eastlink - larger than life - cimic group · eastlink - larger than life. cranbourne train stabling...
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VOLUME 1 2008THIESS
Airport LinkInnovative designs a winner
Project ArkLandmark 21 level project
BundambaNation’s largest recycled water scheme
EastLink - larger than life
Cranbourne Train Stabling and Station UpgradeLocation: Melbourne’s outer eastValue: $37 millionThe project will provide new train stabling facilities and upgrade to Cranbourne Railway Station and bus interchange. The project is the first stage of the broader Dandenong Rail Corridor Project, the largest single commitment in the Victorian State Government’s 10 year $10.5 billion long-term public transport plan.
Dawson AllianceLocation: 140 kilometres south-west of GladstoneValue: More than $500 millionThe Dawson Alliance project is the largest design and construct contract awarded in the Australian coal industry to date and forms a significant part of Anglo Coal America’s (ACA) $1 billion upgrade. Originally formed to design, construct and commission a new Coal Handling and Processing Plant (CHPP). It now includes bulk earthworks contract, a turnkey project for the design, construction and commissioning of a 27 kilometre overland conveyor system, as well as the construction and commissioning of three receival stations and a new 2.5 kilometre northern overland conveyor.
Project snapshot
Prominent HillLocation: South AustraliaValue: $800 millionThe contract with client Oxiana involves setting up mine infrastructure including construction of the workshop, offices and fuel facilities; and undertaking mining activities on site for six years. Following the initial set up, mining commenced on schedule in October 2006. Now in full swing, Thiess is currently mining 3.5 million bank cubic metres a month.
Calder Freeway UpgradeLocation: Melbourne’s outer westValue: $53.5 millionThe project will see Thiess design and construct the Harcourt North section of the Calder Freeway. The project comprises a 6.5 kilometres dual carriageway between Faraday and Ravenswood, inclusive of three super-T bridges, grade separations, wildlife crossings and new resident access roads.
Thiess is one of the nation’s most prolific infrastructure construction companies with iconic projects like the Snowy Mountains Scheme, Sydney Harbour Tunnel, Lane Cove Tunnel, Epping to Chatswood Railway Line, Melbourne’s $2.5 billion EastLink project and recently awarded Airport Link in its impressive portfolio.
With more than 70 years experience, Thiess has projects in each state of Australia. With extensive operations in Indonesia, and more recent expansion into India, our projects are as diverse as the people that work on them.
contentsBoggo RoadNEARING COMPLETION
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RRRooooaaaaaaaddddddddddddddddddddddddPLETIONN
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BundambaNATION’S LARGEST
RECYCLED WATER SCHEME
ndddaaaammmmbbbbbbbbbbbbbbbaaaaaN’S LARGEST
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EastLinkLARGER THAN LIFE
04 MESSAGE FROM THE MANAGING DIRECTOR
05 AIRPORT LINK: INNOVATIVE DESIGNS WIN CONTRACT
06 BUILDING DESIGNS ACHIEVE SIX STARS
10 RAAF RELOCATION PROJECT COMPLETED
11 SOUTH ROAD: UPGRADE OF VITAL LINK
18 MINING POSITIONED FOR GROWTH
20 HELPING WOMEN RE-ENTER THE WORKFORCE
21 TURNING WASTE INTO WATER
22 COST EFFECTIVE VIRTUAL TRAINING
23 MAKING THE MOST OF E-WASTE
24 SNOWY SCHEME: 50 YEARS ON
26 TRACKSTAR: SUCCESSFUL PARTNERING
27 EPPING TO CHATSWOOD RAIL LINE
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Welcome to the first edition of our new quarterly magazine, Directions, featuring many of our exciting and diverse projects.
Airport Link... is the largest public private partnership project ever awarded in Australia
Thiess has achieved some major successes and milestones recently. We are part of the BrisConnections consortium named as preferred tenderer for the $4.8 billion Airport Link project in Brisbane. This is Australia’s largest public private partnership project.
As we gear up for Airport Link, another big project has been successfully completed. Melbourne’s $2.5 billion EastLink, a 39 kilometre toll road constructed by Thiess John Holland, that opened to traffic on June 29.
We are also involved in Australia’s most significant water recycling project, major rail developments, mines in India and Indonesia, and constructing environmentally friendly office towers in Sydney and Brisbane.
The common thread in these diverse projects is Thiess’ commitment to making partnerships work.
We recognise working as a partner, whether in an alliance, a public private partnership, a joint venture or a consortium, takes more than technical expertise.
We are proud of our ability to work in successful business relationships that produce outstanding results. Delivering projects early, finding innovative ways to avoid or reduce community and environmental impacts and developing better methods to do the job are some of the outcomes you will read about in this edition.
Companies often say that people are their greatest asset. At Thiess, this is a lot more than a popular catchphrase. We work hard to offer our people rewarding and satisfying careers, such as our programs to attract and retain women in mining.
Our values of teamwork, innovation, integrity and performance are reflected in our work every day. Thiess’ Westmead Hospital project team certainly put these values into practice, delivering the project five months early, as well as raising substantial funds for the hospital’s work in caring for newborn babies.
It’s now 74 years since the Thiess brothers opened for business, and 50 years since they won the major tunnelling contracts on Australia’s historic Snowy Mountains Scheme. Landmark projects are delivered differently these days, but the focus on partnerships still lives on.
D K Saxelby
Managing Director Thiess Pty Ltd
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New community connections, improved public transport access, and enhanced green space and recreational facilities are just some of the outcomes achieved for the Brisbane community through innovative design on the Airport Link, Northern Busway (Windsor to Kedron) and Airport Roundabout Upgrade Projects.
New community connections, improved public transport access and enhanced green space and recreational facilities
Innovative design solutions to leave lasting benefits
To design and construct these three projects, BrisConnections has contracted Thiess John Holland Joint Venture, who will work with design partners Parsons Brinkerhoff and Arup.
BrisConnections will finance, design, construct, operate and maintain the 6.7 kilometre Airport Link toll road, Australia’s longest road tunnel.
The projects also include designing and constructing the Northern Busway (Windsor to Kedron) and the Airport Roundabout Upgrade. Together, the projects will reduce traffic congestion and provide essential new connections to two of south-east Queensland’s most important economic centres – the airport and the city.
Announcing BrisConnections as the preferred bidder on May 19, Queensland Premier Anna Bligh said BrisConnections
improvements to the reference design added significant value.
Features of the successful design include:
• Relocating Airport Link underground to minimise construction impacts on surface roads
• Minimising surface structures and improving traffic capacity at Kedron by relocating the busway station and road bridges underground
• Excellent pedestrian and cycle access, underground location and smart design of Lutwyche Busway Station
• Partially burying two of Airport Link’s three ventilation stations to dramatically reduce noise and visual impacts.
As well as faster, less congested and safer connections for motorists and public transport users,
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the projects will connect and expand existing networks of cycle and pedestrian paths. Sustainability is a priority – project design includes parkland and waterway upgrades, and more than 5000 new trees and one million new plants.
In another joint venture partnership, Thiess Services and John Holland Services will operate and maintain Airport Link for a five year fixed price contract.
With a total value of $4.8 billion, Airport Link, Northern Busway (Windsor to Kedron) and Airport Roundabout Upgrade is Australia’s largest transport infrastructure project.
Detailed design is already underway and construction will commence later this year. All projects are scheduled for completion by mid 2012.
Highlights of a winning design• Three projects, one integrated
solution
• Smart engineering solutions with integrated urban design
• Launching two Tunnel Boring Machines for tunnelling will reduce the overall construction period and significantly reduce community impacts
• Flyover bridge and highly efficient signalised intersection to replace the airport roundabout
• Living green wall feature at the Toombul portal of Airport Link – an Australian first sustainable design element
• New community connection for Brisbane’s northside, linking parklands and creeks for pedestrian, recreational and commuter cyclists
• Enclosed spoil conveyor system to transport spoil will remove 80,000 truck movements from local roads
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Aiming for the stars in sustainable designThe Ark, a new office tower project, is about to kick off in North Sydney’s CBD, taking sustainable construction to new heights.
Thiess will raise the bar for environmentally sustainable design with the recently awarded $101 million contract to design and construct an office tower in North Sydney’s CBD.
The landmark 21 level project dubbed Project Ark was awarded by Investa Property Group and will be located at 16-40 Mount Street, North Sydney.
The office tower, designed by Rice Daubney Architects, will feature a unique, complex façade with larger cantilevered floors and external terraces. Tri-generation gas turbines will provide energy for electricity, hot water, heating and cooling for the building.
The building is designed to achieve at least six stars for both the Green Star sustainability rating and the Australian Building Greenhouse Rating - during construction and operation.
Thiess NSW/ACT general manager Brendan Donohue said the project was the subject of “…intense competition against Sydney’s most experienced, top- tier construction companies.
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“Our ability to secure this high-profile office development within such a competitive marketplace demonstrates Thiess’ reputation for innovation and performance, and our ongoing commitment to sustainable construction.”
The award of this contract follows Thiess’ successful completion of premium office towers at 18 Marcus Clarke Street and 7 London Circuit in Canberra in 2007.
Excavation works are currently underway, with construction scheduled to finish in early 2010.
About InvestaInvesta is a commercial and
residential property developer, and manages property assets of approximately $8.3 billion. This includes an Australian commercial office portfolio of close to $5 billion and external funds managed on behalf of retail and wholesale investors of $2.4 billion.
The building is designed to achieve at least six stars
Artist impression of ‘ARK’ building soon to be developed at 16-40 Mount Street, North Sydney
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The team recently received the coveted 5 Star Green Star Office Design rating for their design from the Green Building Council of Australia.
Thiess general manager Queensland David McAdam said the rating recognises Thiess’ strong capabilities in designing and constructing environmentally sustainable office buildings.
The sustainable design innovations featured as part of 400 George Street include a smart approach to construction. By using MEVA, a re-useable formwork, the project will reduce more than 40,000m2 of waste plywood - similar to the
building’s commercial space. A revolutionary air-conditioning system will save 700,000 litres of water and 100,000 kilograms of carbon dioxide through recycling each year.
“Our design for 400 George Street has used a number of initiatives to reduce water consumption,” Mr McAdam said.
“Rain water will be used for irrigation, waterless urinals will be installed, and AAAA rated fittings will ensure that water usage is at its lowest.”
Mr McAdam believes the forward thinking attitude of joint venture clients Leighton Properties and Grosvenor Australia has enabled Thiess
to deliver cost effective, environmentally sustainable, functional and efficient design solutions.
The 34 storey tower sets a standard for future developments in the dynamic precinct emerging in the west of Brisbane’s CBD. Primarily comprising of commercial office space, 400 George Street also includes four basements of car parking, a retail and café area, food hall and restaurant.
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08Smart office building an energy saverThiess Queensland’s building team has saved 40,000m2 of materials and will reduce water and energy use through smart sustainable design for 400 George Street in Brisbane’s CBD.
88 Next stop:Boggo Road Busway
Construction of the $226 million Boggo Road Busway in Brisbane’s inner south is more than 85 per cent complete.
Linking the Eastern Busway to the Eleanor Schonell Bridge south of Brisbane, the Busway is part of a network that will eventually span the city.
The Boggo Road Busway Alliance which includes Thiess, Queensland Transport, and Sinclair Knight Merz, is on schedule to complete the project in mid 2009.
Once operational, it is expected that 600 buses per day will travel on the route, potentially carrying 20,000 passengers. Every full bus takes 40 cars off the road, reducing travel times, congestion and greenhouse emissions.
The Busway will allow people to easily change between bus and rail services at Park Road rail station, providing access to the Gold Coast and Cleveland rail lines.
Construction of the $226 million Boggo
The Boggo Road Busway is a 1.5 kilometre dedicated busway between the intersection of Ipswich Road and O’Keefe street to the Eleanor Schonell Bridge in Dutton Park.
Thiess used specialised tunnelling equipment to protect the heritage-listed Boggo Road Gaol during excavation.
The gaol, built in 1903, forms an important part of Dutton Park’s identity.
Despite variable ground conditions, the project team completed the tunnel excavation underneath the gaol without damaging the iconic buildings.
During excavation a specialised tunnel support system, involving canopy tubes was used with latticed steel beams to support the tunnel roof and ground beneath the gaol.
More than half the tunnel’s 640 metre length has been excavated and the tunnelling team expects to break through to Dutton Park in Brisbane’s south in late September this year.
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Every full bus takes 40 cars off the road, reducing travel times, congestion and greenhouse emissions
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The $133.4 million Victorian projects are delivering a new Officer Training School (OTS) at RAAF Base East Sale, and a new Recruit Training Unit (RTU) at RAAF Base Wagga.
RAAF College is responsible for training more than 5500 recruits and officers each year. The projects provide new working accommodation, training facilities and live-in accommodation for students.
Unlike previous Defence construction contracts, the RAAF College Relocation projects have been delivered under a new collaborative contract model with Thiess as Managing Contractor.
The Managing Contractor Contract is the first of its kind in Australia and saw Thiess partner with the Department of Defence from the outset of the projects. This involved Thiess assisting with developing a detailed business case and participating in a Parliamentary Standing Committee on Public Works hearing.
A new collaborative contract model has been the key to successfully delivering two major RAAF College Relocation projects.
Thiess Managing Contractor’s Representative for the projects, Don Gault, said the close involvement and communication with key stakeholders was vital to the success of the projects.
“The projects involved a range of different stakeholders from different divisions within Defence,” Mr Gault said.
“Our primary goal was to deliver outstanding OTS and RTU facilities that gave RAAF College the capability to provide training effectively. By engaging stakeholders throughout the life of the projects, we were able to achieve that.”
Defence Support Group, Base Commanders, RAAF College OTS, and RTU were involved in every stage of the projects to ensure facilities would provide the capability the RAAF College required.
Intensive workshops throughout the design phase resulted in facilities purpose-built for operations. Regular construction inspections allowed feedback to be received and actioned without adversely impacting handover schedules.
RAAF Relocation
Missionsuccessful in
projects
“It was important that we had a clear understanding of project expectations,” said Mr Gault.
The new RAAF College boasts improved functionality and addresses the problems created by ageing temporary accommodation.
The facilities meet all targets for environmentally sustainable design. The Headquarter buildings are certified to 4 Star Green Star for environmental sustainability. The facilities also achieved a 4.5 Star Australian Building Greenhouse Rating for water management, electrical devices (including sensor activated lighting), and heating and cooling systems.
Buildings collect their own rainwater for toilet and shower amenities, with grey water fed into ponds for irrigation and gardening use on site.
The site has also been designed to encourage the RAAF College community to cycle around the grounds as much as possible, with trails, bicycle racks, and showers featured throughout the colleges.
A key to the projects’ success has been the collaborative working relationships behind the scenes
11South Road:Thiess upgrades vital link
Winner of the South Australian Excellence Awards, the $118 million South Road Upgrade is taking shape in Adelaide.
South Road is Adelaide’s busiest and most critical main arterial freight route. It forms a vital link in South Australia’s north-south transport corridor, linking industry and communities in the south with the port to the north.
In 2005, the South Australian Government announced the first stage of a plan to transform South Road into a continuous non-stop route from the Southern Expressway to the Port River Expressway, a distance of 22 kilometres, to reduce congestion and improve road safety.
Thiess has formed a joint venture, to undertake the design and construct contract for the project, which will ultimately see the grade separation of South Road and the ANZAC Highway, Adelaide’s busiest intersection, through an underpass and a 31 metre span bridge.
One of the first projects in Australia to be delivered using the Early Contractor Involvement procurement model, the project team worked with the Department for Transport, Energy and Infrastructure and key stakeholders during design development. This ensured early innovation and integration of constructability into the design.
Close collaboration between client, designers and contractor achieved considerable savings and has resulted in an innovative, yet constructable design
solution that addresses a number of critical challenges. These include minimising impacts on the local community and local traffic, protection and enhancement of the local environment and the sustained health and safety of all stakeholders.
The project reached a major milestone this month with the southern half of the ANZAC Highway bridge completed and opening to traffic on schedule. Five lanes are now operating, while work continues to complete the northern side of the bridge and the underpass.
Manager for Thiess in South Australia, Doug Dally, said the bridge opening had generated great interest and excitement in the community.
“The improvements this upgrade of South Road will deliver for Adelaide are tremendous. It’s generating a lot of excitement as the community sees the project taking shape.
“With billions of dollars in major projects in the pipeline, including major upgrades in transport and infrastructure, and with the state enjoying all-time high employment rates, we’re glad we’re part of this new era of growth. We’re looking forward to sharing our expertise and learnings from projects all around the country to benefit South Australia.”
The South Road Upgrade is on schedule for completion in late 2009.
Monash upgrade makes historyThe $1.39 billion Monash-Citylink-Westgate Upgrade is the largest State-funded road project in Victoria’s history.
Working through the Westgate Freeway Alliance (WGFA), Thiess will be responsible for the Westgate Freeway Upgrade portion of the project. Alliance partners include VicRoads, Baulderstone Hornibrook, Hyder Consulting, Parsons Brinckerhoff and Thiess.
The Alliance will design and construct much needed improvements to increase safety, reliability, and traffic throughout the State’s busiest freight and traffic corridor.
Since its opening, traffic volumes on the Westgate Freeway have grown steadily. Today it carries up to 180,000 vehicles every day. As well as linking the Westgate Bridge and CityLink tunnels, the Freeway services Melbourne’s port precinct. It connects this busy commercial area with the Princes Highway and the Western Ring Road in Melbourne’s north.
The works will feature significant design improvements, especially to the Bolte Bridge and Montague Street interchanges and a state-of-the-art freeway management system. New lanes and ramps will eliminate traffic weaving with motorists able to choose their desired lane, clear of merging traffic.
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131313EastLinkEastLink, one of the largest public private partnerships (PPP) ever carried out in Australia, opened on June 29 more than five months ahead of schedule. Eleven thousand people worked 14 million man hours. They combined a distinctive urban design, innovative construction and manufacturing, and world-class safety for workers and commuters to create one of Australia’s greatest engineering achievements.
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NS – larger than life
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World-class safety for commuters
EastLink has two tunnels under the Mullum Mullum Valley (Mullum Mullum and Melba), connecting the Eastern Freeway extension past Springvale Road with EastLink in Ringwood, south-east of the city. The tunnels are each 1.6 kilometres long, with three 3.5 metre wide lanes, and a height clearance for vehicles of 4.65 metres.
The tunnels have been designed in line with the World Road Association (PIARC) standards and deliver world-class safety management.
A unique feature is the mechanism to prevent over-height vehicles from entering the tunnels. Vehicles exceeding the tunnel clearance limit will be detected before entering and trigger warning signs. Boom barriers at the tunnel entrances will lower to block access. These barriers can also be lowered if an incident has occurred inside the tunnels. This is designed to prevent potential harm to approaching motorists.
Environment matters Throughout construction,
TJH achieved a balance between progressing works and maintaining minimal impact on the environment. The environmental team conducted some 7000 inspections to make sure relevant standards were adhered to.
Millions of dollars were invested in ecological initiatives including the Mullum Mullum Valley tunnels safety features, dust and noise control measures, flora and fauna protection, environmental management policies, and avoiding the excessive use of potable water.
More than $50 million was spent designing and constructing the landscaping, including realigning and rehabilitating creeks, constructing wetlands, installing a shared use pathway and revegetating open space areas and parkland.
panel noise walls, 147 wing and fender walls and 321 piers and cross heads.
Traffic challenge Effective traffic management
plans ensured construction ran smoothly, with minimal impact on local businesses and residents.
Distinctive by design The urban design provides
EastLink with its distinctive identity. All aspects of the toll- way have been carefully planned and creatively designed – from the tunnel portals, pedestrian bridges, noise walls, the EastLink Operations Centre building, exposed rock faces and bridge abutments through to handrail detail.
The overall urban design theme draws on the palette and textures of the local environment, using colours and designs that are sympathetic and non-intrusive to the natural landscape. Several iconic art pieces were commissioned by ConnectEast and placed along the motorway as part of the urban design. These designs and art pieces were featured on ABC1’s Sunday Arts program – a first for an infrastructure project.
EastLink - a $2.5 billion PPP – is a 39 kilometre toll road connecting Ringwood and Frankston, and includes new tunnels beneath the bushland in the Mullum Mullum Valley. Constructed by Thiess John Holland (TJH), EastLink provides a new, quicker way to travel between Melbourne’s north-east and south-east.
When construction began in early March 2005, it was an historic occasion – the first road project of this scale in Australia. Proposed in the mid-1960s, the link had been included in Melbourne’s street directory since 1969. It remained a concept for 36 years.
The Victorian Government announced in September 2002 that the project would finally go ahead, and in 2004 ConnectEast was awarded the 39 year contract to design, construct, operate and maintain the toll-way. TJH was awarded the design and construction component of this contract. Three years later, EastLink has already picked up awards for budget, sustainability and innovation.
Paving the way More than 1.3 million tonnes
of pavement – equal to 2954 fully laden jumbo jets – has gone into the two million square kilometres of roadway.
EastLink’s pavement is made up of five layers of asphalt, including an extra Open Graded Friction Course to reduce noise and increase skid resistance.
The workmanship of both asphalt contractors, Boral and FRH, was praised as being among the best in the country, consistently producing surfaces above standard ride quality.
A manufacturing facility was established at Morwell in the Latrobe Valley to produce more than 22,000 precast concrete products for construction, including the large Super T-Beams.
During peak production, the workforce transformed more than 3000 tonnes of concrete (more than 200 concrete trucks) per week into 1600 beams, 4631 off-structure barriers and parapets, 1446 rock faced cantilever noise walls, 336 vent stack panels, 13,589 post and
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More than 11,000 dedicated people spent more than 14 million man hours creating EastLink
Environment initiatives on EastLink• Environmental considerations included in daily
pre-starts, and Job Safety and Environment Analysis (JSEAs)
• Site Environmental Plans posted at each site compound to ensure workers were aware of relevant environmental restrictions and conditions
• To minimise impact on waterways, runoff was treated in sediment ponds and reused in construction activities
• Noise and vibration monitored to ensure minimal inconvenience to local communities
• Energy efficient high pressure sodium (HPS) lighting installed on site
• Removed trees mulched and used for landscaping• Recycled concrete used where possible, and
recycled plastic fence posts trialled• Not-for-profit forestry offset organisation,
Greenfleet, engaged to offset the company’s light vehicle fleet emissions
• Landscaping included predominantly indigenous plants that are drought tolerant, require minimal watering, and provide a habitat and food for local fauna
• More than 3.6 million plants placed along the 45 kilometre EastLink roadway and bypasses created a 500 hectare linear parkland
Taking its toll EastLink’s tolling system is one
of the most advanced in the world. The 13 tolling points each have four gantries housing the necessary equipment to detect and classify vehicles entering the toll zone. Each gantry also contains the necessary equipment to record images of the vehicles front and/or rear number plate as well as equipment to detect and communicate with the electronic tag installed on board the vehicle.
EastLink’s tolling system is compatible with other toll roads in Australia, enabling EastLink tags to be used on other tollways in Victoria and nationwide. Tags from other toll roads can also be used on EastLink.
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recycled water Nation’s largest
scheme
Recycling water is a vital step towards a sustainable water supply…
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Delivered through a partnership between Thiess, Black & Veatch, and joint venture with the Queensland Department of Infrastructure, the world-class facility is a core component of the State Government’s $2.4 billion Western Corridor Recycled Water Project.
Thiess’ role included procurement, constructing the civil work and structures and installing electrical, process and mechanical equipment for piping and processing the water.
Qld Premier Anna Bligh who attended the opening of Stage 1A said the team “… met a timetable that some said was impossible. It is a tremendous feat of engineering recognised around the world.”
Project Director Gus Atmeh said the strong partnership enabled the team to transform their vision into a reality.
“Working together provided innovative and sustainable solutions to tackle south-east Queensland’s water shortage through the safe delivery of a world-class recycled water asset in record time.
“We not only delivered the infrastructure, but also produced the quantity and quality of water required in that time-frame with an exceptional safety record whilst meeting all legislative and environmental requirements,” Mr Atmeh said.
“Without the combined experience and design flexibility in working collaboratively, this innovative first-class plant would not have been possible in such a short time-frame.”
The first stage of the plant, which supplies treated water to the Swanbank Power Station, was named Waste Water Project of the Year at the Global Water Awards in London this year.
The Bundamba Advanced Water Treatment Plant (AWTP) broke industry records when the first stage was completed in record time - less than 10 months, 14 months faster than industry best practice.
The next stage will expand the plant to deal with additional volumes of water from existing waste water treatment plants at Oxley and Wacol. Once completed, the plant will provide an alternative water supply for industry and power generation. It will recycle up to 66 megalitres of water a day.
The Bundamba plant is the first of three AWTPs that will become the largest recycled water scheme in Australia. The other two plants will be at Luggage Point and Gibson Island near Perth.
The entire project is scheduled for completion in October 2008.
The USA Environmental Protection Agency Administrator Stephen Johnson visited the Bundamba AWTP in May 2008 to understand the functionality and technical aspects of the operational processes of the plant.
Mr Johnson also reviewed the environmental guidelines implemented to safely operate the plant, and reduce risk to workers and the environment.
He commended the Queensland Government for finding a sustainable alternative long-term solution to south-east Queensland’s water shortage.
He praised the project for its vision in combining different technologies to create a world-class plant, and the project team for setting an industry construction benchmark.
The project was delivered ahead of schedule with the first purified recycled water available just 300 days after the project commenced. This was achieved without compromising the safety of workers – not a single lost time injury occurred in those 300 days. The project has since been widely acknowledged as the world’s best practice for a project of this type.
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National
growthpositioned for
Thiess
The national mining business will be better positioned to leverage operational efficiencies and best practice in health, safety and environmental management, as well as financial management.
The new national business will leverage best practice across our operations. Thiess’ goal is to maintain a safe, secure and profitable business into the future – for Thiess and our clients.
The Tarong Coal Project – Meandu Mine is one of Thiess’ recently acquired contracts.
Since commencing operation of the mine in February 2008, a commitment to continuous improvement has extended the life of the mine by adding more than 3MROMT of coal that was previously not recoverable.
The result is a significant reduction in direct costs and fleet requirement, and a more sustainable mining operation.
Retaining the knowledge and experience of employees gained over a 25 year history on site was key to the mine’s successful transfer from owner-operator to managing contractor.
More than 60 per cent of the existing workforce joined the new Thiess team, thanks to a human resource transition strategy underpinned by transparent processes, and open and honest communication.
The mine plan developed by the project team is being implemented using consultation and change management techniques. This effort is showing positive results with the workforce’s take-up of changes such as:
• Optimising waste haulage routes to reduce hauls by up to three haulage trucks
• Reviewing blasting requirements to increase ‘free-dig’ areas with little productivity penalty-reducing overall costs
• Using selective blasting and excavation practices to increase coal handling preparation plant yield
• Incorporating cast blasting into the dragline mining methodology, accelerating coal exposure
• Improving truck and shovel techniques for removing pre-strip waste.
In addition, the leverage of Australia’s largest fleet, with a written down value of more than $600 million, has significantly increased ancillary equipment. The flexibility and experience that comes with managing Australia’s largest fleet is also reducing plant maintenance down time and expenditure.
The collaborative efforts of Thiess’ mine planning, fleet maintenance schedules, and coal handling preparation plant management will deliver direct cost savings to the client in the 2009 financial year.
Thiess has formed a national mining business to ensure its continued strength and excellence as a leader in the mining industry.
mining business
Thiess is taking its world-class capability and experience in complex open cast pits to India, after becoming the first foreign company to be awarded a mining contract there.
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US$250m win in IndonesiaPT Thiess Contractors Indonesia has secured a US$250 million mining contract with PT Inkor Prima Coal (IPC) at their Samboja Coal Mine Project.
The Samboja Coal Mine Project is located 45 kilometres north of Balikpapan, East Kalimantan in Indonesia. The five year contract will include providing overburden removal and mine support services. Works are expected to commence in June 2008.
President Director of Thiess Indonesia Roy Olsen said the contract gives Thiess Indonesia a strong platform on which to build a partnership with IPC.
“Current activities and resources in East Kalimantan mean we are well positioned to deliver the requirements of the Samboja Coal Mine,” Mr Olsen said.
He said the project is an ideal fit with the company’s ongoing pursuit of additional mine work and recent capital investments.
“We already have a major presence in Balikpapan supporting our other Kalimantan mining projects, so the proximity of this project makes it a natural fit into our existing operations,” he said.
Thiess Indonesia recently committed to an additional US$250 million investment in plant and equipment to boost its capacity to meet the country’s booming resources sector.
The Chitarpur Coal Project will involve the immediate infrastructure development and the subsequent 20 year operation of a greenfield open cut coal mine situated in the North Karapura coalfield in Jharkhand State.
The contract followed two years of negotiation between Thiess and the owners of the Chitarpur Coal Project, the Abhijeet Group. Mining operations are expected to commence in October 2009.
The Abhijeet Group is a family-owned Indian infrastructure organisation that is making inroads in India by setting up power, cement and steel plants. Thiess is considering other ventures with the group, and is also in negotiations with other major industry players. Offices have been established in New Delhi and Calcutta to focus on mine logistics, planning and servicing projects in India.
The contracts worth $1 billion will see Thiess India develop and operate an open cut coal mine in the state of Jharkhand for 20 years.
Thiess’ Chief Executive Asian Operations Bruce Munro said the win sets a solid foundation for Thiess’ planned growth in the India market.
“The Chitarpur Coal Project is significant for Thiess not only because it is our first contract in India, but also because it is an unprecedented win. Being the first foreign company in India to win a mining contract is recognition of our world-class capability and experience in complex open cast pits.
“There is huge potential for Thiess in India. We are entering a sector which, until now, has been dominated by Government authorities. However, the growing demand for power and resources has led to the industry being liberalised,” he said.
“A key factor in the success of the project will be a strong safety culture and maximising local employment and training – an approach used in Thiess’ operations around the world.”
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mines India
The five year contract will include providing overburden removal and support services
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At Thiess, the percentage of women employed is approximately 15 per cent and growing. Thiess is continuing to develop strategies to attract and retain more women in the business.
One example is, Burton Coal Mine in Queensland’s north is embracing women returning to the workforce, and exploring alternative career models for part-time/remote working professional mums. It actively promotes recruitment of women across all areas of its operations.
These efforts to attract more women into the business is paying dividends where almost half of the Burton project leadership team are women, including Technical Services Superintendent Gabriela Love (pictured).
Ms Love said career opportunities for women are endless, and the mining sector is an internationally recognised career.
“Although mining is a challenging career, the hardest challenge of all is juggling a career and family.
“In practical terms, it’s a daily organisational nightmare where morning and evening schedules are minute-critical in our 24/7 operation. It’s a game of chess to balance all the operational, technical and people needs to meet our client’s business goals,” Ms Love said.
In her 24 years in the industry, Ms Love has seen many changes to the working environment.
“Thiess has women in senior roles, and this creates a positive image and role model for women in the company. They have also given publicity and exposure to women within the Group through networking opportunities, which strengthen the ties between women working on separate locations.
“At Burton, Thiess is exploring alternative career models and actively promoting recruitment of women across all areas of the operations,” Ms Love said.
To entice women back into the work force, Burton engaged in a promotional campaign called Enginhearing to target female engineers within three mining towns – Dysart, Moranbah and Glenden.
The road show and one-on-one talks have resulted in two female engineers joining the Thiess team.
“One of the engineers, Wendy, has commenced full-time as a process engineer in the Coal Handling Processing Plant. The other has two school aged children and is being set up to work from home,” Ms Love said.
Women are becoming more visible across the engineering and mining landscape, although they currently represent less than 10 per cent of the engineering workforce in Australia.
Thiess encourages people from a diverse range of backgrounds to join its 15,000 strong workforce
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Women are becoming more visible across the engineering
Helping women re-enter the workforce
Thiess recruits women across all disciplines and geographic regions, and places a priority on addressing workplace diversity across its operations.
It is also in the process of recruiting an entire mining workforce for its new mining operation Lake Vermont near Dysart. Thiess is encouraging women to join the new mine which will employ a total of 250 employees including mine workers, technicians, maintenance employees, engineers, administration, graduates, supervisors and more.
“Creating the right environment and culture will help women pick up the phone and ask how they can be part of this exciting work environment and challenge,” Ms Love said.
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By 2012, the W2W Alliance will deliver major upgrades to treatment plants at Woodman Point, Beenyup and Subiaco.
The $352 million program covers the design, construction and commissioning of upgrades to increase capacity at the three metropolitan wastewater treatment plants, and to reduce odour emissions from the Woodman Point plant by 50 per cent by late 2008.
The W2W Alliance brings the international and local engineering design and construction expertise of Black & Veatch, Thiess and Sinclair Knight Merz together with the Water Corporation.
BeenyupThe $147 million upgrade to the Beenyup
Treatment Plant, will increase the capacity by at least 15 million litres a day, while maintaining current high standards of odour management.
Turning waste into water
SubiacoLike Beenyup, the $68 million upgrade
to the Subiaco Treatment Plant, will also increase the capacity by at least 15 million litres a day, while maintaining the same high standards.
Woodman PointThe $137 million upgrade to the Woodman
Point Treatment Plant, will increase the capacity by at least 177 million litres a day, while also maintaining current high standards of odour management.
In one of Western Australia’s most substantial wastewater programs, the W2W Alliance is working with the Water Corporation to meet the needs of Perth’s growing population, while protecting public health, amenity and the environment.
Desal plant to make a big splashThiess will partner with French-based international water treatment specialist Degrémont to bid for the Melbourne desalination plant - the centrepiece of the Victorian State Government’s $4.9 billion water plan.
The consortium will merge the design and construct strength of Thiess, the international expertise of Degrémont, and the financial security of Macquarie Bank.
Degrémont brings more than 120 years experience to the operation of water utilities in Australia and New Zealand and has earned a reputation as an industry leader when it comes to working in public private partnerships.
The project will provide the single largest boost to Melbourne’s water supply since Thiess constructed the Thomson Dam more than 25 years ago.
The plant will be built on Victoria’s Bass Coast in Wonthaggi and, when complete, will provide up to 150 billion litres of potable water per annum - more than a third of Melbourne’s yearly water needs.
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Thiess Services continues to grow its waste management business by beginning a 10 year waste collection and recycling contract worth more than $225 million.
Located on the NSW Central Coast, it is the second largest contract of its kind in Australia.
Covering the local government areas of Gosford and Wyong and employing around 100 people, the service involves collecting general waste, garden vegetation, litter-bin waste, bulk kerbside waste and domestic recycling.
The Somersby-based facility will process up to 25 tonnes of domestic recycling every hour, requiring 61 new collection vehicles.
Thiess Services’ new waste and recycling facility has environmentally-savvy features such as:
• Light sensors throughout the administration building
• Low-power kilowatt rating motors and accessories that consume less energy
• 300,000 litre water retention system for truck washing
• Ability to collect refrigerators intact and avoid rupture in compaction vehicles
• Load cells on collection vehicles to measure when trucks are nearing capacity
• Ultra Low-Sulphur Diesel Engines with catalytic converters that meet Euro 4 standards
• Highly efficient MRF process that produces less waste
More than a load of rubbish
Simulator training tackles skills shortageAn $800,000 mine truck simulator could prove a cost effective way to help tackle skill shortages in the mining industry.
With mining equipment costing $3 million per truck and a damaged tyre costing up to $50,000, the Thiess-supplied training simulator is an alternative way to train people without slowing down mining activities.
Housed in a shipping container for portability, it is a peripheral video environment configured as a 793D Caterpillar dump truck. Its real-life animation is able to simulate driving conditions including blowouts, rain and other operational events.
The simulator is located at TAFE SA’s Port Augusta campus. It is one of three pilot projects launched in February this year under the Australian Regional and Mining Skills (ARAMS) project. Others are underway in Dubbo (NSW) and Townsville (Qld).
Opportunities for the simulator’s use are extensive. For example, there is potential for the simulator to be used as a marketing and education tool for the mining industry, giving students first hand experience of what opportunities await them in the mining sector.
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“Companies can certainly reduce their environmental footprint by clearing out items that are never going to be used again, rather than holding on to them,” he said.
When required, the facility ensures complete destruction of hardware, up to and including the physical shredding of hard drives. Certificates of destruction can be provided as guarantees of data security.
Recoverable parts and commodities are forwarded to end users throughout Australia and internationally for use as raw product in other recycling and manufacturing processes.
Collection serviceThiess Services provide collection services
for e-waste throughout NSW, the ACT and south-east Queensland.
“Our staff visit and inspect a client’s premises and create a tailor made collection service for them. This can include distributing collection bins up to 32 cubic metres or smaller cages,” Mr Calleja said.
While current legislation in NSW allows e-waste to be disposed of legally to landfill, the ACT adopted a no waste to landfill
Recycling unused or obsolete electronic equipment makes good environmental and economic sense
The possibility of heavy metals including lead, mercury, selenium and cadmium entering the environment means disposal methods other than landfill are required. Other materials, including steel, aluminium, precious metals and plastics make unwanted electronic items prime targets for recycling.
RecyclingIn NSW alone, 5000 tonnes of computers
and 5000-15,000 tonnes of televisions are disposed of in landfill every year. More than five million computers sit idle in warehouses, but will eventually be disposed of as landfill.
The new Thiess Services facility receives and dismantles e-waste through a combination of manual and automated means to yield basic components for further sorting and processing.
Virtually any electronic device that has had a power cord attached to it is processed. Almost 98 per cent of products are being recycled.
Thiess Services Regional Manager Tony Calleja said recycling unused or obsolete electronic equipment makes good environmental and economic sense.
Thiess Services’ new e-recycling facility at North Wyong on the NSW Central Coast is combating the growing amount of electronic waste ending up in landfills.
policy in 2005. The facility receives this material from the ACT for recycling and processing. Environmental groups are currently lobbying other states to follow the ACT’s lead and dispose of e-waste in an environmentally responsible manner.
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Dam good workThiess has played a significant role in major water infrastructure across Australia taking responsibility for the construction of more than 80 dams in half a century.
In conjunction with our Alliance partners Thiess is continuing to deliver sustainable solutions for the water resources industry. Our experience includes constructing Australia’s highest dam, the 180 metre Dartmouth Dam, and the largest dam in volume, the Talbingo Dam, that has an embankment volume of 14.5 million cubic metres of fill.
Thiess is currently involved in the $351 million Hinze Dam project that will raise the dam wall from 93.5 metres to 108.5 metres. By project completion, this vital water asset will provide up to 225 million litres a day for the Gold Coast community in Queensland and enhance flood mitigation in the lower Nerang River catchments.
All projects are focused on delivering excellence in close consultation with local communities and contractors.
Snowy: Five decades on
Valued at more than $18 million, the contracts were the largest of its kind ever awarded to an Australian company and would cost 12 times that amount to complete today.
The delivery of these projects on time and under budget helped establish Australia as an independent and resourceful country with proven, world-leading construction capabilities. Thiess also set a world record on the Tooma-Tumut Tunnel, excavating 526 feet in a six-day-week compared to 30 feet per week achieved by other companies.
The models of delivery may have changed, but Thiess’ commitment to innovation, forward thinking, and delivering exceptional outcomes continues on projects today.
It was 50 years in May since Thiess was awarded the Tooma Dam and Tooma-Tumut Tunnel contracts in NSW as part of the historic Snowy Mountains Scheme.
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Westmead Hospital is one of the largest tertiary-level health facilities in metropolitan Sydney, delivering high-level health care services to the community.
The first contract of its type for the procurement of public health facilities within NSW, Thiess was responsible for design briefs, design documentation together with the construction of individual packages of works.
A dedicated on site team worked closely with the Western Integrated Network (WIN) Program Director and the Western Sydney Area Health Service (WSAHS) to ensure minimal disruption and completion five months early.
of care at
Thiessqualityextends
Westmead Hospital is
WestmeadAfter working and constructing directly above the Neo-Natal ward at Westmead, Project Director Chris Milne, Foreman Luke Gallagher and Site Manager Mark Foster learned that the Neo-Natal unit was under funded for important equipment needed to function more efficiently.
Joining forces with Darren Marton from the ‘no way campaign’ – drug and alcohol awareness - they set out to raise the much needed funds.
“Raising funds for the hospital gave our project team a focus above just that of a builder, helping to develop a special relationship with the nursing staff,” Mr Foster said.
The fundraising appeal also gained the support of many Thiess subcontractors and suppliers, raising $132,000 for the Centre of Newborn Care.
Over the life of the project the Westmead team raised in excess of $250,000 for various local charities including Neo-Natal Emergency Transfer Service, the Millennium Foundation, and Intensive Care Unit Simulated Education Facility and Neo–Natal Appeal.
Pacific Highway upgrade well underwayWork on NSW’s $320 million Coopernook to Herons Creek deviation is in full swing with the corridor for the new highway route taking shape.
The project involves constructing a continuous 32.7 kilometre stretch of highway between Coopernook and Herons Creek (between Taree and Port Macquarie), with a focus on providing a high standard four-lane dual carriageway. It also includes bypasses of the towns of Moorland, Johns River and Kew.
Thiess is part of the successful Coopernook to Herons Creek (C2HC) Alliance delivering the project with the NSW Roads and Traffic Authority (RTA)and Parsons Brinckerhoff. The project builds on Thiess’ proven experience as an alliance partner and demonstrates the individual team members’ ability to work collaboratively toward best-for-project outcomes.
The construction will reuse existing highway assets in the upgrade where possible, including bridges, drainage structures and 4.5 kilometres of existing highway pavement.
The project is expected to be completed in early 2010.
The project builds on Thiess’ proven experience as an alliance partner
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Thiess continues to embrace innovative contracting methods and, through alliance contracting, is establishing partnerships with other industry leaders to deliver outstanding results on projects.
Alliance contracting builds collaborative working relationships that enable fast, high quality results to be achieved and risks to be equally shared between partners
outstanding results on projects
TrackStar Alliance was formed in 2006 as part of the Queensland Government’s plan to develop infrastructure for the expected influx of more than a million people into south-east Queensland in the next 20 years.
Queensland Rail (QR), Thiess, United Group, Connell Wagner and Maunsell Aecom have created a long-term business to deliver a range of rail projects.
Breakthrough innovations have already led to more than $130 million (13 per cent) in cost savings to QR and the Government before the projects began. The creation of a unique and enduring culture of peak performance has been the magnet to attract quality people who challenge mindsets and create best value outcomes.
The TrackStar projects are part of the $107 billion South East Queensland Infrastructure Plan and Program (2007-2026), Queensland’s largest ever investment in infrastructure.
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TrackStar awardedTrackStar Alliance was awarded an
“Honourable Mention” for Excellence in Major Project/Capital Alliances for Australia and New Zealand at the Alliance Contracting Excellence (ACE) Awards in Sydney on May 28.
TrackStar Alliance Manager Mike Zambelli said this award recognises the Alliance’s commitment to delivering the best possible outcomes for QR and the Queensland Government.
“This award is powerful evidence that QR and its alliance partners are delivering a program of complex rail projects with innovative and cost effective solutions that are recognised as leading the industry,” Mr Zambelli said.
The TrackStar team has now reached 900 personnel from a standing start two years ago and is turning over $270 million in the 2007-08 financial year.
“We are demonstrating certainty of delivery and best value to all stakeholders with unprecedented levels of integration with QR,” he said.
Alliance:On the right track
TrackStar
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The Epping to Chatswood Rail Line, now nearly complete, is the largest publicly-funded infrastructure project currently underway in NSW. Its 12.5 kilometres of underground passenger rail line will link the Main North Line near Epping to the North Shore Line near Chatswood.
This new line will be fully integrated into the CityRail network, create the capacity for an additional 12,000 rail passengers a day and make public transport more attractive to a greater number of residents and visitors to Sydney.
The Thiess Hochtief Joint Venture’s works involve the design and construction of the twin tunnels, dives, cut and cover structures and other civil works to accommodate a new twin-track underground heavy rail line.
This includes bulk excavation and concrete structures for three new underground stations at Macquarie University, Macquarie Park and Delhi Road, together with an underground extension to the existing Epping Station. Alstom is the exclusive subcontractor for systems elements.
Commissioning work for the rail line is well advanced, with train testing now underway.
The complex task of readying the Epping to Chatswood Rail Line for the operation of trains began in March. The testing involved using a diesel train within the tunnels to undertake final checks on the geometry of the track and overhead wiring. The process was completed successfully, enabling the commencement of trials using electric trains.
Thiess’ Site Environmental Officer Jim Steen, while working on the Epping
to Chatswood project, received an environmental award for his concrete recycling initiative as part of the National Recycling Week/Thiess Recycling Challenge.
The award, aimed to promote recycling, energy efficiency and greenhouse gas abatement initiatives, highlights the opportunities and magnitude of savings that are possible on projects.
“On the Epping to Chatswood Rail Line project we needed to rehabilitate the M2 site. This involved digging up approximately 6000 tonnes of concrete, before regrading to levels specified by the client,” said Mr Steen.
“At $9 per tonne, taking the broken-up concrete away would have been quite expensive. So we decided to recycle it ourselves.”
The good practices and technologies of this initiative have since been captured so they can be transferred to other activities and projects.
Epping rail link nearing completion
www.thiess.com.au