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Skytrain: Delivering for Hanson

Slide 1 North West Rail Link – John Hewitt 25/08/15

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Summary – NWRL SVC Project Works

• 4.6 km of precast segmental viaduct, 450 piles, 120 piers, 1,200 segments, 2300 parapets

• 230 metre cable-stayed bridge over Windsor Road at Rouse Hill – “An impressive structure set to become a distinctive local landmark”

• Station platforms • 3 Super T bridges

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North West Rail Link

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Skytrain Contract $340 million contract awarded to ISJV on 17th Dec 13. Involves building a 4 km skytrain structure between Bella Vista and Rouse Hill, along with other surface works like bridges, embankments and railway cuttings. Skytrain contract is one of three major contracts for the construction and operation of the North West Rail Link.

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NWRL Project Team

Client: Transport for NSW (TfNSW) Contractor: Impregilo Salini Joint Venture (ISJV) Design: SMEC

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Impregilo Salini (ISJV)

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Proportions considered • Width and depth ratios, edge design and column

supports to ensure its appearance blends in with the environment

Sustainability initiatives • Minimise the use of resources/materials - have a low

carbon footprint Rail infrastructure elements • Incorporated into the design holistically and be able to

be maintained – such as acoustic sound walls, downpipes and lighting.

Design Principles

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Environmental • Conservation of resources

Social • Individual and community wellbeing and safety

Economic • Economic prosperity and productivity

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Transport for NSW definition of sustainability

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Piling work and excavation - Concrete piles form the foundation of the Skytrain structure.

Pier construction - Erecting piers to support the precast box girders that will provide the overall support for the Skytrain structure. Girder installation - Installing precast box girders that will be joined together to create spans from pier to pier.

Parapet installation - Installing a parapet as a safety barrier for staff working on the Skytrain at the outer edge of the girder and be used to minimise noise impacts

Construction

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Video – ISJV Tender Submission

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Supply all concrete: Circa 80,000m³ concrete: • 38,000 m3 for precast viaducts – Mulgrave batch plant • 35,000m3 ready mix concrete – Metro Concrete Supply all precast units: 4000 precast elements: • 2300 Precast parapets • Super T’s • Station platforms Lease: 22,000 m² at Mulgrave for approximately 2 years (no labour) Supply: 3000 m³ of gravel pavement Mulgrave plant: ISJV to fund all new plant assets and improvements

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ISJV / Hanson Agreement

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Mix Designs

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• Use AS3600 Special Class concrete and produce a consistently light colour concrete through use of cementitious material and aggregate only. No pigments or applied surface finishes.

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Urban Design Requirements

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• Achieve an Infrastructure Sustainability Council of Australia “Design” rating score of at least 65

• Use blended cement that contains waste industrial products such as flyash and ground granulated blast furnace slag

• Produce low carbon concrete • Achieve a minimum 1 point under the Green Star

Mat-4 concrete credit criteria for Portland cement, aggregate and water

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Sustainability Requirements

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The mix water for all concrete used in the project to contain at least 50% captured or reclaimed water (measured across all concrete mixes in the project) ISJV B80 specification added a new clause 2.7…all mixing water shall be tested daily at each source of supply for Chloride,Sulfate, Total Alkalis and Total solids

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Water

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TAFE NSW – Western Sydney Institute Precast Pre Employment Training Program to train the long term unemployed to be ‘Job Ready’ This is a requirement of TfNSW.

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Labour

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• High early strength for segments: 15MPa @ 14 hours, 26MPa @ 38 hours, and 59MPa @ 28 days

• Colour consistency throughout all elements • Sustainability objectives • Certainty of supply of materials • Some B80 mix designs have a very short lead

time from discharge to site – slump control

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Concrete challenges

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TfNSW preliminary construction program

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Concrete delivery schedule

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Mulgrave – ISJV leased land

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Construction phase

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New Factory Layout

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SHORT LINE - With this method, the form is stationary while the

segments move from the casting position to the match casting position

and then to the storage. This method requires a very accurate placement

of the match cast segment, for this reason a geometry control is used.

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Curing of the match cast segment just cast

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We made it happen!

10,000 m³ fill

decommission hollowcore

facility

remove batch plant relocate

crane

remove hollowcore

product

new carpark & amenities

new batch plant

council approvals

130 new employees

new workshop

new noise wall

contracts

concrete mix

approvals

agitators

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• Safety • Batch plant commissioning date • Ordering system for Precast • Invoicing • $1.2M Performance Bond – Continuity & Timely

supply • Quality • Brand exposure

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Challenges

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100m³/hr concrete batching plant. Upgrade of services. One level hard stand site. Two gantry cranes +. Relocated gantry crane. 7000 m² covered casting facility. Amenities for 130 workers. Extra heavy vehicle access. New maintenance workshop Noise wall 24hr manufacturing licence

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Legacy

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The first segment and pier

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Exciting times

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The Future for Hanson Precast?