major construction phase activities

8. Major Construction Phase Activities

8.1 Overview

8.1.1 Pre-construction Phase

Activities to occur prior to commencement of construction include the following, discussed in more detail in Annexure XX, Appendix 8, Volume 7.

Passage of any necessary Legislation and the issue of required permits;

Contractor pre-qualification, determination of labour conditions, and validation of estimates of workforce availability;

Completion of site preparation plan (land-use plan, storages, transport, communications, fire prevention, safety and security, health, etc.);

Preparation of materials handling plan;

Provision of services to contractors (water, electricity, air, effluent, etc.);

Finalise Construction EMP

Completion of civil engineer’s constructability analysis, including type of civil structures and impact on time schedules;

Quantification of prefabrication level in civil construction;

Mechanical, electrical and instrument (MEI) construction;

Main equipment delivery; and

Provision of temporary facilities.

8.1.2 Construction Phase

Subject to approval of the project, (anticipated to be towards the end of 2006), the construction period is likely to commence at the earliest practicable time, construction activities are estimated to extend for 26 months. The infrastructure required for the project will be constructed at the same time as the pulp mill.

Commissioning of the pulp mill operations and commercial production is anticipated to commence early in 2009. (Refer to Chapter 9 for more information on the commissioning phase). The pre-requisites for commencement of construction and for the feasibility of the proposed timeframe are:

Approval of the preparatory engineering report. This is to serve as the basis for execution of the project;

Completion of project organisation;

Engagement of engineering companies;

Volume 1: 8-442 32/11709/9026 Bell Bay Pulp Mill

Draft Integrated Impact Statement

Preparation of civil works contracts, with first contracts (site preparation, earth moving) ready to be awarded; and

Main equipment contracts having been prepared following selection of critical suppliers during the second and third quarter of 2006.

Preparation of an optimal schedule, supported by a critical-path for efficient execution.

As provided in section 1.2.6, the following anticipated major milestones determine the critical path:

Gunns’ Board investment decision Within 1 month of irrevocable approval of the project

Start of earthworks Subsequent to Gunns’ns’ Board approval.

Start constructing the pulp mill/infrastructure

Within 6 to 8 months of approval.

Start-up Following the 26-month construction period.

Commissioning An 18 month period following completion of start-up

8.2 Construction Activities

There are three main categories of construction activities: civil works; mechanical, electrical and instrument (MEI) construction; and main process equipment erection.

8.2.1 Civil Works

Subject to approval for the proposed development, most of the site preparation for the pulp mill will occur in the first eight months of the construction phase. Site preparation involves vegetation clearing, constructing temporary fences and gates, general excavation, blasting and site levelling.

Sequence of development

The sequencing of the development is described below:

Forestry operators will undertake clearing and grubbing of the site.

Immediately following, earthworks will commence by way of stripping of topsoil (to the extent that it is available given the limited thickness, inconsistency and rock content) and stockpiling for later reuse on the site.



Winning of materials including clay, weathered rock and hard rock will commence including crushing and blending the various material types to suit specific applications.

Placement of the won material will occur concurrently in order to form the working platforms.

Construction of Mill facilities will then commence.

The anticipated sequencing of the completed earthwork platforms is as follows:

– RL 5 Platform including placement of rock fill and seawall, complete to Design Surface Level. Required within 10 weeks of completion of contract mobilisation time.

– Balance of other Platforms to be constructed to design surface levels. Required within 26 weeks of completion of contract mobilisation time.

Stockpiling of topsoil

After clearing, the entire earthworks footprint will be stripped to a nominal depth of 150 mm. The actual depth shall be determined depending on conditions encountered and may vary across the site.

Stripped material suitable for later reuse as topsoil will be placed into temporary stockpiles in accordance with DIER Standard Specification R22. Typically the stockpiles will be placed in strategic locations in order to minimise multiple handling and cartage distances.

Screening

Screening will be required to sort material for further use in embankments or pavements. Screening equipment will be placed within the limit of works in strategic locations in order to minimise handling and transport. Refer to IIS Volume 2, Section 4.5 for further details.

Location of Stockpiles

Stockpiles will vary in size and shape and will be placed within the affected works area as shown within the limit of works based on strategies to minimise handling and transport.

Access

The primary and permanent access to the Mill Site will be via a new internal road which joins the existing access road into the Longreach Chip Mill, approximately 100 metres East of the North Chip Mill weighbridge. A temporary access road will also be established off the existing Longreach Chip Mill road during the initial earthworks phase whilst the permanent access is built.

Additional accesses to the proposed Mill Site will be required and are described in IIS Volume 1, Section 1.2.5 “Construction Access Road”. Refer to IIS Volume 2, Section



13.10.1 for specific details of Landfill/Reservoir/Quarry access including configuration and construction methodology.

Following site preparation, the installation of utilities such as underground pipes and roads will occur in addition to the laying of foundations and the erection of building frames.

Main process equipment will be delivered to the site by the main equipment supplier. Either the supplier or a separate contractor will erect the equipment on site. In the latter case, the equipment supplier supplies only required specialist supervision to see that equipment is erected in accordance with instructions and quality requirements. The main process equipment should be delivered as prefabricated modules of maximum size to reduce the site work. If a separate erection contractor is used, the main equipment supplier will be required to inspect and approve the erection prior to grouting and connection to other installations. The main equipment supplier will be responsible for mechanical completion, pre-commissioning and commissioning of the equipment. The construction phases for principal components is discussed in the following sections.

8.2.2 Initial Earthworks

The details of initial earthworks and excavation will be developed as part of a detailed mining plan for the site. This will be based on further geotechnical assessment to be undertaken during detailed design. The following is a possible scenario for development of the site based on information available at this conceptual stage.

It is proposed that the bulk of earthworks will be undertaken within the first six months of construction, with minor works to continue for another three months.

Four main work areas have been identified for planning purposes, the precast/fabrication area, the effluent treatment plant/chemical plant area, the pulp production area and the wharf (Figure 8-1). Please note that this figure is indicative only.

Initial clearing will not occur progressively but clear the whole work area to allow for simultainious development of the four sites. Vegetation will be be selectively logged, then cleared. Cleared vegetation will be mulched, burnt and/or buried.

Cut and fill balances are provided in Section 8.3. Earthworks have been proposed in three stages.

Stage 1: three months

initial clearing of the site;

construction of the crushing plant and aggregate stockpile areas within the precast/fabrication area;

opening the initial working face on the eastern side of the effluent treatment plant/chemical plant area and excavation of approximately ¼ of this area;



opening the initial working face on the eastern side of the pulp production area and excavation of approximately one third of this area; and

construction of the wharf and warehouse area cut and approximately 80 % of the fill area.

Stage 2: two months

expansion of cut and fill in all areas. Completion of the wharf and warehouse earthworks. Construction of the temporary carpark. Some services such as water mains may be installed during this phase.

Stage 3: one month

finalisation of main earthworks, major detention basins, canteens and construction phase offices.



The following equipment is typical of what may be used during construction. Vehicle numbes will vary with each stage. The exact composition of the construction fleet will be determined by the construction contractor.

Excavators 150 tonne capacity

Dump trucks 100 tonne capacity

Dump trucks 50 tonne capacity

Bulldozers (D9/D10)

Graders (140 H)

Earthworks construction will be undertaken during two eleven hour shifts per day, seven days week. Blasting will occur up to twice a day, seven days a week. Most of the rock excavated will be crushed and used for site levelling.

Concrete batching will not commence on site until approximately month six.

Up to four crushers may be located on site at the peak period.

Benching

The current design of the mill platforms is based on the following batters slopes for material other than rock:

1.5H:1V in fill and for provision of the services construction zone

1H:1V in cut

The current design will be reviewed in the light of the latest geotechnical information prepared by Pitt & Sherry and where rock is encountered the batter slopes will be steeper depending on the quality of the rock.

Blasting

All blasting shall be in accordance with AS 2187–1993 Explosives–Storage Transport and Use, and Notes for the Tasmanian Shot–Firer, Workplace Standards, Dangerous Goods Act – 1998, Dangerous Goods General Regulations – 1998, Australian Dangerous Goods Code, Volumes 1 & 2 – 1998 and the Australian Explosives Code - 2000. Blasting shall only be carried out by persons licensed under the Dangerous Goods Act 1998 and shall be in accordance with current Regulations.

Expolosives will be stored on site during site preparation. The storage of explosives on the site will be in licensed magazines which will comply with AS 2187.1-1998 and AS 2187.2-2006. Any Transport of explosives on public roads will comply with the Dangerous Substances (Safe Handling) Act 2005, Dangerous Substances (Safe Transport) Act 1998, the Dangerous Goods (Road and Rail Transport) Regulations 1998 and the Australian Code for the Transport of Explosives by Road and Rail.



A blasting risk assessment has been prepared by Orica Quarry & Construction Services and is included in IIS Volume 2, Appendix 33. Prior to blasting a detailed Blasting Plan will be prepared and designed to achieve the requirements of this clause.

The Blasting Plan shall include specific details of:

Drilling Pattern: Burden, Drill hole spacing, Hole depths, Hole diameters;

Explosive Loading: Explosive type and quantity, Explosive initiation method, Delay details, Charge mass per delay, Powder factor, Stemming details;

Blasting Procedure: A description of blasting procedure;

Monitoring Methods: A description of monitoring methods;

Details of Trial Blasting: A description of trial blasting; and

Control of Access to Areas of Blasting: A description of the control of personnel movements on the site and public access during blasting.

All structures within 500 metres of proposed blasting works and across the river within a distance of 1.5 km will be identified and a dilapidation survey of these structures will be carried out in accordance with DIER Specification G2.3. The surveys shall be undertaken by an experienced and qualified person, as required by DIER Specification G2.3 and shall include a comprehensive photographic record. Surveys of structures shall be sufficient to provide a complete and accurate record of the condition of the structures and all component asset elements.

Fully monitored trial blasts will be conducted in order to demonstrate that the proposed blasting procedures do not produce excessive ground vibrations. As a minimum, trial blasts shall involve measurement of ground vibrations at the structures to be protected. Trial blasts shall be carried out prior to commencement of bulk blasting for construction works and at any change in proposed blasting methods. Monitoring shall be undertaken by experienced operators using purpose designed and calibrated ground vibration monitoring equipment. The results of trial blasts vibration monitoring shall be reported in a similar form to Form A of AS2187.2–1993.

The initial trial blasts shall be designed to achieve ground vibrations below the following peak particle velocity limits.

20 mm/sec adjacent to heritage listed structures

25 mm/sec adjacent to all other structures

25 mm/sec adjacent to underground services

Higher peak particle velocity limits may be applied to the overhead 22 kv transmission line subject to the conduct of trial blasts and approval of Transend.

Variations in blast methods will only be made if it can be demonstrated that maximum ground vibration levels are not exceeded.

The Contractor should note that overhead power and transmission lines, Alinta gas pipeline and optic fibre cables are located in the vicinity of the works. Contact with the



relevant service owner/operators prior to commencing works in these areas and shall comply with the requirements of these authorities in undertaking the works. The Contractor shall be responsible for liaising with, and co-ordinating any inspections or works required by, Service Authorities in undertaking the works.

8.2.3 Pulp Mill

Construction of the pulp mill itself is estimated to commence with approval and extend over a 26-month construction phase until the proposed commissioning date in early 2009 (assuming approval is granted in November 2006). Individual components of the pulp mill will be given a specific construction schedule to ensure effective planning and operational compliance to the critical path. Details of the breakdown are included in Appendix 7, Volume 6.

8.2.4 Wharf

It is estimated that completion of bulk earthworks activities associated with the construction of the storage warehouse will occur within five months of commencement. In the first twelve months of the construction period, sections of the wharf will be completed to enable receipt of heavy lift and/or large plant and equipment required for the construction of the pulp mill. This equipment will be transported from the wharf to the pulp mill construction site.

8.2.5 Landfill

The conceptual construction steps are as follows:

Construct permanent access road to the landfill area

Construct permanent cut off and diversion drains

Construct temporary access road into construction waste cell footprint area

Clear vegetation from construction waste cell footprint area

Remove soil cover from construction waste cell footprint area and stockpile for future reuse

Construct construction waste cell

Construct drainage collection lines in the construction waste cell, including pipe through cell wall to energy dissipater

Construct leachate line from the landfill to the pulp mill effluent treatment plant

Construct turning circle/car park and construction lay down area at the site office area

Construct site office and ablutions block

Construct temporary access road into (process waste) Cell 1 footprint

Construct temporary surface water drains around the Cell 1 footprint



Clear vegetation from Cell 1 footprint area

Construct the landfill leachate collection buffer storage pond and pumps downstream of the final landfill footprint

Remove soil cover from Cell 1 footprint area and stockpile for future reuse

Construct Cell 1

Commence construction of the Cell 1 liner and leachate collection pipe work

Implement regular quality control program for the Cell 1 liner and leachate collection pipe work construction

Connect construction cell drainage system to Cell 1 leachate collection system

Undertake final quality control check of Cell 1 liner and leachate collection pipe work

Connect the leachate collection system to the leachate collection buffer storage pond, allowing temporary overflow (which will be uncontaminated) to the natural drainage system pending the construction of the leachate sump and pump system

Construct landfill leachate sump and pump system

Connect the landfill leachate sump and pump system to the leachate line once the pulp mill effluent treatment plant is commissioned

Commission the landfill leachate collection buffer storage pond and sump and pump system located downstream of the final landfill footprint

Commission Cell 1 of the landfill by carefully placing the first layers of mixed waste systematically out across the entire geomembrane ensuring no damage to the membrane. (The electrostatic precipitator dust from the lime kiln if delivered to the site in an unhydrated form will generate considerable heat on coming into contact with moisture in the other wastes. The heat will be sufficient to damage plastic materials, including geomembranes and pipes. Unless hydration occurs at the pulp mill site, mixing of the dust with other wastes will need to be undertaken in a controlled area, with adequate distance and/or insulation from underlying membranes and pipes).

When it is no longer needed, close and cap the construction waste cell

Construct the internal domestic waste cell in Cell 1 once approximately 1 m of mixed waste has been spread and compacted in the area

Operate Cell 1 of the landfill until full

Construct Cell 2 prior to the filling and capping of Cell 1 to the conceptual quality controls outlined above

Progressively continue to close cells and construct new cells for the life of the landfill.

Note: Wherever topsoil needs to be removed, it will be stored for later use as the final capping layer and/or for other site rehabilitation.

Construction is anticipated to be completed 3 months prior to pulp mill start-up.



8.2.6 Quarry

As mentioned above, the permanent access road to the landfill area will be constructed so as to allow access to the quarry. The construction/operation period is expected to be a maximum of five years.

8.2.7 Water Reservoir

As mentioned above, the permanent access road to the landfill area (and the quarry) will allow access to the water reservoir). The likely construction period for the water reservoir will be from month 8 to month 17 of the period of construction.

8.2.8 Water Supply Pipeline

The water supply pipeline will involve progressive construction works along the route. Construction activities will occur in short blocks along the pipeline alignment. Progressive vegetation clearing will occur along the route. An open cut trench will be formed, the pipe will be laid and secured, and the trench will be backfilled and vegetated as outlined in various sections of the Draft IIS. Permanent right of access along the easement is required.

Construction of the entire water supply pipeline will take approximately nine months and will occur between month 8 and month 17 of the period of construction.

8.2.9 Effluent Pipeline

The onshore component of the effluent pipeline will be constructed in progressive stages. The construction method will be consistent with that used for the water supply pipeline construction.

Construction and Burial Method of Outfall Pipe

The construction method for the offshore pipeline will be determined in the detailed design phase following the collection of site geotechnical information, the collection of meteorological and oceanographic (metocean) information, and completion of a cost/risk assessment. Two material types will be assessed: steel or glass-fibre reinforced plastic (GRP).

Climatic conditions including wind, currents and tides, waves and precipitation will be factored into the schedule of construction works.

Construction will involve some preparation works and construction onshore.

The construction concept has been developed based on open-cut trenching, followed by towing-out prefabricated weight-coated steel pipeline string sections.



The pipeline materials will be verified during the detailed design of the project. If the proposed geotechnical and metocean investigations reveal that a steel pipeline is unviable, then provided the ambient sea state conditions prove to be favourable for extended periods, the outfall could be constructed using GRP pipe material. GRP will eliminate the need for an onshore stringing and launching site, but will require full trenching and backfill offshore.

Open-cut trenching

The installation of the ocean outfall pipe is based on the following main activities:

Pre-fabrication of pipeline string(s) onshore;

Excavation of trench onshore and across the beach to the low water mark using onshore based excavation equipment;

Dredging of trench / seabed preparation offshore using dredging equipment;

Launching of pipeline string(s) using winch-pontoon or similar; and

Trench backfill / onshore site restoration (Atteris, 2006).

Dredging is normally performed using shallow water dredging equipment, such as a cutter suction dredge, or a clamshell or backhoe dredge. In this case, backhoe dredging will be the most suitable method for the following reasons:

A backhoe dredge is capable of dredging weak and weathered rock, and can quite easily be fitted with a subsea rock breaker when stronger rock pockets are encountered;

The turbidity in the water column from the dredging operations is generally more limited compared with other dredging methods;

A backhoe dredge has the ability to accurately create a relatively narrow trench; and

A backhoe dredge is an effective tool to assist with trench backfill.

Long ocean outfalls constructed with concrete weight coated steel pipe, such as the pulp mill effluent outfall, are usually launched into position from an onshore launchway (roller track) using the bottom-tow method, whereby the pipeline is dragged along the trench bottom and/or seabed with a specifically designed submerged weight.

In view of the onshore topography, the outfall pipeline string will be pre-fabricated in several shorter lengths of 200-250 m sections. A technically suitable stringing and launching site has been identified approximately 1 km onshore (Appendix 52, Volume 16). The launching alignment will require some excavation including auger boring under the highest dune in order to avoid disturbance of Xanthorrhoea aff bracteata (EPBC listed species). To overcome limited elevation differences in the terrain along the pipe launching alignment, temporary steel towers will be constructed. Vegetation clearance and the construction of a hardstand access will be required along the alignment. Revegetation of the site after construction will be required to safeguard the environment and to protect the outfall pipeline from erosion of its protective cover.



At this stage, it is assumed that the trench will be backfilled through the beach and out to the 10 m water mark, a distance of approximately 750 m.

An eight-month period of construction is anticipated. However, the manufacture and coating of the steel line pipe materials will be critical and depending on this, the construction period may need to be confirmed.

8.3 Aggregate and Fill

The total cutting volume of soils and rock will be about 2.7 million m3.

Estimated quantities of aggregate and fill for the pulp mill and wharf area is provided in Table 8-1. Further discussion is contained in Volume 2.

Table 8-1 Cut and Fill Volumes for the Pulp Mill

Area (m2) Excavation (m3) Fill (m3)

Pulp Mill area 390,000 1,800,000 1,230,000

Effluent treatment and chemical plant

210,000 250,000 465,000

Wharf and pulp storage area

42,000 350,000 4,000

Prefabrication area 135,000 360,000 224,000

Total 777,000 2,760,000 1,923,000

Source: Jaakko Pöyry, 2006.

The excavation/cut volumes of specific soil and rock types are provided below.

Table 8-2 Excavation Volumes of Soil and Rock

Silty clay (m3) Rock (Dolerite and Jurassic) (m3)

Pulp Mill area 625,000 1,161,000

Effluent and chemical plant

100,555 161,000

Wharf facility and pulp storage area

159,000 224,000

Precasting / fabrication

125,000 232,000

Total 1,009,555 1,778,000

Source: Jaakko Pöyry, 2006

The total area for the pulp mill, effluent treatment, chemical plant, sub station area, wharf facility and pulp storage area will be 777,000 m2, (Jaakko Pöyry, 2005, Annexure



XV of Appendix 8, Volume 7). The construction method for the water supply pipeline and most of the onshore effluent pipeline will be the trenching method. A trench will be dug/cut, and the pipe laid and backfilled. It is highly likely fill will not be required along the pipeline routes. If construction results in surplus fill, contractors will be responsible for organising to move clean fill to appropriate clean fill sites. If no clean fill sites are available at the time, the fill will be transported to the pulp mill site.

8.4 Transport

It is proposed that regular bus services and private motor vehicles will transport workers to the site during the construction phase.

8.4.1 Construction Traffic Generation

The workforce required for the construction phase of the pulp mill must arrive and depart the site utilising the road transport network. A combination of light and heavy vehicles is proposed to be utilised to transport personnel to the construction site.

In the event the workers accommodation facility is developed, personnel will be transported to the site during the peak period of the construction phase, a peak traffic generation of approximately 900 vehicles per day plus 40 buses per day has been assumed. A major percentage of this construction traffic will enter or leave the site during the respective morning and afternoon peak hours, with the remaining traffic entering or departing outside these peak times.

Approximately 40 % of the construction traffic is assumed to arrive from George Town, (entering the Tamar pulp mill access from the northern approach of the East Tamar Highway) and 60 % from Launceston (and entering the Tamar pulp mill access from the southern approach of the East Tamar Highway). It is likely that George Town will provide residence for at least 800 persons of the construction workforce due to its proximity to the site.

It has been assumed that 70 % of the total daily construction vehicle generation enters the Tamar pulp mill access during the morning peak hour (7:00 – 8:00 AM) and 70 % will depart during the afternoon peak hour (4:00 – 5:00 PM). Since buses will primarily be used to transport workers, it is assumed that 90 % of all bus traffic will enter/ leave within the respective peak hours.

These assumptions are considered a ‘worst case scenario’ for construction traffic, as they assume that a high percentage of the construction workforce will enter or leave within the same peak hour. It is likely that construction hours will vary between trades, and that this will have an effect on traffic generation across the day. Construction related deliveries will also account for a significant proportion of traffic generation outside the general peak hours.



8.4.2 External Site Construction Activities

The operation of the pulp mill requires infrastructure external to the site to be constructed to enable its successful ongoing operation. The various construction activities external to the site include the following:

Effluent pipeline construction;

Water supply pipeline construction:

Landfill construction;

Water reservoir construction;

Construction of workers’ accommodation facility;

Construction of landfill site;

Utilisation of quarry during construction period;

Construction of transmission lines; and

Construction of gas pipeline.

Effluent Pipeline Construction

The proposed effluent pipeline will follow a route similar to that of the existing Alinta Gas Pipeline in an adjacent easement, but with extensions from the Bell Bay Power Station to the pulp mill and a divergence on Cimitiere Plain to the outfall point off Five Mile Bluff (Jaakko Pöyry, 2005). Most of the effluent pipeline will therefore follow the East Tamar Highway north from the pulp mill site to George Town, where it will follow the Alinta easement across mostly agricultural land or follow the established road reserves to Low Head and Four Mile Beach.

The effluent pipeline follows and crosses the East Tamar Highway just north of the Bell Bay Power Station and Bridport Main Road near the intersection with the East Tamar Highway.

From the outskirts of George Town, the effluent pipeline follows or intersects roads within the local government road network up to Four Mile Beach. These roads are maintained by the George Town Council and are listed below in order of intersection with the pipeline, from the pulp mill site:

Bell Bay Road;

Main Road;

Mount George Road;

William Street;

Dorset Street;

Cemetery Road;

George Street;

Davies Street;



Stonehouse Street;

Arnold Street;

Soldiers Settlement Road;

Aerodrome Road;

East Beach Road; and

Bellbuoy Beach Road.

The effluent pipeline is proposed to follow, but not cross, the route of the railway line and the adjacent Alinta pipeline easement, from the intersection of the East Tamar Highway and Bridport Road, north to the end of the East Tamar Highway, where the line diverts to Bell Bay.

Effluent Pipeline Construction Traffic

The construction of the effluent pipeline will be likely to generate minimal additional traffic on the roads listed above. This traffic will be centralised around the area where the pipeline is being constructed.

Potential impacts such as loss of access, road closures, and traffic changes are discussed in more detail in Volumes 2 and 3 and Appendix 43, Volume 15.

Legislative Transport Approvals for Effluent Pipeline Construction

The construction of the effluent pipeline will require numerous road crossings on both State and local roads. This will require permits under the Highways and Jetties Act 1935 for State road closures, and under the Local Government (Highways) Act 1982 for local government roads.

All associated works within the road reserve will need to comply with DIER Code of Practice for Works on Roads as well as with Australian Standard, AS1742.3.

Landfill Construction

A landfill is proposed for disposal of waste generated during construction and operation of the pulp mill. The design capacity of the proposed landfill is up to 1.1 million cubic metres.

The location of the proposed landfill site is near Williams Creek on the western side of the Tippogoree Hills, approximately 9.5 km southeast of George Town. Vehicular access to the proposed landfill site will be approximately 1.4 km north of the existing Tamar woodchip mill access, on the eastern side of the East Tamar Highway.

The safe intersection sight distance required by the Austroads document, Guide to Traffic Engineering Practice, Part 5, 2005 Intersections at Grade, for a design speed of 100 km/h, is 250 metres. Consultants, Pitt and Sherry (2006a) prepared a report on the Solid Waste Landfill Concept Design, which incorporated details on the likely traffic and transport impacts of this component of the pulp mill. Available sight distances of the



access location for the proposed landfill were measured at 265 metres to the south and greater than 300 metres to the north. The sight distances at the proposed access meet Austroads safe intersection sight distance requirements.

The pulp mill will generate up to 200 tonnes of waste material to be disposed to landfill per day. The waste material may be transported to the landfill site in a range of trucks with varying capacities. The following variations of truck movements during a typical 8-hour shift working day were identified:

10 tonne truck generates 20 round trips/day, or 2.5 trips per hour;

15 tonne truck generates 13 round trips/day, or 1.6 trips per hour; and

20 tonne truck generates 10 round trips/day or 1.3 trips per hour.

Activities associated with the landfill may include 4 round trips per day for light utility vehicles.

The traffic distribution of this traffic will predominantly be between the landfill and the pulp mill site.

Water Reservoir

A water reservoir is proposed to provide the pulp mill with up to a seven-day water reserve in the event of failure of the water supply pipeline or in case of restrictions on drawing water from Trevallyn Dam.

The reservoir will comprise an earth embankment constructed across a small saddle east of the pulp mill site in the foothills of the Tippogoree Hills.

Access to the water reservoir site will be required for construction purposes and for occasional maintenance during the operation phase of the pulp mill and will be by the access roads constructed for the proposed landfill and the quarry.

The construction of the water reservoir will generate a small amount of heavy vehicle and associated traffic.

Quarry Construction

Access to the quarry will be by the East Tamar Highway along a gravel roadway at the same location as the access roads to the landfill and the water reservoir.

Access points will be required and incorporated with access to the landfill and the water reservoir. An access road is proposed at the lower end and sides of the two quarry benches.

An estimated peak of 50 truckloads per day will be required to haul the estimated 1,000 cubic metre of rock. The trucks will travel between the quarry and the pulp mill site during specific periods during the construction phase.



8.5 Construction Workers

The estimated maximum number of personnel required during the peak construction phase will be 2,900 people on site (Jaakko Pöyry, 2005). The estimated workforce is based on the typical requirements of similar projects. This is illustrated in Picture 5/4 in Appendix 7, Volume 6. Labour will be sourced from Tasmania, the mainland and (where required), internationally. It is expected that of the construction workforce, approximately 50 % will be sourced from the mainland, 40 % from Tasmania and 10 % overseas. Gunns’ preference will be to source Tasmanian labour where possible.

As previously mentioned, a workers accommodation facility is proposed to accommodate 800 workers. The facility will be located on the south side of George Town bounded by Main Road, Pembroke Road, South Street and Agnes Street. Any accommodation shortfall will be addressed by other, complementary, housing solutions outside the scope of the accommodation facility project.

The 800 residents will be housed in clustered layouts with ensuite accommodation, complete with site-contained services and amenities, together with emergency and most operational services. Details of the workers accommodation facility are provided in Volume 3.

8.6 Construction Hours

Construction works are proposed to occur twenty-four hours per day, seven days per week. This will vary depending on the various construction activities being undertaken at various times.

Management measures are recommended throughout the IIS to minimise the potential impacts from construction including restricting construction activities such as blasting and rock crushing to daytime working hours.

8.7 Temporary Construction Equipment

When construction machinery is not in use, it will be stored in one of the three laydown areas of the pulp mill footprint. A portion of the precasting area may also be used as a temporary construction storage area.

An appropriately bunded area will be provided for the storage of hydrocarbons and oils and for any service facilities such as oil changing and greasing. Clean-up kits will be available in the event of a spill.

An appropriate location will be provided in the landfill, quarry, and water reservoir areas for temporary storage of equipment. Machinery will be located away from sensitive areas such as waterways and clean-up kits will be provided in the event of a spill.

A workers accommodation facility, subject to need, will be provided and is discussed in Volume 3.



8.8 Checkout

During checkout, the function of all equipment, machinery and processes and process control systems will be tested (checked-out) with start/stop sequences, interlocks, and simulated disturbances. This is estimated to take place in the last three months before start-up.

The Drying and Baling Area may be started a month in advance of the new fibre line, with purchased pulp, to be able to do the test run before the new Fibre Line produces its own pulp.

The checkout and water-run activities are principally for quality assurance purposes. The aim of checkout is to ensure a successful start-up by eliminating problems due to mechanical, electrical and instrument defects or to installation errors and inconsistencies. Carefully executed checkout and water-runs provides satisfactory and continuous production.

The tuning and calibration of instruments (including adjustment of valves, stuffing boxes and cooling water) are carried out as far as possible without process media. In some cases, temporary piping must be installed for circulating water within a test system.

The checkout of individual sub-systems can start after the completion, inspection and acceptance of the respective MEI installations.

During checkout of the plant, it will be verified that the erection work has been completed and inspected, and that all specified inspection, examination or testing activities have been performed and approved.



major construction phase activities

Documents