Street Link, now renamed the Go Between Bridge after a popular Brisbane rock band, was a key component in Brisbane City Council’s TransApex transport plan.

Now completed, the new bridge represents a major achievement for the construction sector and it serves to highlight the benefits of efficient project management and the ability of many to work as a single, coordinated team.

The need for such a project was initially highlighted in 2005 as a result of the TransApex Prefeasibility Report. In that report, the need for a cost effective connection across the Brisbane River, between Milton and South Brisbane, was identified and so the viability of building a bridge or a tunnel was then assessed. The tunnel option proved to be unviable for a number of reasons. It would be far too costly; would have more construction impact on both sides of the river and would not provide the variety of transport connectivity solutions required.

The ambitious decision was then made by the Brisbane City Council to build the much needed bridge. But linking one side of the river with the other would require careful and strategic planning to overcome the many logistical challenges standing in its way. Not least would be the construction of a huge piece of infrastructure in the extremely confined space of a city landscape, all this, while minimising delays for the constant flow of commuter traffic. Not least was the need to ensure that local commerce in the area could continue their business without interruption or dealing with the inevitable; the many political interests which are inherent in any major, headline project where taxpayer funds are involved.

Ultimately, the Hale Street Link Alliance was formed to design and construct the link and to deal with those numerous and critical obstacles and there was no relief for any of the project team throughout the journey which began in July 2008. When the bridge was finally opened on the 5th of July 2010, it was clearly a triumph for all involved and the difficulties faced along the way paled into comparison with the magnificent structure that now spans the Brisbane River.

Above: The officlal opening of the Go Between Bridge on 5th July 2010 Better yet, it’s a $338 million connection made with superb construction efficiency given the daily logistical challenges faced by the project team. It was also completed ahead of schedule and on budget.

The Go Between Bridge connects Merivale and Cordelia Streets in West End to Hale Street and the Inner City Bypass at Milton.

It’s anticipated that the bridge will cater for around 12,000 vehicles per day and save motorists around 15 minutes during peak hour while avoiding the usual congestion on the William Jolly Bridge.

The new bridge is also the first inner-city vehicular bridge constructed in Brisbane since 1972 and it features four lanes dedicated to vehicles with a special pedestrian and bicycle pathway. The bridge’s pedestrian and cycle pathways connect to Coronation Drive and the Bicentennial Bikeway at Milton as well as Riverside Drive and Montague Road

at South Brisbane.

The Go Between Bridge is a three span, twin concrete box girder structure using balanced cantilever construction. Overall the bridge is 300 metres in length with the main bridge span at 117 metres. It is supported by two river piers located 74 metres north and 80 metres south of the abutments on each

river bank. A 3.6 metre wide pedestrian pathway is located on the eastern (city) side of the bridge and a cycleway on the western (Toowong) side.

The Go Between Bridge is relatively steep so the pedestrian path was built as a separate

(Continued on next page)

Precision Kerbs - The Michael Welsh Factor T

HE Hale Street Link Alliance recently completed, featured 3 major construction partners, Seymour Whyte, Macmahon Constructions and bridge builder, Bouygues Travaux. But like all major infrastructure projects there were various construction support services supplied by other smaller companies. One of those subcontractors was Precision Kerbs; a company that specialises in kerbing and as far as founder, Michael Welsh is concerned, ‘precision’ is exactly what his business is all about.

Michael began his working life in the construction industry as a bobcat driver for Shamrock Civil Engineering Pty Ltd. But such was his enthusiasm for his chosen profession that he took it upon himself to learn almost everything there was to know about building, including bricklaying and concreting. Over the next few years he mastered the various aspects of construction and soon became a Leading Hand employed on major projects.

Three and half years ago Michael Welsh established his own company and he hasn’t stopped working since. It’s hardly surprising given that Michael has a totally professional and disciplined approach to kerbing and channelling and he doesn’t suffer fools. Michael operates with a strict

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safety first work ethic and employs his own permanent team. They are a select group of people who are prepared to do the hard yards and perform to the highest industry standards possible.

Such is the team’s reputation that these days Precision Kerbs is rapidly becoming the preferred kerbing option and apart from the Hale Street Link Project, the company has also applied its talents on behalf of Origin Alliance on the Ipswich Motorway, the Boggo Road Busway Project, RAAF Base Amberley, Northern Busway and many others. Shamrock Civil Engineering, his former employer, obviously holds Michael in high regard and still call on his talents when a project requires kerbing.

When you talk to Michael Welsh about kerbing and channelling he talks in fractions of millimetres and when on the job, pays strict attention to detail. It’s that acute level of accuracy that has made Precision Kerbs a company in demand. You can’t beat a word of mouth recommendation and there’s no doubt that such praise from those who have experienced his talents will ensure that Michael Welsh and Precision Kerbs will be in demand for a long time to come.

For more information contact Michael Welsh, Precision Kerbs on: 0403 566 086

Carpark Specialist We’re proud to be associated with the Hale St Link Alliance.

Our work included carparks and access roads to the ‘Go Between Bridge’ as well as works on Coronation Drive, Islands and Road Widening.

• Roads • Driveways • Subdivisions • Commercial & Domestic • Main Roads • BCC Standards • Code Compliant

Owner Operated - Quality Assured 44 Canopy Place, Burpengary Qld 4505

Michael: 0403 566 086 (bookings/quotes) Joy: 0419 659 210 (Admin) Fax: (07) 3888 4519 Email: precisionkerbs@bigpond.com

Australian Main Roads Construction News - Page 15

HALE STREET LINK A LANDMARK ACHIEVEMENT (Continued from previous page) structure and his allows for the path gradient to comply with equitable and disabled access requirements.

The project didn’t just involve building a bridge; it also included a two-lane viaduct on Coronation Drive over the Hale Street intersection on the north side and a significant amount of roadworks. These included the installation of signalised intersections on both sides of the River, plus toll collection systems and equipment. There was also landscaping works and environmental works as well as improvements and upgrades to utility services.

The Hale Street Link Alliance (HSLA) consisted of the principal, Brisbane City Council and four major companies. These were, Bouygues Travaux Publics, Macmahon Holdings, Seymour Whyte Holdings and Hyder Consulting.

During the construction process itself, temporary changes to traffic movement through the inner-city location were required and this was pre-empted by detailed planning and an extensive consultation process with the local community, businesses and all stakeholders.

The initial design was also changed in an effort to minimise the project’s impact on traffic flow through the area. As a result, although it had been forecasted that unavoidable delays for motorists could be up to 40-50 minutes on Coronation Drive, the amended design significantly reduced those delays.

Throughout the whole construction process careful consideration was given to traffic management, both in terms of public transport and the private motorist and there’s no doubt that this kind of proactive planning was effective in reducing the

Above: Hale Street Link under construction inevitable delays that could be caused by such a major infrastructure project.

For instance, construction of the Coronation Drive Overpass was deliberately scheduled for between November 2009 and February 2010 as traffic modelling had revealed this period to be the lowest in yearly traffic volume. The strategy worked because over the four months it took to construct the overpass, motorists endured the least possible interruption, given the huge construction task involved.

To assist the broader community, various methods of communication were employed and these included a Visitor’s Centre, special community liaison groups, a website, newsletters and SMS communications.

Beyond the Hale Street Alliance and its employees, the project provided employment for many subcontractors. But everyone involved in the project had to work to schedule and fulfil daily deadlines and most of the construction work had to be performed in a confined space. Construction crews also had to deal with the inherent dangers of working within the constant flow of inner-city traffic.

It’s therefore to the great credit of Brisbane City Council and the Alliance partners that the management of such a complex project ensured that construction was completed

so efficiently and safely. In any event a new landmark has been created and all involved deserve congratulations for a job well done.

Bluestar Civil provide multi-skilled support

B Above: Construction works on Hale Street Link Project

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The company undertakes a broad range of civil and environmental works including: • Project Management • Bulk & Detailed Earthworks • Remediation & Environmental Works • Haulage • Road Construction • Reinforced Earth Walls • Bridge Construction • Pipe Laying • Conduit Laying • Wetland Construction • Creek Diversions

Page 16 - Australian Main Roads Construction News

LUESTAR Civil Pty Ltd is one of those unique Australian companies, the kind that can stand alone or provide a variety of support services for any project. Such was the case with the recently completed Hale Street Link Project where the Bluestar team, working alongside Multifix, constructed the south side retainer walls.

However, that wasn’t the company’s only contribution. Bluestar’s workforce is multiskilled so anything is possible in a day’s work.

During the Hale Street Link Project, Bluestar laid pipes and built foundations for walk ways and access points. The company also established an on-site labour hire service, which was a particular advantage for those involved in the project. At short notice Bluestar were able to provide access to extra concreters, machine operators, steel fixers, carpenters and general trades-people when required. Bluestar were also able to provide plant and equipment including 5 to100 tonne excavators through a cross-hire arrangement.

Bluestar’s Director, David Henderson has worked for over 30 years in the construction and related industries in a variety of fields including tunneling, heavy concrete, earthworks and remediation and speaks

highly about the overall management of the Hale Street Link Project.

From his perspective the site was one of the more difficult to traverse with limited access for materials and equipment. Any work performed had to meet strict and tight deadlines and had to be performed in a confined space. However, David speaks in glowing terms about how the project managers were decisive and quick to respond to ensure that the full range of small but crucial projects continued without interruption.

David Henderson is grateful for the opportunity provided by the Hale Street Link Alliance and also, to confirm their efficient management, stated. “At no time during the project was there any compromise in quality or safety in the nine to ten months my team were involved we had no lost time injuries or incidents.”

The multi-skilled capacity of Bluestar Civil allows the company to undertake a broad range of civil and environmental projects including; project management, earthworks and remediation, haulage, road construction, reinforced earth walls, bridge construction, pipe and conduit laying, wetland construction and creek diversions.

For more information: www.bluestar-civil.com.au

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D&M - THE COMPLETE PLANT HIRE SOLUTION F

OR the last two years, no matter when the call came, whether at night or during the day, D&M Plant Hire provided men and machines for the earthworks along Montague Road and Coronation Drive for the Hale Street Link project.

Their task included challenges such as working machinery while floating on a barge in the Brisbane River, working in very confined spaces, using 22 tonne excavators in a busy urban setting and performing under tight time limits for several different supervisors.

D&M were responsible for a large majority of the earthworks on Montague Road and Coronation Drive, and according to the Hale Street Link Alliance Construction Manager, Sydney Phillips, “have proved to continually provide benefit to the project through being reliable, providing competitive rates and excellent level of service both from operators and office personnel.”

Machinery provided for the Hale Street job included small bobcats, excavators and combos ranging from 1.5 tonne through to 40 tonne excavators, tandem tip trucks and trailers, water carts, and backhoes.

D&M floated their own machinery onsite, as well as floating other machinery for the project and organising haulage for outside materials to be delivered to site.

All operators received ongoing training in machinery operation, site safety and protocols, in addition to general site induction and pre-engagement drug testing.

Projects of this magnitude can’t risk delays through equipment failure. One of the strengths of D&M is their 24-hour in-house engineering and mechanical service backup, and their ability to have any essential unique part such as specific bucket or attachment manufactured immediately to order by sister company Titan Manufacturing.

On all their assignments, D&M take great care to protect the environment.

All machinery is generally turned over every two to three years, which not only guarantees each project the best possible machines, it minimises pollution risks from oil leaks. As a company, D&M also take a responsible approach to minimising the carbon emissions from their business.

D & M Plant Hire have been in business for the past 37 years. This expansive industry experience combined with operator knowledge, mechanical staff support and the administrative staff’s ability to build rapport with clients so as to understand their needs and manage logistics to provide specific machines in tight time frames, makes D&M a preferred supplier for major projects like Hale Street Link.

Above: D&M Plant Hire were responsible for a large majority of the earthworks on Montague Road and Coronation Drive

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Some of D & M Plant Hires Services can include: • Road Works • Demolition • Precision Work • Bulk Earthworks • Sub Divisions • Building Dams • Rubbish/Fill Removal • Swimming Pools • House Footings • Railway Works

D & M Plant Hire has a large range of late model, reliable equipment to assure minimum downtime and maximum work performance.

Some of D & M Plant Hire’s machinery includes: • 1.5t–8t combos • 1.5t–40t Excavators • 900–1800mm wide Bobcats • Positrack Bobcats • Backhoes • Tippers (Tandem and Single Axle) • Truck and Dogs • Semi Tippers • Water Carts • Graders • Low Loaders • Service and Field Vehicles

As well as supplying the latest model machinery such as Kobelco, Case, Hitachi and Komatsu, D&M Plant Hire also has an extensive supply of attachments to assist you in getting the job done on time.

• Rock Breakers • Post Hole Borers • Hydraulic Rock Grabs • Pulverisers • Shears • Compaction Wheels • Trenchers • Profilers • Broom Attachments • Screening Buckets • Swamp Mats • Vibe Plate • Rippers • Spreader Bars • Tilting Batter Buckets • Heavy Duty Dig Buckets

ALL SUBURBS - BRISBANE GOLD COAST - SUNSHINE COAST Above and below: Earthworks by D&M Plant Hire

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JOB TOO BIG OR SMALL Australian Main Roads Construction News - Page 17

TIGER BRENNAN DRIVE EXTENSION NEARS COMPLETION T

HE Northern Territory Government’s Department of Construction and Infrastructure (DCI) in conjunction with the Department of Lands and Planning (DLP) can be justifiably proud of their achievement with regard to Tiger Brennan Drive. It is the largest and most significant road project in the Northern Territory’s history and will dramatically ease traffic congestion, improve road safety and reduce travelling times between Darwin and Palmerston.

Importantly, access to the East Arm Port will be dramatically improved and as the wharf is likely to play a pivotal role in Australia’s industrial growth within the Asian economy, the project will directly contribute to the trade advantages that can be gained within the region.

Apart from the obvious benefits for motorists as they travel between the Darwin CBD, Palmerston and Outer Darwin areas, it’s expected that the new road will cater for about 34,000 vehicles per day and relieve pressure on other arterial roads in the Darwin urban area, including the Stuart Highway.

Stage One is now complete and Stage Two of the extension project is well underway.

This involves the construction of 7.5km four lane dual highway to extend Tiger Brennan Drive, from Berrimah Road to the Stuart Highway. This will also include associated road works along the route. A major component of this stage is the construction of two overpasses at the Stuart Highway and Roystonea Avenue intersection, including a shared pedestrian and cyclist bridge across the Stuart Highway linking Darwin and Palmerston cycle paths.

The cost of the second stage is $101million and is funded by a shared arrangement between the Australian and Northern

a schedule that allowed the contractors to dedicate construction resources earlier than would be normal under a design and construct delivery method.

The results speak for themselves and according to Louise McCormick, Project Manager DCI. “Despite the many challenges encountered, there’s no doubt that the pre-planning made a huge difference. It allowed us to anticipate logistical problems before they occurred and act promptly and decisively as a team to coordinate a proactive response. I believe it has been a most rewarding project for all concerned.

We’ve finished ahead of schedule, within budget and with no time lost from injuries.”

INITIATIVE HAS ITS OWN REWARDS

Above: Works during Stage 1 of Tiger Brennan Drive Territory Governments. The Australian Government has contributed $63.5 million in total including $38 million for the Stage Two interchange. The project is ahead of schedule and Stage Two is expected to be completed by November this year.

UNIQUE STRATEGY POWERS RESPONSE Large infrastructure projects are never cheap but the efficiency of the design and construction process in this case has ensured that the project will deliver real value for money. One of the main contributing factors occurred in the earliest stage of the project when the Department of Construction and Infrastructure employed an innovative design and planning strategy.

By utilising the Early Contractor Involvement (ECI) delivery method, the Department were able to minimise the intensive resources usually required in the tender process of a normal design and construct delivery method. This meant that the contractors could apply their expertise to the project during the detailed design stage.

The benefits produced from that early involvement were numerous. Not least was a mutual understanding of the project logistics and the development of a realistic timetable to achieve the desired results. The ECI method also cultivated a genuine team approach between all the project partners.

This partnership would ultimately produce a high performance response to design and construction.

The ECI also achieved better integration of specific construction methodologies and motivated early acquisition of critical construction materials. It also produced

One of the other time efficient policies applied by the DCI was a value management process that ran in tandem with ongoing design and construction. As an example, there was limited time to plan the layout of the interchange; however there were several solutions available. So the key project members conducted a series of workshops to determine the best value for money solution.

The team would firstly apply a set of rules highlighting all the aims to be achieved by the interchange with an emphasis on safety.

Following discussions, these would be scored accordingly to produce a short list of solutions. The project design team would then review and refine those solutions and return them to the workshop for further evaluation. The workshop team would process the remaining solutions, reducing the list even further subject to the rule criteria.

This process would continue until ultimately it produced only one solution.

Using this method, the result reflected the best value for money solution and it was achieved in the shortest possible time. This value for money, workshop initiative was

(Continued on next page c)

Specialising in: • Marking of Roads • Car Parks • Air Strips • Sports Courts • Safety Markings on all types of surfaces • Supply and Installation of Pavement Markers

Above: Mates Sibia Babia and Daniel Good enjoying work onsite (doing a Certificate III in Civil Construction while working on the project)

PAT COLEMAN Mobile: 0438 326 685 8 Butler Place Holtze NT 0830 PO Box 774 Palmerston NT 0831 BH: (08) 8932 2880 Fax: (08) 8932 2902 admin@topendlinemarkers.com.au Page 18 - Australian Main Roads Construction News

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TIGER BRENNAN DRIVE EXTENSION NEARS COMPLETION (Continued from previous page) applied to various aspects of the project without interfering with the ongoing construction process.

BRIDGE ARTWORK WELCOMES VISITORS One of the unique features of the Tiger Brennan Drive project is the inclusion of a special and artistic ‘Gateway Entry Statement’ to greet motorists as they enter Darwin City. Located on the walls and parapets of the two bridges on the approach to the city, the artwork is based on the six northern seasons, which unlike the normal, four southern seasons, are of special significance to people who reside in the Northern Territory.

The DCI project team collaborated with the Arts Co-ordinator from Larrakia Nation

and three artists were selected to develop the featured artworks. The indigenous artists chosen for the task were Kenny Reid, Peter Browne and James Gaston.

There are two bridges on the approach to the city and it was decided that the first bridge should centre on ‘land’ themes, while the second, as you get closer to Darwin and the ocean, should reflect aspects of the sea.

Significantly this also celebrates the heritage of the Larrakia as ‘saltwater people’.

Over 30 prints were created using lino-printmaking techniques to produce the artworks to scale so they could be accommodated on the bridge superstructures. By enlarging the original artworks and using moulds they could then be incorporated into the concrete parapets of the two bridges and act as relief patterns in the concrete.

A PROJECT OF THE PEOPLE AND FOR THE PEOPLE The Department of Construction and Infrastructure implemented a number of highly original initiatives designed to involve local stakeholders and the broader community. One of these included a special Open Day when the general public were given access to the entire work site with all proceeds going to charity. Bus tours were provided including a group of tour guides, featuring engineers, trainees and important members of the project team. Children were catered for with food and drink stalls, jumping castles, dump truck and helicopter rides, sandpits - fully equipped with Tonka

Truck toys just like the real machinery on site. The DCI even had an onsite radio station keeping people up to date with music and news about the project.

The Open Day was a marvellous initiative.

DCI and the project partners deserve congratulations for their organisation and involvement in the event. At a time when rhetoric is often the order of the day in other parts of Australia, the project reveals a typical Northern Territory ‘no nonsense’ approach to business. Perhaps more importantly, it also reveals that Tiger Brennan Drive will truly epitomise the adventurous spirit of its namesake and is very much a historic project that will serve the people of the Northern Territory for a long time to come.

Above: Tiger Brennan Drive aken April 2010. This bridge now forms part of the inbound Stuart Highway lane

Above: Tiger Brennan Drive taken July 2009

Norsign N.T. the clearest sign of all M

ACMAHON’s construction of the $110 million Tiger Brennan Drive Extension, on behalf of the Northern Territory Government (Department of Planning and Infrastructure), is rapidly nearing completion and Norsign N.T. has been there every step of the way since the project began in 2008.

Back then Norsign was responsible for traffic control and road work warning signs and as the construction process has progressed, Norsign has produced the permanent regulatory and directional signs required to ensure safety for all motorists on the new extension.

The company is extremely proud of its involvement in such a landmark project and it’s a clear sign that Norsign N.T. is the preferred option for signage and it’s easy to understand why. The importance of highly visible, directional and safety signage is a critical component on every road in Australia, but outdoor signs need to withstand a variety of climatic conditions and this is where Norsign N.T. excels.

The company, established in 1987, is located in Darwin and uses cutting edge technology to manufacture an extensive range of signs for a variety of industry sectors including mining and construction, as well as signs for roads and infrastructure.

Norsign N.T. is a 3M accredited sign manufacturer and has the largest screen printing facility in the Northern territory and is equipped to complete all large format digital printing projects. Using advanced

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computerised technology, the company can manufacture both metal and plastic signs in standard configuration. The Norsign team can also manufacture signs designed to meet individual customized requirements.

The production process is highly disciplined and best practice quality is always assured and supported by the company’s QA ISO 9001 rating. All signs produced by Norsign N.T. are also manufactured to conform to international uniform standards.

Norsign’s reputation for excellence has long been established and is clearly illustrated by the proven record of long-term-reliability in all types of climatic conditions. If you want to test the durability of a sign there’s no better place to do it than in the wet and dry extremes of the Northern territory or the harsh, vast expanses of outback desert country in Central Australia.

The Tiger Brennan Drive extension is on schedule and when completed it will dramatically ease traffic congestion, improve safety and reduce travelling times between Darwin and Palmerston. It’s to the credit of Norsign N.T. that the company has played its part in the delivery of the new road. It highlights Norsign’s contribution to long list of signage requirements at the request of the Northern Territory Government and the company has clearly enjoyed and appreciated its involvement with Macmahon.

For further information on Norsign N.T. contact General Manager, Murray Jackman on 08 8947 0733 or: murray@norsign.com.au

Proud to be involved with the Tiger Brennan Drive Extension Project

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Australian Main Roads Construction News - Page 19

‘Gateway Entry Statement’ using landscape and public art to tell stories of the environment and culture of the Top End

C

ITY entry welcome statements being constructed for Darwin are using landscape and public art to tell stories of the environment and culture of the Top End. The Northern Territory Department of Lands and Planning is developing these themes as part of the greening Darwin strategy.

Stage Two of Tiger Brennan Drive part of a major highway to cater for about 34,000 vehicles travelling each day between Darwin, the satellite city of Palmerston, and surrounding rural areas - is under construction.

Two traffic bridges and a shared pedestrian and cycle bridge are part of a major interchange on Tiger Brennan Drive. They are providing opportunities to integrate urban design and artwork to welcome motorists to Darwin.

Local Indigenous artists from Larrakia Nation Art Centre collaborated with design consultant Clouston Associates to produce the artworks and colour treatments for the interchange. The art focuses on plants and animals indicative of the build-up to the Wet Season.

The first bridge encountered on the journey into Darwin is the shared pedestrian and cycle bridge.

It will feature curved steel balusters representing wind blown spear grass in the build-up.

On the vehicle flyovers, Indigenous motifs etched into concrete panels are fixed to the parapets, and can be seen by motorists as they pass under the bridges.

The vehicle bridge furthest from the Above: One of the unique features of Tiger Brennan Drive is the inclusion of a special and artistic ‘Gateway Entry Statement’ to greet motorists as they enter Darwin City

Above: The vehicle bridge closest to the sea and Darwin shows aquatic motifs such as mangrove roots - important fishing and gathering places for the Larrakia people

Above: The vehicle bridge furthest from the sea shows land oriented designs such as green ants - very active during the build-up Page 20 - Australian Main Roads Construction News

sea features land-oriented designs: • Green ants - very active during the build-up.

• Billy Goat Plum trees – flowering marks the time to hunt shrimps, prawns and crabs.

• Pandanus palms - valued for making fish and prawn traps.

The vehicle bridge closest to the sea, and Darwin, displays aquatic motifs: • Mangroves – important fishing and gathering places for the Larrakia people.

• Shrimps, prawns and crabs – caught in fish traps often made of Pandanus Palm fronds.

These artworks celebrate the Larrakia people as a “saltwater people” with connections to both the land and sea.

The totemic art will be extended to the bridge abutments, which will be painted with large images of Pandanus palms, woven baskets, traps and waterdwelling animals: crabs, mud skippers and prawns.

Installation and commissioning of the panel art has been supervised by the Department of Construction and Infrastructure.

The composition for the interchange is “Gunemeleng”, or the start of The Wet. These works will complement future plantings along the highway, defining the six seasons of the year identified by the Bininj people of Kakadu.

At the opposite end of the highway, an interpretation of “Gurrung”, or the late Dry Season, is planned for the McMinn St and Tiger Brennan Drive intersection. The welcome statement marks the entrance to the Darwin CBD and will complement a theme to be developed for the Daly St Bridge, another city gateway.

Above: Bridge workers moving unpainted panel www.amrcn.com.au

TIGER BRENNAN DRIVE EXTENSION NEARS COMPLETION SKM SHAPING THE FUTURE S

INCLAIR Knight Merz (SKM) is an employee-owned organisation, with a global network of offices supporting clients across Australia, New Zealand, Asia, South America, Europe and the Middle East.

SKM was established in 1964 and its history is rich in landmark achievements, having forged a reputation to become one of Australia’s leading engineering, science and project delivery firms.

SKM’s successful growth is illustrated by an increasing and a highly skilled workforce now moving beyond 6000 employees globally.

Of those, 4,500 are located throughout Australia. Internationally respected, SKM was the 2009 winner of the BRW Private Business of the Year (Turnover >$100 Million) award, and in 2010 the firm was recognised as the “Best consulting engineering firm (revenue over $200m)” at the Beaton/BRW Client Choice Awards.

SKM has played a major role in the strategic Tiger Brennan Road project in the Northern Territory. As a key member of the team, alongside Macmahon and the NT Department of Construction and Infrastructure, the company participated in a unique design and construct strategy.

Referred to as the Early Contractor Involvement (ECI), it enables the project participants to combine their skills in a proactive manner at the outset to ensure greater efficiency in design and construction. It was the first time that an ECI had been incorporated in the Northern Territory and the outcome was highly beneficial in producing a quicker response time and a much improved, overall project economy.

SKM’s design team for the project was

predominantly Darwin-based with inputs from SKM offices in Sydney, Perth, Kuala Lumpur and Melbourne. The SKM design team was responsible for all design aspects of the 7.5 kilometres of four-lane highway and grade separated interchange.

The interchange comprised a pedestrian and cycle-bridge as well as two, three lane, three span road bridges. This project will extend Tiger Brennan Drive from Berrimah Road through to the Stuart Highway, including a new signalised intersection with Tivendale Rd. This improvement will divert heavy traffic from Wishart and Berrimah Roads, allowing motorists a less congested journey. Two overpasses at the Stuart Highway end of the project will also be built to provide a free-flowing interchange without traffic lights.

The $90 million Tiger Brennan Drive Extension project is the largest and most significant section of the $110 million East Arm Port Access Route being funded by the Australian and Northern Territory Governments to improve traffic flow to East Arm Port and Palmerston.

It is one of the most significant infrastructure projects in the Territory’s history and will improve road safety, reduce travelling time and ease traffic congestion for the 34,000 vehicles travelling between the rural area, Palmerston and Darwin each day.

It will also improve and provide more direct access to East Arm Port. The project not only caters for the future growth of Darwin, but also makes provision for projects such as the rapid transit corridor and Weddell interchange.

SKM’s project expertise stretches across a

Above: Shared pedestrian/cycle bridge with spear grass balusters. The white posts will be replaced with cast aluminium sculptures full range of market sectors including power and energy, building and infrastructure, mining and metals, water and the environment. SKM provides services in transport and urban infrastructure, defence and government, as well as environmental planning and management, social infrastructure and program management.

The firm’s range of skills also extends to information technology and communications, asset management, project management, risk analysis and strategic consulting.

SKM also provides specialised training programmes including safety inductions and project leadership, and aims to embed sustainability in all project design and

delivery.

SKM’s purpose is to deliver a positive and enduring impact on the world. In that regard, the firm works with clients to provide independent technical, strategic and commercial advice as well as project delivery skills. The firm’s success has been built on its ability to develop and maintain longterm, mutually beneficial relationships with a broad range of clientele both in Australia and overseas.

SKM will continue to build on its success by designing and developing innovative projects for clients, which contribute to the future growth and prosperity of communities around the world.

Above: The pedestrian and cyclebridge that provides grade separated access from the City of Palmerston to the Regional Cycleway network

Above: The pedestrian and cyclebridge under construction www.amrcn.com.au

Australian Main Roads Construction News - Page 21

Another Landmark Project - Mandurah Entrance Road A

LMOST one year after delivering the State’s single largest infrastructure project, the New Perth Bunbury Highway, Southern Gateway Alliance (SGA) is on track to opening another landmark project, the Mandurah Entrance Road (MER), ahead of schedule.

The $155 million MER project is funded by both the State and Federal Governments and is the second alliance-delivered contract for SGA, which comprises Leighton Contractors, WA Limestone and GHD, working in conjunction with Main Roads Western Australia.

Construction of the MER commenced in September 2009 and is currently around 90% complete. When it is opened to traffic in the coming months, the 6.5 kilometre, 4 lane dual carriageway will provide motorists with a direct link between Mandurah and the Kwinana Freeway extension in Stake Hill.

Approximately 600,000 cubic metres of material was utilised from the road reserve for the project’s earthworks, while an additional 100,000 cubic metres of sand was extracted from the site and placed at the future Road B reserve in the MER’s immediate vicinity.

More than 700,000 square metres of paving material was imported to construct the road, which comprises varying layers of subbase, basecourse and deep lift asphalt.

Machine guidance technology was utilised in both earthworks and paving operations for greater efficiency. Data was rapidly transmitted between the field and design office, and was able to be used up to finished subgrade, subbase and base course surfaces.

The MER straddles the passenger railway line for approximately 4 kilometres and is separated by extensive retaining walls.

The Mechanically Stabilised Earth

SPIERS

Above: Mandurah Entrance Road project site, looking north (MSE) walls, comprise 3575 concrete panels measuring 2 metres x 2 metres in height and approximately 160mm in thickness. Each panel was placed using an excavator and on average, between 50 and 80 panels were placed each day.

The MSE wall features a painted design

by a local artist, and is one of the largest painted artworks in a transport context in the world.

Just over 4020 linear metres of TL5 Concrete slipform barriers have also been installed adjacent to the railway line for added motorist safety.

The barriers are cast using a unique concrete design mix, which allows the barrier to maintain its shape without using formwork. The kerbing machine used was imported from the United States and the mould is specially designed for the type of barrier.

(Continued on next page a)

HAULAGE & EARTHMOVING

SEMI TIPPER, SIX WHEELER, LOADER & BACKHOE Positracks with numerous attachments, Loader has Bucket/Jib and Forks, Mini Excavator • House Pads • Clearing • Firebreaks • Driveways • Drainage • Contract Work • Limestone • Sand • Mulch • Garden Supplies • Rural Needs

Murray Spiers: 0412 494 345 Baldivis Page 22 - Australian Main Roads Construction News

Above and below: Part of the painted retaining wall, one of the largest painted artworks in a transport context in the world

Above: Mandurah Entrance Road and Kwinana Freeway interchange, looking west

Spiers Haulage and Earthmoving Pty Ltd

O

NE of our first projects was with the Southern Gateway Alliance in March 2007, where we were involved with haulage and earthmoving for the New Perth Bunbury Highway. Initially over the first two years we conducted bulk haulage operations moving raw materials for the project. As the project progressed we expanded our involvement into earthmoving using a fleet of Positracks, Loaders and Mini Excavators. Over the length of the project we were involved in a variety of activities but our main focus was on the finishing works such as completing drainage and rehabilitation works We again joined forces with the Southern Gateway Alliance on Mandurah Entrance Road backfilling tunnels on Parklands Tunnel and Fremantle Tunnel. Once the rail tunnels were completed we moved onto landscaping and rehabilitation works.

These works continue today in the form of a maintenance contract on remedial works.

During the course of these works we purchased attachments for our Positracks to assist Main Roads WA in further rehabilitation works on both Mandurah Entrance Road and the maintenance of both the Kwinana Freeway extension and the Forrest Highway. Both of these roads form the New Perth Bunbury Highway.

The project was highly beneficial for Spears Haulage and Earthmoving because it provided an opportunity for the company to diversify and to prove that we could respond at short notice to any demands placed upon the company. We pride ourselves on our ability to adapt to any project requirement, to work unsupervised and to complete the task required to the highest of standards.

www.amrcn.com.au

Another Landmark Project - Mandurah Entrance Road (Continued from previous page) SGA worked with the Public Transport Authority to construct two rail tunnels in the earlier stages of the project, which was by far the most intensive part of the ultimate construction program.

A 220 metre long tunnel was constructed in Parklands to enable the northbound carriageway of the MER to cross to the eastern side of the railway line, while the existing tunnel at Mandurah Road was extended by 170 metres to enable a roundabout to be constructed.

The Parklands tunnel features 220 precast concrete arches and 15 headwall panels, which were manufactured in Perth and transported to site. The tunnel extension at Mandurah Road was constructed using 144 precast concrete arches and 4 headwall panels. Both tunnels were constructed concurrently, over three weekend rail shutdowns.

The MER ties in with Mandurah Road via a unique two lane roundabout, which has a centre island of approximately 56 metres in diameter. The roundabout comprises three legs including the MER and Mandurah Road both north and south bound, as well as a stub end for Exchequer Road, which is to be completed by council.

At the northern end, the MER ties in with the Kwinana Freeway extension via a diamond type interchange that was created as part of the New Perth Bunbury Highway project.

Minor connections have been created at Education Drive to service the Peel TAFE

Campus, as well as at Stock Road north for the adjacent quarry.

Almost 2 kilometres of limestone walls have been erected at various locations to mitigate noise generated by MER traffic.

The noise wall construction presented a challenge for crews, as the majority of the wall sits on a large hill, meaning the wall had to be stepped 135 times, or every 6 metres.

The limestone blocks that make up the walls are 1 metre x 0.35 metres x 0.35 metres and weigh approximately 184 kilograms each. The average height of the completed noise wall is 3.10 metres.

The sealed shoulder of the MER provides a cyclist amenity and a large underpass has been erected to enable safe passage for pedestrians and fauna between Marlee Reserve and Black Swan Lake in Parklands.

Smaller underpasses and 7 kilometres of wire fencing have also been provided to encourage fauna to cross under the road.

The entire project site comprising 30 hectares of land has been rehabilitated using 100,000 native seedlings and 130 kilograms of native seed.

A series of walking trails have been constructed and nine artificial nesting boxes known as “Cockatubes” have been installed in the adjacent Marlee Reserve as legacies for the local community.

SGA continues its outstanding safety record, having completed around half a million man hours on the MER project to date, without a Lost Time Injury (LTI).

Above: Asphalt works at the Mandurah Road roundabout

Above: Machine guidance technology was used to construct the road

Above: Constructing the Parklands tunnel

Site and Postal Address: 1310 Ludlow-Hithergreen Road, BUSSELTON WA 6280

08 9753 2136 08 9753 2050 0428 931 798 0428 522 909

Phone Fax Terry Darryl

info@geospread.com.au

Geo Spread specialise in: Spreading mulches, topsoil, compost, fertilizers for rehabilitation/landscaping.

Other services include: Land clearing; Timber downsizing; Mulching Bulk Cartage of Mulches and Compost.

Above: Constructing the Mandurah Road tunnel www.amrcn.com.au

GeoSpread’s contribution to the SGA Project was Topsoil respread for the purpose of rehabilitation on embankments and medians on the new alignment.

Australian Main Roads Construction News - Page 23

Bypass surgery $

331 million and 13,250 tonnes of concrete were just two of the ingredients required to build a new freeway to carry some 70,000 cars a day through Melbourne’s outer west.

The 9.3km Deer Park Bypass was a major project funded by VicRoads and the Commonwealth Government, connecting the Western Ring Road in Melbourne’s Sunshine West to the Western Highway in Caroline Springs.

As well as four lanes of standard road, the project, overseen by Leighton Holdings, called for freeway interchanges, both a rail and a road overpass, an underpass, noise walls and a new shared-use path for pedestrians and cyclists. And, in keeping with Melbourne’s reputation as Australia’s style capital, aesthetics were important, too.

Located on volcanic grassland plains and punctuated by industrial estates, grazing land and expanding suburbs, the design integrated built form and colour into the landscape, using large scale, sculptured barriers and other strong elements to create a striking visual identity.

The initial precast elements of the project called for the supply of 128 prestressed precast T-Roff bridge beams for the bridge structures.

After a lengthy selection process, the contract for their supply went to Westkon

Precast, which was also able to fulfil other project requirements, supplying over 100 very heavily reinforced (N-Bar) wing wall and fender wall panels, close to 1000 parapets, on and off-structure barriers and half-barriers.

Production of the 128 prestressed precast concrete beams, weighing between 30 and 100 tonnes each, began in November 2007 and was completed by September 2008. During the same period another 349 prestressed precast concrete beams for another Leighton Holdings project were also being cast.

Stressing beds capable of holding 1500 tonnes each were used to manufacture the beams – some up to 1800mm deep and weighing 96 tonnes.

The moulds were enclosed with automatic temperature controlled hot and chilled water pipes, to ensure high early strength enable demoulding the following day.

The beams were removed from the moulds using portal cranes, which also offered storage space for over 100 of these massive beams.

Testimony to the smooth running of the project was the fact that it was completed eight months ahead of schedule, with all parties – including many Victorian motorists – pronouncing themselves more than happy with the results.

Deer Park Bypass

Wallbrink & Associates

Client: VicRoads & the Commonwealth Government

Engineer: GHD Precast manufacturer: Westkon Precast

Chief contractor: Leighton Holdings for VicRoads

(Article courtesy of National Precast Concrete Association Australia.

Website: www.nationalprecast.com.au)

Architect: Peter Elliott Architect + Urban Design Landscape Architect: Steve

Saw Formwork on the edge of tomorrow

T

(Nth QLD)

Page 24 - Australian Main Roads Construction News

HE introduction of precast concrete many years ago revolutionised the construction industry and although that dramatic change to the ‘off-site’ construction process has now become a distant memory, both the production methods and the versatility of precast formwork continues to evolve.

One particular company that leads the way in advanced construction techniques in concreting, formwork and tilt panel production is SAW Formwork Pty Ltd. Amongst its many talents, the company can also perform on-site or off-site panel production for builders and developers, execute detailed earthworks and create ‘super flat’ concrete floors.

Headed by founder and Managing Director, Stephen Wollschlager, the company is rapidly developing a reputation as the preferred option within the construction sector, particularly in Queensland.

Although SAW Formwork is a relatively young company, its state of the art, proactive design approach has already been recognised by ANCON Beton Pty Ltd, a leading Australian and Asian consultancy.

ANCON Beton specialise in advanced concrete technology and in recognition of SAW Formwork’s high quality workmanship, has now placed the company on a select list of Australian preferred concreters.

Closer to home, in the company’s Townsville facility, the reasons why SAW Formwork is rapidly becoming a dynamic force in the world of advanced concrete solutions are obvious. Stephen Wollschlager

cut his teeth on concrete formwork long before he established his business, so he knows his product, the construction industry and the concrete solutions that will be required by tomorrow’s builder.

But what is pleasing to note, in a company faced with the typical challenges that arise when soaring beyond the early stages of growth, is Stephen’s holistic approach to business. It’s reflected by the way his dedicated team approach any project and it can be measured by the enthusiasm of the apprentices learning the trade on his factory floor. It’s a serious quest for the most technically advanced concrete solutions, yet it’s all done in a calm environment of discipline, with an emphasis on best practice training, research, safe work practices and the highest standards of quality. SAW has a Quality Management System in place which has been certified as complying with the ISO9001:2008.

SAW Formwork is an exciting company and there’s no doubt that it’s a company clearly focused on the concrete construction needs of today and more importantly, tomorrow.

There’s also no doubt that we’ll be hearing a lot more about Stephen Wollschlager and his team at SAW Formwork. When you’re standing on the edge of tomorrow, you can almost see the future and know that the best is yet to come.

FOOTNOTE: SAW Formwork, as a manufacturer of precast concrete elements, is certified as a Registered Supplier of Precast Concrete Elements for Main Roads.

www.amrcn.com.au

Lateral thinking for fast track result Before

R

EPLACING an ageing rail underbridge to challenging specs in a super short 60hour timeframe called for lateral thinking and some highly coordinated teamwork.

The old, low clearance bridge in question was a 1940s timber ballast top spanning the Yass Road in Queanbeyan, NSW. The new bridge was to have both an increased 20 metre span to accommodate future road widening, and a higher clearance – increasing from its previous 4.1 metres to a desired 5.3 metres – but with no possibility of either lowering the road or raising the tracks above to achieve it.

Solving this problem required intelligent design and use of materials, and a variety of precast components filled the bill.

The design solution The designers opted for use of an external ‘I’ beam design – but that was the only standard part of the solution.

To maintain the existing rail level, a modified precast cross deck section was conceived, with use of 8 no. 1200mm diameter bored piles located outside the existing bridge structure, along with cast in situ columns to form the sub-structure. The headstocks and abutment beams were cast as high as possible under the existing bridge, while concrete packing beams gave the new bridge greater clearance.

The need for speed The need for speedy execution led to the use of a multi-contract approach. This reduced lead time – but also required a high level of co-ordination and teamwork between contractors.

Works were broadly divided into the sub-structure, site works and the precast superstructure, which was in turn divided in two.

One contract, for the conventional requirements such as standard rail girders, was awarded to Structural Concrete Industries for casting at its Teralba factory.

The contract for the specially designed

components – the 20 metre girders and the cross decking – went to Waeger Precast.

Minimal rail closure “Building complex 20 metre beams is a big ask in any project and was a very satisfying milestone for us,” says Karl Waeger, who oversaw the design and manufacture of the beams and decking.

“For the decking, although the rails had to be set low, the girders had to be set high.

We used conventional precast principles and adapted them to create the cross decking with a small drop-down step in which to set the rails.

“It all came together exceptionally well, with all the components and contractors working to plan. We opened the road and the railway again within 60 hours and with a brand new bridge to show for it. It was a real achievement.”

Rail Bridge - Queanbeyan NSW Client: Australian Rail Track Corporation Design: Opus International Consultants, Sydney Site works: Bridging Australia and Track Australia Precast manufacturers: Structural Concrete Industries for conventional rail girders; Waeger Precast for the main post tensioned girders, infill panels and cross decking

(Article courtesy of National Precast Concrete Association Australia.

Website: www.nationalprecast.com.au)

After

Precast Concrete today’s cost effective solution T

HE ability to pre-cast concrete structures is a huge advantage for the modern construction industry but the practice first saw the light of day in ancient Rome. Back then the Romans used moulds filled with concrete to build their aqueducts and tunnels. More recently in 1905, the man responsible for inventing the football goal net, engineer John Alexander Brodie, pioneered the use of precast panelled buildings and from that point on the use of pre-cast concrete structures became common building practice around the world.

When Graham Appleton and Niall Werner combined their 30 year extensive pre-casting experience to establish Specialty Precast in Queensland they wanted to go one step further. To provide a service that could produce high quality, precast concrete products to allow greater flexibility in design applications.

Graham and Niall thrive on a challenge when working with concrete and no job is too difficult. They have provided thousands of precast concrete solutions over the years and have a wealth of experience acquired during their careers in senior roles within the precast industry. Their company can supply a wide range of precast concrete products for civil contractors, engineers, construction developers and building contractors who require high quality structural and architectural precast concrete solutions.

The company operates from a very modern, 1200 square metre undercover factory in Virginia complete with a pair of 12.5 tonne overhead cranes for the heavy lifting. The ability to work undercover

means that if there’s an urgent deadline to meet then the production team can work in almost any weather.

Specialty Precast employ a skilled workforce to ensure that, not only are all client requirements quality assured, but that if there’s a need for innovation to solve an unusual concept design they have the expertise to perform the task. By utilising efficient precast concrete manufacturing methods, coupled with efficient materials handling systems, quality is constantly monitored and maintained throughout the process.

The benefits of the company’s precast concrete system are passed on to customers with guaranteed delivery and shorter construction times. The company can also save a builder time and money by completing the precast solution off-site and then delivering the structure to the site at a time to suit the builder’s schedule.

Specialty Precast has the resources and expertise to meet the most demanding situations and can provide effective solutions for a wide range of building projects. These include manufacturing precast panels for multi-story buildings, columns and beams, culverts and custom architectural precast.

The company also manufactures concrete boat ramps, retaining walls, walkways, signs, monuments and precast concrete structures for a variety of applications.

There’s no doubt that Graham and Niall could teach the Romans a thing or two about today’s modern techniques used in the manufacture of precast concrete solutions.

Tel: (07) 3265 6626 www.specialtyprecast.com.au

Quality supplier of precast concrete product solutions for civil construction, building and architectural projects.

• Columns and beams • Panels

• Retaining walls • Boat ramps / toe planks

• Road bridge components

Contact Graham Appleton or Niall Werner

Tel. 07 3265 6626 www.amrcn.com.au

www.specialtyprecast.com.au

Australian Main Roads Construction News - Page 25

NSW ROAD SERVICES DIRECTORY Listed on this page is a comprehensive representation of NSW companies providing a range of professional services for Road Infrastructure Projects throughout the State and is also a recommended guide to NSW Civil Engineering Companies, NSW Local Government Councils, also the Road Traffic Authority, for the services they provide to projects of all sizes.

STABILISING & PAVING

ASPHALT SERVICES

Sub-Divisions Hard Stand Areas Sporting Courts

BORAL Asphalt has the resources & capability to service major infrastructure projects involving asphalt pavements.

Roadways RTA Councils Mines

Weโ re also experienced & resourced to carry out XPSLT UISPVHIPVU UIF 4PVUI 1BDJรถD 3FHJPO

Private & Government Contractors

We have a range of dedicated professionals and the plant and equipment to service the challenging demands of major projects.

We also have the backing of the combined resources of Boralโ s Australian Construction Materials.

Services include:t 4QSBZ TFBMJOH XPSLT t 4QFDJBMJTU UFDIOJDBM TFSWJDFT t 1BWFNFOU NBJOUFOBODF t 1BWFNFOU SFIBCJMJUBUJPO

Contact Rob McGuire:- rob.mcguire@boral.com.au ph: (07) 3268 8011 fax: (07) 3268 1071 mob: 0401 896 461

In-Situ Stabilisation

Asphalt Paving & Repairs

Excellence Professional Organised XXX CPSBM DPN BV

Safety www.accurateroadrepairs.com.au p 02 4942 6100 f 02 4942 6111

STEEL FIXING SERVICES

CIVIL CONTRACTORS

QUALITY STEEL FIXING Servicing the Civil Construction Industry since 1988 โ ขLoaders โ ขSide Tippers โ ขBatch Plant โ ขTrailers โ ขFlo-con โ ข Tippers โ ข Aggitators โ ข Water Truck โ ข Low Loader โ ข Excavator Brad Pemberton 0412 325 364 Phone 6655 5026 ~ Fax 6655 3027 bpecontractors@yahoo.com.au

EARTHMOVING SERVICES

BOWSMARK Earthmoving and Plant Hire ABN: 78 003 312 507

Phone 02 4987 2999

Fax: 02 4987 2988

peter@bowsmark.com

Equipment: 3t to 20t excavators, 3.5t to 12t rollers rigid tippers, skidsteer loaders, laser level, rock hammers, augers Specialising in: Excavations, pipelaying, clearing, rock revetment, all site preparation, bulk and detailed excavation.

Bowsmark focuses on safety and taking care of the environment while delivering excellent service to their clients.

LINEMARKING SERVICES

Sydney โ ข Roads Wide โ ข Bridges โ ข Freeways Experienced & Reliable

0422 896 803 Reliable Steel Fixing Bronte

SWEEPING SERVICES

ECONOMY SWEEPERS PTY. LTD. Supplier of Road Sweeper Services to the RTA, Councils & Major Construction Companies throughout NSW โ ข Road Sweepers โ ข Pedestrian Sweepers โ ข Ride-On Sweepers โ ข Water Carts

(02) 4942 4999

24hrs, 7 days a week

TEMPORARY WORKS ENGINEERING

Pike Engineering Pty Ltd Office: 111 Denniston Ave, Guildford West NSW 2161

Phone: 0410 664 396

Email: info@jrlinemarking.com.au Weโ ll quote on any job, from small to large projects, simply pick up the phone and call Joe on 0410 664 396. Weโ ll even come out to your site to measure up with you.

www.jrlinemarking.com.au

SAFETY BARRIER SERVICES

PH: (02) 4227 6119 MOB: 0419 261 858 PO Box 362, Fairy Meadow NSW 2519

TRADE SERVICES CONTACT

ARMCO BARRIERS PTY LTD North Queensland (Whitsundays) Office PO Box 259 Airlie Beach, Qld, 4802 Ph: 0427 760 110 Fax: 07 5597 1611 Free Call: 1800 808 619 www.armcobarriers.com.au Page 26 - Australian Main Roads Construction News

Advertise Here Call (07) 5492 6740 www.amrcn.com.au www.amrcn.com.au

QLD ROAD SERVICES DIRECTORY

Listed on this page is a comprehensive representation of Queensland companies providing a range of professional services for Road Infrastructure Projects throughout the State and is also a recommended guide to Queensland Civil Engineering Companies, Queensland Local Government Councils, also Main Roads Queensland, for the services they provide to projects of all sizes.

ASPHALT SERVICES

ROAD-BASE PAVING AUSTRALIA-WIDE SERVICE

BORAL Asphalt has the resources & capability to service major infrastructure projects involving asphalt pavements.

Leaders in road-base paving for the civil construction industry

We’re also experienced & resourced to carry out XPSLT UISPVHIPVU UIF 4PVUI 1BDJÜD 3FHJPO

• Superior “ride-abilityâ€? • Increased production • No trimming required, therefore no wasted material • More efficient when working within time constraints of cement treated products

We have a range of dedicated professionals and the plant and equipment to service the challenging demands of major projects.

We also have the backing of the combined resources of Boral’s Australian Construction Materials.

Services include:t 4QSBZ TFBMJOH XPSLT t 4QFDJBMJTU UFDIOJDBM TFSWJDFT t 1BWFNFOU NBJOUFOBODF t 1BWFNFOU SFIBCJMJUBUJPO

Road-base paving machines for: • Highway construction • Motorway upgrades • Airport runways & taxiways • Road tunnels

Contact Rob McGuire:- rob.mcguire@boral.com.au ph: (07) 3268 8011 fax: (07) 3268 1071 mob: 0401 896 461

XXX CPSBM DPN BV

CRANE SERVICES

• Hard stand areas • Railway formations & ballast • Sub-divisions • Post-flooding repair work

Ph: 02 4871 1000 Mob: 0438 435 558

www.beaumontstabilising.com.au

SAWING & CUTTING SERVICES SUNSHINE COAST

CONCRETE & ASPHALT SAWING ‘Prompt, Professional Service’ ALL YOUR SAWING & DRILLING NEEDS

Floor & Wall Chasing

Hydraulic Equipment

Asphalt Sawing Floor Grinding Core Drilling Soff Cut

Expansion Joints Concrete Sawing Hand Sawing

Central Park Drive Yandina QLD 4561

Fax: (07) 4572 7154

EARTH WALL SERVICES

(07) 5446 7900 24 HOURS 7 DAYS

Wall Sawing P.O Box 367 Yandina QLD 4561

suncon@bigpond.net.au

SWEEPING SERVICES

We pride ourselves on the quality of walls installed and the safety systems we implement to ensure Safety and Quality are at the forefront of our work crews. This ensures that no matter the size of project our clients receive the same standard of performance.

(07) 5594 5386

www.6pconstruction.com.au GUARD RAIL & BARRIERS

TRANSPORT SERVICES

ONTIME GUARDRAIL FOR ALL YOUR GUARDRAIL & BARRIER REQUIREMENTS

0417 333 113 STEPHEN MILLINGTON

stephen@ontimeguardrail.com

PILING & ANCHORS

TEAM

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Drilling, Anchoring, & Shotcrete Specialists

Call (07) 5492 6740

Multi-strand Anchors, Rock Bolts, Soil Nails

Ischebeck Self-drilling Anchor System Shotcrete & Concrete Pumping Drains, Inclinometers, Micropiles, Bored Piers Grouting, Stressing, Bar Testing

www.amrcn.com.au

TRADE SERVICES CONTACT

Phone - (07) 3888 6775 www.teamra.com.au

www.amrcn.com.au Australian Main Roads Construction News - Page 27

M80 Ring Road Upgrade will improve 38km Western and Metropolitan Ring Roads HE M80 Ring Road Upgrade will improve the 38km Western and Metropolitan Ring Roads, from the Princes Freeway at Laverton North to the Greensborough Highway at Greensborough. The Victorian and Australian Governments are jointly funding the $2.25 billion upgrade, which is expected to take more than 5 years to complete.

The upgrade involves a minimum of three through lanes in both directions for the entire length, additional lanes between some interchanges to improve safety for traffic entering and exiting the freeway, and installation of electronic systems and devices including ramp signals to manage traffic flow.

The upgrade will improve safety, ease congestion, reduce travel times and improve reliability, especially during peak periods.

To minimise the impact on road users, the M80 Ring Road will be upgraded in sections, with the most congested sections being worked on first.

T

Tulla Sydney Alliance (TSA) In July 2009, a partnership between VicRoads, Thiess, Parsons Brinckerhoff (PB) and Hyder, referred to as the Tulla Sydney Alliance, was created to deliver the first section of the M80 Ring Road Upgrade between east of the Calder Freeway and Sydney Road.

Major construction on this first section started in December 2009 and is scheduled for completion by the end of 2012.

Works have started on the Tulla Sydney Alliance section between:

• Pascoe Vale Road and Merlynston Creek, Glenroy • Calder Freeway and Airport Drive, Keilor Park • Airport Drive and east of Tullamarine Freeway, Tullamarine • East of Tullamarine Freeway to Pascoe Vale Road, Glenroy.

TSA Project Summary: • Upgrading the section of the M80 Ring Road to a minimum of 3 lanes in each direction and up to 5 lanes in some locations • Generally, widening the existing carriageway in the centre median with some widening on the shoulders • Widening of the Steele Creek Bridge and Merlynston Creek Bridge in the centre median • A new ramp from Tullamarine Freeway south bound to the M80 Ring Road Altona bound • Removal of the existing ramp from Tullamarine Freeway south bound to the M80 Ring Road Altona bound • Additional lanes between Tullamarine Freeway interchange and Pascoe Vale Road that are dedicated to specific destinations • Changes to the design of some of the existing ramps to improve safety • Construction of a new bridge over Moonee Ponds Creek for Greensborough bound traffic. This new bridge will be next to and higher than the current road • Improvements to the east bound exit ramp at Sydney Road, and introduction of a second right turn lane

Above: Western Highway to Sunshine Avenue Section • Introduction of Intelligent Transport Systems including a Lane Use Management System, Variable Speed Limit Signs on gantries, Variable Message Signs, CCTV cameras and ramp signals on entry ramps throughout the length of the project.

Western Highway to Sunshine Avenue The second section of the M80 Ring Road to be upgraded will be from the Western Highway to Sunshine Avenue, St Albans.

The first contract for $31.8 million has been awarded to BMD Constructions for

Above: Tulla Sydney Alliance (Calder Freeway to Sydney Road) Section highlighting works are underway Page 28 - Australian Main Roads Construction News

a portion of works between Furlong Road and Sunshine Avenue, with construction to commence by mid 2010.

Improvements will include two extra lanes in both directions including widening of the bridge over Furlong Road to improve traffic flow.

The next contract for Western Highway to Furlong Road is currently out to tender.

Planning works VicRoads is currently carrying out planning and preconstruction activities for future sections of the M80 Ring Road.

Above: Tulla Sydney Alliance (Calder Freeway to Sydney Road) Section www.amrcn.com.au