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FOURTHQUARTER201403POWERFULPARTNERSHIPRoclaTeamsUptoMaintainPolePositionBLOOMFIELDBEAUTYRiverCrossingBridgedinRemoteQueensland WELCOMEWelcometothenalissueofTheWorksfor2014.Thepastyearhasbeenanotherchallengingoneformanyorganisationsintheinfrastructureandconstructionindustries.HoweverRoclasinnovationandeciencyhasresultedinanumberofsuccessfulprojectsandsatisedcustomers.Ourstoriescrossthespectrumfromanimpressivepre-stressedconcretebridgeinfarnorthQueenslandthathasre-connectedcommunitiestoarangeofroadsafetybarriersolutionsfortheGreatNorthernHighwayrealignmentinPortHedlandWAandaprotectiveretainingwallatDarlingtonPointNSWwhichwillprovideimprovedoodprotectiontothearea.WhatisnotableabouttheseprojectsandmanyothersistheirpositiveimpactonthecommunitiestheyservesomethingwetakegreatsatisfactioninbeingapartofatRocla.Wehopethatyouandyourfamilieshaveasafeandhappyholidaysandwearelookingforwardtoworkingwithyouallinthenewyear.IfyouvegotastoryabouthowRoclahashelpedyousolveaproblemletusknowwedlovetohearfromyou.HappyreadingTheRoclaTeamGotacommentEmailusatworksrocla.com.au.FormoreaboutRoclasystemsandsolutionsvisitwww.rocla.com.auorcall131004.PIPELINESYSTEMSBARRIERSYSTEMSPOLENETWORKSTRUCTURESSLEEPERS02 SUPER-SIZEDCDSUNITFUTURE-PROOFSMAJORMELBOURNEBUSINESSPARKWithacatchmentareaofaround200hectarestoserviceaCDSP3024UnitwasneededtomeetinfrastructuredemandsforbothpresentandfutureuseofthedevelopmentsaidAndrewCliftonMarketDevelopmentEngineerforRoclaWaterQuality.WhenyoulookattheunititselfplusalloftheadditionalprecastconcretecomponentssuchasthediversionchamberthisisoneofthelargestCDSUnitssoldbyRoclainAustraliahesaid.TheprojectisbeingundertakenbyassetownerAPAMAsianPacicAirportsMelbournewithSpiireAustraliadevelopingtheinitialdrainagestrategyandbeingsubsequentlyengagedtoundertakedetaileddesign.AswellascreatingamajornewbusinessparkprecinctforMelbournesWesttheprojectwillresultinasecondentrancetotheAirportrelievingcongestiononthemainentranceviatheTullamarineFreeway.Theintegratedstormwatermanagementsystememphasisesbestpracticewaterqualitytargetsandincludesa100000cubicmetreretardingbasinaspartofthedesign.PIPELINESYSTEMSThedevelopmentofalargebusinessparkprecinctwithintheTullamarineAirportlandhasresultedinacontracttosupplythelargestCDSGrossPollutantTrapGPTthatRoclasCampbelleldteamhaseverundertakeninmetropolitanMelbourne.03 ROCLACONCRETEBOXCULVERTSBESTFORFLOWAsizableRoclaConcreteBoxCulvertandlinkslabsolutionhasbeeninstalledonthenalstagesoftheChestereldParksubdivisiondevelopmentinWarragulEastVictoriatobridgeamajorcreekcrossing.LongtimeRoclacustomerTribuziContractorshavedevelopedthedrainageandcivilworksfortheentiresubdivisionstartingaroundfouryearsagowithstages11and12nowbringingtheworkstocompletionwithatotalof250homesites.ThecreekcrossingsolutiondesignedbyMilesCivilDesignofWarragulfeatures34of1500x900x1.22RoclaConcreteBoxCulvertsand17linkslabswhichwerealldeliveredtositeandthenplacedinasingledayusinganexcavator.ThisisaboutasbigasajoblikethisgetsanditallwentinwithinadaywithnodramassaidSteveBassedofTribuziContractors.Withthecreekbeingdivertedaroundthesideoftheworkstoenablelayingofthebaseandplacementoftheculvertsusingpre-castproductswaskeytoachievingthestarttonishtimeframeof3-weeks.BoxculvertsarethebestmethodtouseinasituationlikethisbecauseofowsaidSteve.Thissolutionisdesignedfora100-yearfrequencyood.Withboxculvertsyoualwaysgetabetterowratethanpipesandtheirshapeallowsforalowernishedroadsurfacelevel.ItsapracticaloptioninthesecircumstancessaidRobertBurnsSalesRepresentativeforRocla.Inadditionusinglinkslabsbetweentwochannelsofculvertsalsomeanslessmassinthewaterwaylesscostandlessweighttomovearoundthesite.WarragulisoneofthelargestgrowthareasineastVictoriaabout100kmeastofMelbournewithanumberofnewsubdivisionsbeingdevelopedoverthelastveyearstomeetthedemandforpeoplemakingalifestylemovefromthecitytothecountry.TheChestereldParksubdivisionhasviewsofMtBawBawtothenorthandStreleckiRangestothesouth.PIPELINESYSTEMS04 Thecompletionofthisprojectallowsforthedevelopmentoftwonewestatescomprisingapproximately400newhomessaidMarkSteggallDirectorofGippslandPipelines.Thenewpumpstationcutsothemajorityofsewerowupstreamwherethesewerwouldhavebeenovercapacity.Oncethedevelopmentofthetwonewestatesiscompletetherewillstillbecapacityleftintheexistingsewerline.Thisisanexampleofdevelopmentandwaterauthoritiesworkinghandinhandtoensuretheinfrastructureisbuiltaheadofthedemandrequiredbythenewhousing.AlotofwhatwedoremainsoutofsightandthereforeoutofmindsaidPaulClarkofGippslandWaterbuttherealityiswhenevernewresidentialorcommercialbuildingtakesplacewearetheretomakesurethesupportinginfrastructureisdoneright.Waterandsewerageservicesareamongthemostcriticalofamenitiesforfuturegrowthandwetakegreatprideinbeingabletocontributetothegrowthofourlocalcommunities.HavingendsandseweraccessstartershaftscastintheRoclafactoryatCampbelleldmeanteasierandquickerconstructionandlesstimeonsitefortheinstallationsaidRobertBurnsRoclaSalesRepresentative.Thesitehadlimitedaccesssoa200tonnecranewasusedtoinstallthepumpstationandstoragetanksmeaningtimingwascriticalespeciallywiththenotoriouswetGippslandweather.Marksaidtheprojecthadfaceditsfairshareofchallenges.Wehadveryrestrictedaccessonsitesowehadtosplitthedeliveriesandcarefullyprocuretherightsegmentsinthecorrectorder.RobertfromRoclawasveryhelpfulandunderstandingofourneedsonsite.Hedideverythinghecouldtohelpandwasverymuchpartoftheprojectteamhesaid.PROVENPRODUCTFORSUPERSIZESEWERSTORAGEThecontinuedexpansionoftheTraralgonhousingdevelopmentinVictoriahasseenGippslandPipelinesofWarragulengagedbyGippslandWatertoconstructa2400mmdiametersewerpumpstationandtwo90000LemergencystoragetanksthelargestinGippslandtodate.Thesewerpumpstationis7.4mdeepincludingaprecastbasesectionandtheemergencystoragetanksare10.5mlongand12.6mlongrespectively.BothstoragetankswereconstructedofRocla2550X2.1rubberringpipeswithendscastinand1050seweraccessstartershaftssothatextrashaftscouldbeaddedtobringaccesspointstothenishedsurfacelevelsasrequired.PIPELINESYSTEMSInstallationtimeforthetanks-thelargestinGippsland-wasreducedbycastingendsandshaftsattheRoclaCampbelleldfactory.05 NONSTANDARDPOLEPROVESECONOMICALFOR27KMLINERoclahadalreadyprovidedpolestoAusnet.TheyhadagreatunderstandingoftherequirementsandwereabletomeetPowercorstechnicalpricinganddeliverytimeframesfortheprojectsaidRandallLongProjectManagerforNationalProductsforPowercor.Aswithanyprojectofthisscalendingdesiredresultwaskey.Roclaassisteduswiththespecicationsforthe16kNpolesenablingustodesignthelinewiththeminimalnumberofpolesoverthe27kmlinerouteduetoincreasedspanlengthsexplainedRandall.Thishasalsoallowedustohavetighterconductortensionstoalsokeeptheheightofthepolesto18.5metres.As16kNpolesareanon-standardpolerarelyusedontheAusnetnetworkthismayseefuturelinesconstructedusingthistypeofpole.RandallsaidthatRoclahadbeenexcellentinprovidingthevarietyofpolesthatwereorderedfortheprojectwellwithinthepromiseddatesfordeliveryofpoles.TheyhavecoordinatedthetruckdeliveriestositeandinalotcasesforPowercorfromaconstructionperspective.The52windturbinesconstructedatBaldHillsWindFarmwillfeedpowerat66kVintotheAusnetnetworkfromtheLeongathaSouthswitchingstation.PowercorsroleintheprojecthasbeentodesignandconstructtheLeongathaSouthswitchingstationanddoublecircuit66kVlineconnectingtheBaldHillsWindFarmtothe66kVAusnetnetwork.Thelineisconstructedoveradistanceof27kmpartlyoverexistingpowerlineinfrastructureandalongroadsandthroughprivatepropertybetweenPoundCreekandBaldHills.FactsFigures339polessuppliedfromDecember2013toOctober2014Heightsrangingfrom11mto20mStrengthsof32kN24kNand16kNPOLENETWORKSTRUCTURESWhenPowercorNetworkServicesPowercorwasseekingasuppliertoprovide16kNconcretepolesthatcouldbeconstructedtoAusnetServicesAusnettechnicalstandardsforanew66kVlineconnectingtheBaldHillsWindFarmtotheir66kVelectricitynetworktheychosetoworkwithRocla.06 BroadcastAustraliaownsandoperatesoneofthemostextensiveterrestrialbroadcasttransmissionnetworksintheworldwithover600sitesstrategicallylocatedacrossAustralia.RTCommunicationsisoneofthelargestAustralianownedcompaniesfocusingentirelyontheprojectmanagementdesignandinstallationofcommunicationprojects.POLENETWORKSTRUCTURESMULTI-SECTIONALPOLESOLVESACCESSISSUEWhenlookingtoinstalla25mconcretepoleforanewcommunicationsfacilityonEndicottHillMudgeeBroadcastAustraliahitaglitch.Theaccesstracksueredmultipletightbendsmakingdeliveryofastandardtwo-sectionconcretepoletositeimpractical.HavingnotusedconcretepolesinthepastondicultsitespurelybecauseofdeliverabilityPhillipGruberfromBroadcastAustraliawaspleasedwiththeproposedsolutionapoleinthreesectionsratherthantwo.Thismadedeliverypossibleandrelativelyeconomicalcomparedtootheroptionshesaid.Aconcretepoleonthissitewasidealbecauseoflimitedspacewhichcouldntaccommodateafreestandingsteeltower.Concretepolesfortheseheightsareeconomicalandtheyhaveasmallerfootprint.BroadcastAustraliapartnerRTCommunicationswhoarecommunicationsinfrastructurespecialiststookupthechallengeofthisinstallationanddeliveryofthecommunicationfacility.Theyhaveerectedover60RoclaPolesduringthepastsixyearsonvariousprojectsacrossAustraliaaspartofcommunicationnetworks.CompanyDirectorRichardReedsaidtheRoclaproductsweuseandworkwitharewellsuitedtotheneedsofourcustomers.WehavealwaysfoundtheteamwillingandabletoassistusinprovidingsolutionsespeciallyonsiteslikeEndicottHill.Theircustomerserviceanddeliverycapabilitieshavealwaysensuredtimelydeliverywhichiscriticalwhenworkingtowardcustomerrequireddates.07 ROCLACLEANSALLGPTAGOODFITATHILLBANKWhenTripodiGroupwastaskedwithconstructingthestormwatersystemforStage1ofanewsubdivisiondevelopmentinHillbankSouthAustraliatheychosetoworkwithRocla.AsanalternativetoinstallingabioretentionorlargeundergroundltersystemfortheexpansionoftheSurgiCentreinToowoombaconsultingengineersKehoeMyershavespeciedRoclasuniqueenvissSentinelPittheonlyatsourceengineeredsolutiontolteringcarparkwaterrunoavailableinAustralia.ThereweretwoGrossPollutantTrapGPTunitsonesmallerandonelargersaidTonyCostanzoProjectManagerforTripodiGroup.Thesmallonepicksupallthestormwaterrunofromthe1kmlongentryroadandtakesallthesolidsandnastiesoutofitbeforebeingdischargedintoanexistingcreek.Thelargeunitpicksupstormwaterothesubdivisionroadwaysandcleansitpriortodischargetoanotherexistingcreek.WiththeunitsinitiallyspeciedasacompetitorproductTripodiGroupworkedwiththeconsultanttoswitchtoRocla.BecauseofourrelationshipandpreviousworkwithRoclaweinstalledtheirunitsaswewerefamiliarwiththeproductandndthemeasytoinstall.OneinparticularwasinafairlytightareaandwithRoclasunitsbeingcylindricalanddeepratherthansquatitwasabettert.Installationwascompletedinasingleday.Becausewehadpre-dugtheholesbasedonthedesigndrawingsandbecausetheRoclaunitsgotogethersimplyourguysewthroughthemsaidTony.RoclawaspresentfortheinstallationofthelargerGPTunit.ThatsauniqueservicewedontgetelsewheresaidTony.ItshowsusRoclacaresaboutmakingsuretheirproductsareinstalledproperly.WiththeenvissSentinelPittreatingwateratthesurfaceatsourceitmeansyoureessentiallytreatinglowerowsthanyouwoulddownstreamwithanundergroundendoflinesystem.ThismakestheenvissSentinelPitafarmoreeconomicalsolutionsaidNathanSwaerSalesEngineerforRocla.NathansaystheenvissSentinelPitsarealsoeasiertomaintain.Youliftthegratereplacethemediabagsinsideanddropthegratebackdown.Thereisnospecialcleaningequipmentorconnedspacecerticaterequiredwhichmeanscleaningcaneasilybecarriedoutbyexistingmaintenancestaatahugecostsavingtotheassetowner.ThebiggestthingforthissitewasthetightnessduetotheexistinglevelsonthesitesaidMarkBorgeltfromKehoeMyers.Wehadlimitedstormwaterdrainagearoundthesiteroadwayssothereforeallthestormwaterhadtobedischargedeithertosurfaceortheexistingkerbandchannel.Thismeantthedepthofanysystemthatweputinwascritical.FromtheinvestigationofallthedierentfacilitiesavailabletheRoclaenvissSentinelPitwastheonethatallowedustheminimumdepthfromintakeatsurfaceleveltotheoutletinvert.Aftercalculatingtherequiredtreatmentsurfaceareaatotalofveunitswereplacedinthebackcarparkandafurthereightinthefrontofthesite.SteveWilkesHydraulicandCivilManagerfromHutchinsonBuilderswhoweretaskedwithinstallationisafan.TheenvissSentinelPitsaremucheasiertoinstallthandetentionsystemsbecausetheywereinterlockingandcamepackaged.Allwehadtodowasworktheheightoutgetthefallsandtheninstall.Itsaneasystep-by-stepprocess.Forusbeingalargecompanywithnumerousjobsonthegoatanyonetimewedidnthavetorelyondeliveriesofsandcerticationetc.Thisisacompletelycertiedproductthatyousimplybuyandinstall.ENVISSSENTINELPITASMARTSOLUTIONFORDIFFICULTSITEPIPELINESYSTEMSPIPELINESYSTEMSRoclasuppliedtwoGPTunits-oneCleansAllGPT750completewithremovablestainlesssteelbasketandoneFirstDefenceVortexSeparator600.08 PRE-STRESSEDCONCRETEBRIDGELOOKSBEAUTATBLOOMFIELDAremotelocationforanewbridgeinfarnorthQueenslandhaspresentedanumberofuniquechallengesfortheprojectteamtaskedwithreplacingtheoriginalconcretecausewaywhichwasseverelydamagedbyoodingduringCycloneYasiandsubsequentlyclosedinearly2011.PhilipPearsonEngineerCivilfortheDepartmentofTransportandMainRoadsDTMRFarNorthDistrictProgramDeliveryOperationsexplainedThenewbridgehasimprovedoodimmunityandwillsignicantlyimprovereliabilityoftherivercrossingduringtheannualwetseason.Theremotelocationaround75kmsouthofCooktownwastrickyintermsofroadaccessandwaterlevels.TheDTMRundertookaroutesurveyoftheWujalWujalaccessroadanddeterminedthat19mlongprecastpre-stressedreinforcedconcretedeckunitswerethebestchoice.Inadditiontheexistinglow-levelcausewaywasfrequentlyinundatedwithwaterduetotidalowsandrainfallruno.TheconstructionteamworkedcloselywithRoclatoensurethattheprecastpre-stressedreinforcedconcretedeckunitsweredeliveredtositewithinspecictimeframestoalloweachdeckunittobeliftedothetruckandplacedontotheheadstocks.Thebridgedesignconsistedofreinforcedconcretecastinsitu1200mmdiameterpilesreinforcedconcretecastinsituheadstocksprecastpre-stressedreinforcedconcretedeckunitsandreinforcedconcretecastinsitudeckslab.AsaTMRRegisteredsupplierofprecastpre-stresseddeckunitsRoclawaschosentosupplythedeckunitsthroughatenderprocess.TheBloomeldRiverbridgeprojectreceivedexcellentsupportfromthelocalcommunityandWujalWujalAboriginalShireCouncilwhichthroughitsinvolvementintheprojectwereabletodeliverStage2ofthecommunityfootpathproject.Thenewpre-stressedbridgeatBloomeldRiverCrossingispositioned3.5mabovetheoriginalconcretecausewaytotheright.PIPELINESYSTEMS09 Tollisconstructingthebaseonafour-and-a-halfhectaresiteinDarwinsEastArmindustrialprecinctforglobaloilandgasexplorationandproductioncompanyINPEXanditsjointventurepartnersintheIchthysProjectthathasmajoroshorefacilitiesabout820kmsouthwestofDarwinintheBrowseBasin.Thefacilityisexpectedtoprovideupto120000man-hoursofemploymentduringconstructionandupto20permanentjobsoncecompleteattheendofthisyear.Adelaide-basedcontractorMcMahonServicesAustraliaMcMahonselectedRoclaAdelaidetosupplyseveralhundredmetresofclass4rubberringjointedpipeofvaryingdiametersalongwiththreeCleansAllGrossPollutantTrapsGPTs.MarkPolecSeniorProjectManagerforMcMahonsaidTheinstallationofthisstormwaterinfrastructurewasonthecriticalpathsowewantedtomanageitasbestaspossible.WeconsideredthatRoclawasourbestoptiontominimiseanyriskofnonorlatedeliveryandorpoorqualityproducts.PipeswereloadedinAdelaideandtravelledviarailtoDarwinarrivinginexcellentconditionsaidRobdeNyssalesrepresentativeforRocla.ToensurecontinuityofsupplypipesweresourcedfromWodongaCampbelleldandAdelaide.CleansAllGPTswereloadedinGailesQueenslandanddelivereddirecttoDarwin.FourRoclafactoriesworkingtogethertodeliveraseamlessprojecttotheNorthernTerritoryscapitalhasresultedinaqualityresultforallconcerned.RoclasengineeringteamalsoworkedcloselywithMcMahontoensurethethreeCleansAllGPTsweredesignedappropriatelyforNorthernTerritoryconditionsputtingtheirpreviousFarNorthQueenslandwaterqualityexperiencetogooduse.FOURFACTORIESAFEATUREOFSEAMLESSSUPPLYAcollaborativeefortbetweenRoclaPipelineProductsMcMahonServicesAustraliaAhrensandTipTopElectricalhasdeliveredqualitystormwaterandelectricalpitsolutionstotheexpansionoTollGroupslogisticsbaseinDarwinthatbeganinAprilthisyear.PIPELINESYSTEMSTheseRocla3600x3600RCBCcrownunitsarebeingplacedforanunder-highwaykoalacrossingontheCooroytoCurraproject.10 TheintroductionofthenewAustralianStandardforLargeSpan MULTI-PLATESTRUCTUREJUSTTHETICKETFORCOALBINREPLACEMENTInwhatisaninnovativeapplicationoanexistingandlongstandingproductMulti-PlateRoclahasdevelopedauniqueftorpurposereplacementsolutionoranagingcoalbinattheUlanCoalMineinNSW.TheoriginalcoalbinstructurewasimportedfromtheUKandinstalledaround20yearsagowhichmeanttherewasnotechnicalinformationavailablesuchasdrawingsormechanicalproperties.RoclasdesignengineerscollaboratedwithDeanMorrisonfromAspecEngineeringPtyLimitedtondasolutionappropriateforthehighlycorrosiveenvironment.RoundMulti-Plateasaburiedmetalstructuremostoftenusedforculvertsstormwaterdrainstunnelsandbridgescarriesverticalloadsthroughacombinationofinternalcapacityandsoilarchingaroundthestructure.UsingaburiedstructuredesignedinaccordancewithAS2041forabovegroundapplicationnaturallyraisedafewconcerns.Thelargestobstaclewastoensurethestructurecouldperformintheabsenceofhaunchsupportfromsoilfollowedbymanufacturingadurableproductwitha15yeardesignlifeinahighlycorrosivemineenvironment.ThenalroundMulti-Platestructurecomprised49piecesofgalvanised5mmsteelplates10platesperringx4constructedusing10boltsmwithatotalmassof464kg.Itfeaturedariseof7.05manddiameterof9.00ma12mmbaseliftingbraceandverticalsupportbracketallinaccordancewithAS2041AS3774andAS1170.Theclientwasprovidedwithdesignloadsactingonthestoragebinbasedonthebulkmaterialpropertiesonsitefollowedby2DFiniteelementanalysisanddesignforallsupportstructuresincludingbeamspedestalsandbaseplatefabricationdrawingsandcertieddrawings.RoclaexpectsfurtheragingcoalbinstructuresinNSWtobereplacedwiththeroundMulti-Platestructureoverthenext12months.PIPELINESYSTEMS12 Signicantoodeventsin20092010and2012resultedinthedamageofanumberofbusinessesandresidencesinthecatchmentandbecameakeydriverfortheprojectanoutcomeofanextensivestudyundertakenbyVDMConsultantsin2010.Thedetentionsystemconsistsofanearthembankmentincombinationwithalowowpipeatthecreekbedlevelandahighowspillwaytohandlesubstantialoodevents.ItsadetentionsystemratherthanadambecausethecontinuouslowowpipepositionedunderneaththedamwallenablesnormalcreekowstopassthroughthedamonacontinuousbasissaidStephenBoldenSeniorProjectEngineerforCairnsRegionalCouncil.Thebasinhasbeenlocatedgeographicallytotthetopographyintheareaandcombinedwiththeembankmentprovidesforapart-timedamintheeventofoodinginthecreek.Roclasuppliedthe1.8mdiameterclass6reinforcedconcretepressurepipeforthe77mlonglowowpipelinealongwithsubstantialinletandoutletstructurestocontrolwaterow.Becauseofthenatureofthedamthepipeallowsnormalowundernormalcircumstancesandconstrictsowduringaoodeventwhenitscapacityisexceeded.Thepipelinefeaturesa26-degreebendneartheoutlettorealignitwiththedirectionofthecreek.UnderaoodenvironmentexceedingQ20waterfallsoverthespillwayontobaeblocks.Thisresemblesaseriesofsharpteethdesignedtodissipatethehighenergyofthefastowingwateratthebaseandavoidscouring.Rocladevelopedtheformsandcast32oftheunitslocallyattheirCairnsfactory.Thedetentionsystemsoperationispassivewithnooodgatesvalvesorpumping.Thebasinisopenandgrassedwhichmeansitcanbeenjoyedasapublicparkareaformostoftheyear.RoclawasabletoprovideprecastreinforcedpipeunitstotherequiredspecsandwereabletohavethempressuretestedaspartofthemanufacturingprocesssaidStephen.ThosecapabilitiesandtheassociatedadvicemeantRoclaassistedinmatchingthespecicationtotheendproduct.PRODUCTSSUPPLIED31x2.44lengthsof270KPapressurepipeand1x26.5degreebend246tPedestalsforpipetransportandinstallation32xprecastbaes57tPIPELINESYSTEMSROCLADELIVERSFORHIGHPRESSUREPROJECTInaprojectdesignedtomitigateoodingintheMoodyCreekcatchmentinNorthernQueenslandalargedetentionbasinhasbeenconstructedasoneoanumberomeasurestoprotectbusinessesandhomesintheareaintheeventoa20-yearQ20ood.13 Withtheexistingcastinsitusinglespanculvertsbeing60-70yearsoldandonlywideenoughtocarryasinglecarnewinfrastructurewasrequiredtobetteraccommodateschoolbusesandmachineryforthelocalfarmingarea.MurrumbidgeeIrrigationsInfrastructurePlanningManagerJodyRuddsaidtheaimwastobuildastructurethatprovidedsimilarowcharacteristicstotheexistingstructures.ThecrossingsweredesignedbyMurrumbidgeeIrrigationandinstalledbyLadexIndustriesfromWaggaWagga.WhatsmostuniqueaboutthisprojectisthattheowsonallthecrossingsarecontinuoussaidJody.ConstructingtheculvertcrossingspresentedquiteachallengebeingonthemaindrainagesystemleadingoutofGrith.WhilstinstallingculvertcrossingsisnothingnewtoJeRossfromLadexConstructionGroupdivertingchannelswasawholenewchallengehednotencounteredbefore.WeworkedthroughallthescenariossaidJe.Welookedatsheetpilingorre-divertingthewholecanalbutintheendthebestoptionwastocreateacoerdam.MurrumbidgeeIrrigationarepleasedwiththeresultandarenowunderwayonafurtherthreecrossingsutilisingRoclasM-LockPrecastBridgeSystemasolutionforsmalltomediumspans715metresusingprecastreinforcedconcretecomponents.ThiswillbearstforMurrumbidgeeIrrigationbutnotforcontractorLadex.ThisisagreatsolutionforthesmallercrossingsasitwillavoidinowconstructionactivitysaidJody.RoclahavebeenmorethanhelpfulthroughouttheprojectsaidJody.Youtrytominimisesurprisesinconstructionactivitiesbuttherearealwayssome.Roclawerealwaysavailabletoworkwithustomitigatecostsandtimeframeoverruns.BRIDGINGTHEGAPFORIRRIGATIONNETWORKAspartofitsplantoupgradeandimproveroadaccessandwaterowacrossitsirrigationnetworkintheGrithregionMurrumbidgeeIrrigationcommissionedthreenewcrossingseachconsistingofthreeRoclacrownunitswithspecialbaseslabsandheadwalls.ThecompletedbridgesopenedtotracattheendofSeptember.PIPELINESYSTEMS14 PERFECTPARTNERSHIPFORLARGE-SCALEREALIGNMENTAneightkilometrerealignmentoftheGreatNorthernHighwayinPortHedlandaminingtownandironoreportapproximately2000kmnorthofPerthopenedtothepublicmidthisyearandfeaturesarangeofroadsafetyproductsfromRoclaBarrierSystems.SafetyBarriersWAwereresponsiblefortheprocurementandinstallationofthebarriersolutionwhichincludedW-BeammodiedThrie-Beamwireropeandarangeofterminalsandcrashcushions.DirectorofSafetyBarriersWACyndieWoolcocksaiditwasprobablythebiggestnon-miningprojectthecompanyhadcompletedinnorthernWesternAustralia.ChrisWhiteSalesRepresentativefromRoclaBarrierssaidTheoriginaldesignhadnominatedvarioussafetybarrierproductsbutSafetyBarriersWAandRoclaBarrierssuccessfullysecuredthesupplyandinstallsavingsbasedonusingproductsexclusivelyfromtheRoclarange.WhenaskedwhatshevaluesmostfromhersuppliersCyndiesaidOurlong-termrelationshipwithACPRoclaBarriersandthefactthattheyworktogetherwithuswhenweneedthem.Theywillrallyandgetbehindus.Thatloyaltyandbackingofagoodsupplierissomethingwestronglyrelyon.CyndiewentontosayACPisalwaysgoodwithachievingdeadlinesfordeliveryofproduct.Theirproductisofabetterqualitythancompetitorswithbetterqualityboltsandstrongerpostswhichmakesitaloteasiertoinstall.Ourinstallersarebigfansofit.ACPisaRoclaBarriersbusiness.PRODUCTS1800mTL-4Sentrylinebarrierinninesections1300mW-Beambarrier1200mModiedThrie-Beambarrier22xX-Tension350terminals20xThrie-Beamnestedsteelbridgebarrierandconcretewalltransitions17xTrailingterminalsand2xTAU-11crashcushionsBARRIERSYSTEMS15 TheCouncilreviewedvariousoptionsbutthetightsiteconstraintscalledforapre-castsolution.HandlingMassBlocRetainingWallSystemunitswaseasierinthislocationastheycouldtaketheblocksothetruckneartheexistingcarparkandthenuseanexcavatortostackthemsaidSriErraSalesEngineerforRocla.Unitsweigharound1.7teachandfeaturealipenablingeachblocktointerlink.In-situmassconcretewasrequiredforthefootingandstructuralbacklladjacenttothebackoftheblocks-partofthestructuraldesigndevelopedbyCardnotoachievetherequired8mmaximumheight.EurobodallaShireCouncilDesignEngineerMarkSwadlingsaidtheMassBlocRetainingWallSystemwasreallytheperfectsolution.Wewereconstrainedbytheprojectrequiringanearverticalwalland8mupisprettyhigh.MassBlocgavetherequiredareaatthetopofthewalltoconstructthecarparkwhereashadweusedothermoretraditionalsegmentedtypeofretainingwallswewouldhavehadlesscarspacesavailable.Itwouldhavebeentrickygoingthathighwithothertypesofblockstructure.SiteSupervisorforthecouncilEdGwynnesaidhedneverworkedwiththeMassBlocRetainingWallSystembeforebutthatithadgoneupfairlyeortlessly.Wefoundtheblocksverysimpletolayandputinplace.Itsagreatideaanditseasyandquick.Icanseeitbeingusedinmanyotherplaces.MASSBLOCRETAININGWALLSYSTEMPERFECTFORHILLSIDERETAINERWhenEurobodallaShireCouncilneededaretainingwallsolutionupto8mhighforanewhilltopcarparkareaadjacenttoanexistingshoppingcentretheyturnedtoRoclaspermeableMassBlocRetainingWallSystem.Projecttimeframe5weeksNo.ofblocks194Heightofwall8mmaxApplicationHillsideearthretentionPIPELINESYSTEMS16 PERMATRAKBOARDWALKSYSTEMBOTHPRACTICALANDPRETTYFORLUXURYHOUSINGDEVELOPMENTWiththeentrancetotheirnewprestigehousingdevelopmentInsigniainBallaratbeingadjacenttooneofthelongestAvenuesofHonourintheworldIntegraGroupwereseekingagood-lookingboardwalksolutiontofurtherenhancethelandscapedesign.BecausethisisaninllsitewehadalotofstormwaterdetentiontodoandwealsohadtobemindfulnottotakeanythingawayfromtheAvenueofHonourexplainedRichardHowellOperationsManagerforIntegraGroup.Theprojectcalledforasolutionwiththesamecharacteristicsastheexistingconcretefootpaththatcouldaccommodatedetentionunderneath.OnchoosingRoclasmodularPermaTrakBoardwalkSystemIntegragotmorethangoodlooks.ItwasabsolutelytherightproductforthissituationsaidRichard.Ithaslongevitylackofmaintenanceandtheabilitytoreplacecomponentsbutalsotsinwiththefairlyheavyalmostindustrialaestheticwevegotgoinghere.Itlooksgreat.IntegraaredelightedwiththeresultandareintendingtousetheRoclaPermaTrakBoardwalkSystemelsewhereintheproject.ThereareacoupleofparkswherewewilluseitoveratreerootzonewhichmeanswewonthavetoexcavatetherootssaidRichard.PIPELINESYSTEMS17 NewhighcapacityelectrictrainswillbeabletooperatealongQueenslands108kmBauhiniarailspurfromRangalsouthtotheRollestonminebeforetheendofthisyearthankstotheinvestmentinanewconcretepoletransmissionlinebyAurizon.TheAurizonprojectwasspeciedinRoclaDuraspunconcretepolesandisa132kVtransmissionpowerlineandsubstationfeaturingatotalof49polesrangingfrom20m80kNto34.5m80kNandmanufacturedatRoclasRockhampton-basedfacility.GavinRobertsistheSiteEngineerforLaingORourkethecontractorsresponsibleforconstructionoftheline.HesaidtheprojecthadcometogetherincrediblywellthankstocollaborationwithRoclaattheoutsettoaddressconcernsaboutpolelevelingandorientation.Thevastmajorityoftransmissionpoleswerespeciallydesignedforextraheightandstrengthduetothesitebeingaoodriskzone.Thismeantthepolesneededtobeinstalledinthreeseparatesectionsandrequiredthepolebasestobeperfectlylevelandorientatedtopreventanypoleleanortwisthesaid.Thiswasachallengegiventheboredholesweresixmetresdeepmeaningthepolebaseonlystandsonemetreoutoftheground.Roclasuggestedtheuseofadigitallevelwithtemporarystaysaroundtheperimeterofthebasehookeduptochainblocks.ItworkedoutperfectlyanditwasabigreliefwhenwenishederectingtherstpolewhichstoodperfectlyplumsaidGavin.WiththeorientationalsoneedingtobeaccurateRoclaprovidedazeropointonthepolebasesallowingthesurveyorstomarkouteithersideofthepoletolineuptheorientationpoints.Withallthepolespre-drilleditsprettyessentialtogettheorientationrightsothatwhenwerunthewirethecrossarmsarespotonsaidGavin.RoclaSalesRepresentativeSamuelGeorgesaidtheprojectwasagreatexampleofcollaborationwithameetingheldbetweenLaingORourkeandRoclapriortothesupplyofpolesandtheattendancetherstdeliveryandinstallation.ConsistentcommunicationbetweentheRockhamptonfactoryandtheLaingORourkesitemanagerhasensuredthisprojecthasbeendeliveredsuccessfullytospecicationshesaid.POLENETWORKSTRUCTURESCONCRETEPOLELINESUPPORTSELECTRIFICATIONOF108KMRAILSPUR18 WhenstandingthesectionalpolesratherthanusingacranetoholdthepolewhilebeingbackflledandwhiletheflldriedovernightLaingORourkecreatedsupportsusingthetemporarystaysaroundtheperimeterthechainblocksandlongslingsinsteadreeingupthecraneorotherduties.WeusedthissystemtobothhelporientatethepolesandtoleavethereassupportwhilethebackfllwoulddrysaidGavin.19 MASSBLOCRETAININGWALLSYSTEMTOPROTECTDARLINGTONPOINT-MURRUMBIDGEESHIRECOMPREHENSIVEROCLARANGELEADSTOMAJOREXPORTPROJECTIntherststageotheDarlingtonPointLeveeBankpartotheDarlingtonPointFloodplainManagementProjectintendedtoprovideupgradedfoodprotectiontoDarlingtonPoint.Roclahassupplied500MassBlocRetainingWallUnitsalongwith60mo225mmslottedPlastreamSteelReinorcedPipeoraretainingwalltoreinorcetheMurrumbidgeeriverbankduringfoodevents.WiththeirlocalLiquidNaturalGasLNGexportoperationsrampingupthedeliveryoExxonMobilsnewpermanentacilitiescompoundinPapuaNewGuineaisacriticalpieceoinrastructureorthebusiness.TheRoclaPlastreamPipedrainsexcesswaterwhichcanbuildupbehindthewall.Using225mmPlastreamPipewasasmarteralternativetoinstalling100mmslottedpipeasitdissipateswaterquickerandbetterwhileinstallationiseasierasthereisnoneedorasocksaidAdrianEmerSalesRepresentativeorRocla.ThesecondlargestriverinAustraliaandamajortributaryotheMurrayRiverwithintheMurray-DarlingbasintheMurrumbidgeeRiverrunsor1600kmsthroughMurrumbidgeeShire.TheimprovementswerecommissionedbytheMurrumbidgeeShireCouncilandareinresponsetoasignifcantoodeventatDarlingtonPointinMarch2012wheretheriverpeakedat7.7mpromptingtheevacuationohundredsoresidentsandinictingmillionsodollarsworthodamage.LeightonContractorswastaskedwithdevelopingthecompoundandchosearangeoRoclaproductsortheproject.Thesupplyrequirementsincludedsmalldiameterpipestormwaterpitsgrosspollutanttrapsoilwaterseparatorsandboxculverts.RoclaSalesRepresentativeScottFyesaysRoclasabilitytosupplyawiderangeoproductsandmanagethelogisticalchallengesaroundexportingwerekeyactorsinwinningthecontract.BeoresigningthecontracttheclientvisitedRoclasGailesactorytoworkthroughthetechnicaldrawingsandinspectproductupclose.Thiswasalargeorderwhichneededtobesuppliedineightweeks.MakingithappeninvolvedclosemanagementontheproductionprocessaswellasliaisonwiththereightorwardingcompanyandtheclientinPapuaNewGuineasaysScott.PIPELINESYSTEMSPIPELINESYSTEMSDarlingtonPointisasmalltownonthebanksotheMurrumbidgeeRiverintheRiverinadistrictowesternNSW.ItispartotheMurrumbidgeeShirelocalgovernmentarea.20 SKEWEDLINKSLABSGOTOGETHERLIKECLOCKWORKATCHINCHILLAAlongoughtprogramoworkstoimprovetheQueenslandtownoChinchillasdrainagesystemandstormwatercapacityiswellunderwaywithanumberopipelineandcrossingprojectsawardedtolongstandingRoclacustomerSouthEastEarthmoving.OnesuchprojectrecentlycompletedisalargeskewedculvertsectiondesignedtoollowtheangleotheroadwhichcarrieswaterthroughtheChinchillastormwaterchannelunderChinchillaTaraRoad.Witharound85componentstoplaceStuartBazleyromSouthEastEarthmovingsaidtherewasabitoanarttoconstructingtheculvertandlinkslabsystembuthisinitialconcernswerequicklyputtorest.Becausetheywereskewedandwehadspanningslabstherewasnoroomorerrorwhenweweredoingthesetouthesaid.Thespanningslabshavedowelstoattachtothetopotheculvertssowescrewedtimberstothebaseslabsowhenwecranedthemintheywererightonposition.Ittooklessthanaday.StuartsaystheprincipalWesternDownsShireCouncilisveryhappywiththenewtrunkdrainagesystemthatbothlooksantasticandwillhelpimprovewaterowoutothetownoChinchilladuringheavyrainoroodevents.Theskewedslabsrequiredcareulplanningtoensuretheculvertswerelinkedprecisely.StuartBazleyoSouthEastEarthmovinghasbeeninthebusinessocivilearthworksor25yearsandhasdealtwithRoclaoraround20othose.HesaysRoclaisaone-stopshoporhimwhenitcomestoconcreteproducts.ItenderorprojectslikeeveryoneelseandIsourcepricesonlyromRoclabecauseIhaveaterrifcworkingrelationshipwiththem.Roclaarealwaysverycompetitiveandtheirproductissecondtonone.Chinchillastormwaterchannel3.2kmlongrunsromGormleyRdandfnishesattheeasternendotheshowgroundsMorethan170000m3odirtexcavatedOver1moconcretepouredSkewedculvertstructureinstalledeaturing85precastcomponentsPIPELINESYSTEMS21 Polesweredelivereddirectlytomappedlocationsmatchingnalpolesitesreducingthetimingriskandeortofinstallation.22 APOWERFULPARTNERSHIPROCLAANDAPIPTEAMUPTOMEETADEMANDINGSCHEDULEINQUEENSLANDRoclasexpertiseinsupplyingtotime-sensitiveprojectsalongwithitsindustry-leadingDuraspunConcretePowerPoleshaveaidedthesuccessfulcompletionofamajortransmissionlinerelocationinQueenslandbyAustralianPowerIndustryPartnersAPIP.WhentheadvancementofaQueenslandminesopencutcoalfacebegantothreatenanexistingelectricitytransmissionlineAPIPturnedtoRoclatohelpfacilitatetherelocationofthehighvoltagetransmissionfeeder.APIPwereengagedbythemineownertodeterminethemostcosteectiveandtechnicallyfeasiblesolution-timeconstraintsandanemphasisonminimaldisruptiontotheminesoperationswerecriticalfactors.ThechallengewasasisalwaysthecasewiththistypeofprojecttheenddatedoesntchangeandinstallationwindowsaretightsaidSamuelGeorgeSalesTerritoryManagerQLDforRocla.SoforAPIPtotakeonthejobinadditiontohavingtheexpertisetoexecutetheirplantheyaredependentontheirsuppliers-inthiscaseRocla-torstlycommitandthentokeeptoanon-negotiabledeliveryschedule.RoclasDuraspunConcretePowerPolesweretheclientspreferredchoicewiththeexistinghighvoltagetransmissionfeederbuiltusingthesameproduct.HavingpreviousexposuretotheRoclaproductrangeduringhistimeworkingfortheQueenslandelectricityutilitiesAPIPBusinessOperationsManagerNathanRoachsaidthatRoclasDuraspunConcretePowerPoleshavebeenusedextensivelythroughoutQueenslandsupportingtransmissionpowerlinesandthattheyrepresentedthelowestriskoptionforthebuild.ForAPIPbeingabletotrustRoclatoplaytheirpartinprovidingaqualityproductandmeetingtheclientsdeadlineswasasignicantfactor.Roclasknowledgeandexperienceinthemanufactureofconcretepolesiscritical-theyveproventhemselvestobeareliablesupplierreducingtheprojectsriskexposureandinstillingcondenceintheclientthatdeliverydateswillbeachieved.TheyfocusonwhattheydobestandwecanfocusonwhatwedobestsaidNathan.AfterfabricatingtheDuraspunConcretePowerPolesRoclaarrangedthedeliveryofeachpoledirectlytotheinstallationsite.Roclaoeraservicethatprovidesforindividualplacementofpolesascloseaspossibletotheirnalin-placelocation.Theirpreparednesstocustomisedeliveryschedulesandinteractdirectlywithsitepersonnelremovesasignicantvariablewithintheconstructionschedulethislevelofserviceisnotnormallyavailabletotheresourcessector.WithminimaldisruptionakeyrequirementAPIPworkedcloselywiththeclientduringthedesignandplanningphasetoensureoutagewindowswerekepttoaminimum.Worksrequiringaninterruptiontothemineelectricitysupplywereplannedwithinexistingoutagewindowsforpreviouslyscheduledworksonsite.ThissortofscheduleaccuracywasmadepossiblewiththehelpofreliablesupplierslikeRoclasaidNathan.WhenyoucombineateamofhighlyqualiedHighVoltageprofessionalswithreliableexpertindustrysuppliersyoubringtothemarketastrengtheneddeliverymodelandahighlyecientworkenvironmenthesaid.Aligningthecutoverwithaplannedmineoutagemeantaseamlesschangeandminimaldisruptiontothemine.POLENETWORKSTRUCTURES23 FORFURTHERINFORMATIONCallyourlocalRoclarepresentative131004www.rocla.com.auThecontentsofthispublicationarecopyrightandmaynotbereproducedinanyformwithoutthepriorwrittenconsentofRoclaPtyLimited.Productapplicationsdescribedinthispublicationaretobetakenasillustrationsonlyandareprovidedwithoutliabilityonthepartofthecompanyoritsemployeesandagents.TrademarksofRoclaPtyLimited.ABN31000032191.AmemberoftheFletcherBuildingGroup.MassBloctrademarkusedunderexclusivelicencefromMassTecIndustriesLimitedandFletcherConcreteandInfrastructureLimited.TAU-IItrademarkandABSORB350trademarkusedinAustraliaunderexclusivelicencefromBarrierSystemsInc.Super-CorregisteredtrademarkusedunderlicencefromAILInternationalInc.DownstreamDefendertrademarkusedunderexclusivelicencefromHydroInternationalPLC.RoclaPtyLimitedNovember2014.