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SECOND QUARTER 2015 04 SUPER SIZE SUPER-COR Environmentally sensitive site secures safe crossing TRAIN TERRITORY NT Railway construction comes together quickly WELCOME For more about Rocla systems and solutions visit or call 131 004. Welcome to The Works . If there is one thing that continues to be true regardless of what industry or economy were talking about its that where there is a downside there is also an upside. It might be the weaker Aussie dollar stimulating an increase in tourism one primary sector meaning another starts to get the attention of investors. There is always an upside if you look hard enough. As businesses go Rocla has been around a long time. Many of our longer serving employees have seen the coming and going of technologies crises nancial or otherwise and governments. And as much as any business Rocla has needed to look for the upside and evolve with those changes always keeping one thing in mind that if we help our customers do what they need to do to grow and thrive then well thrive too. Sometimes that comes in the form of a specialist service such as the assistance of the Rocla PAD team to design a system to treat 24000L of stormwater per second for stage one of Australands Fairwater Residential development in Blacktown or development an existing product to improve ease of use such as the newly developed CDS Unit Segmental Screen which reduces assembly time and simply bolts together onsite providing a product that is simple to install whilst maintaining services and minimising environmental impact such as the Rocla M-Lock precast bridges installed on Murrumbidgee Irrigations PermaTrak boardwalk system which is preserving a culturally signicant site in Craigieburn. Or it might be our ability to design manufacture and Downstream Defender for the 1b Gateway WA Project and super-sized Super-Cor culverts for a ood-prone crossing at Wobadda Creek in Northern Queensland. Weve once again proled a whole range of projects in this issue each of which faced their own unique challenges but were delivered regardless. We hope youll nd something of interest to your particular practice or industry and if youve got a story of your own wed love to hear about it. Happy reading The Rocla Team Got a comment Email us at 02 ROCLAPERMATRAK BOARDWALK SYSTEM PROVES PERFECT FOR NO-DIG SITE Principle Peet Limited Contractor Warrandale Industries Landscape Consultant Urban Edge Landscape Architects About the Rocla PermaTrak boardwalk system The Rocla PermaTrak concrete boardwalk system is a cost- recreational walkways cycleways and foot bridges. It is ideal for all environments from arid through alpine to coastal terrain including deserts riverbanks wetlands mangroves beaches rainforests and caves. Precast concrete components provide strength design exibility and a long trouble-free life. The system is quick to install and can be extended or relocated at any time. The newly developed Burt- kir-min Reserve in Craigieburn alcoRfom05serutaef PermaTrak boardwalk. With an already vast portfolio of landscaping projects under their belts commercial landscaping specialists Warrandale Industries can now add a further landscaping solution Rocla PermaTrak modular boardwalk system to their list of capabilities. A 50m path of Rocla PermaTrak boardwalk system has been laid as part of a new recreational development commissioned by Peet Limited for Hume City Council in Craigieburn Victoria which features a playground walking paths picnic facilities and shelter. Warrandale Industries Project Manager Tim Buruma says he was aware of the Rocla PermaTrak boardwalk system but hadnt previously installed it. The cultural management plan for the site had identied the land held cultural signicance for the Wurundjeri Tribe which meant we had to avoid any major ground disturbance. Urban Edge Landscape Architects had specied the Rocla system which given its weight and design suited the conditions and fullled the requirements for all parties. Tim says the installation was straightforward and everything went together really well. Id certainly use it again he said. The local community is very pleased with the new facility early April. 03 Many years of discussions between the Cairns Regional Council and Atlantic Civil a division of Rocla nally resulted in the installation of two of the largest Atlantic SuperCor box culverts ever installed in Australia in mid 2014 in one of the countrys most environmentally sensitive areas. The Bloomeld Track is a 30km coastal route between Cape Tribulation and Cooktown in tropical North Queensland set in the heart of some of the oldest tropical rainforest in the world. The track which is World Heritage listed winds along the coastline and is only suitable for four-wheel drive vehicles. It also crosses Wobadda Creek which is susceptible to ooding meaning that prior to the installation of the new crossing the area was a major detour inland. Ron Pascoe Northern Region Sales Manager for Atlantic Civil says Atlantic SuperCor structures to surroundings. The relative light weight of each structural plate made it pretty easy to install. Construction was undertaken by local labour from Cook Shire Council without the use of heavy equipment. Travelers now have an impressive reliable route to Cairns and Cooktown and there was little impact to the environment its been a win all round. This was a very good project to be involved with. The Director of Engineering Services for Cook Shire Council said It is good to be involved with the development of the Cape York Peninsula and working with the Aboriginal communities in this particular area to give better access to their communities for tourism. Designed for a 100-year service life the structures will require little maintenance and from a practical point of view the large spans of the arches reduce the chance of debris build up in high ow times. With the Atlantic SuperCor structures installed in July 2014 nal works including the installation of headwalls and other nishing touches to blend in with the natural environment were completed in March 2015. SUPER-SIZE ATLANTIC SUPERCOR CULVERTS FOR WOBADDA CREEK The completed bridge structure allows safe passage of vehicles during ooding and blends in with the natural surroundings. 04 structures each with a span of 15966mm and rise of 3387mm were installed in the creek in mid 2014. The photo shows fairly typical water levels requiring four-wheel drive vehicles for successful crossing. 05 ROCLA RECRUIT HAS HEALTH SAFETY TOP OF MIND Roclas latest recruit Health Safety Environmental Manager James Smith has already had a healthy introduction to the Rocla family. Being included in the manufacturing team and engaging in multiple initiatives in the first month has James convinced his vision and Roclas values are well aligned. It was boots to the ground James said being immediately called upon to use my previous experience allowed me to offer a different perspective and quickly gauge how Rocla operate. James started with Rocla in May 2015. After several years working as a health and safety professional in similar industries he has brought with him a wealth of knowledge in construction manufacturing mining and aviation safety. Its this diversity that convinced Rocla he ticked all the boxes during the recruitment process and James also feels the company was a perfect fit. The recruitment process was well-managed and comfortable and the new position gave me the chance to move forward with a company that shares my values. The strength of the Fletcher Building group provides many opportunities to grow within the business. With the industry constantly evolving and the focus increasingly being placed on safety Rocla has put further effort into ensuring they stay ahead of the curve with the restructuring of their Health Safety team just one example. Every organisation strives to make sure they meet minimum legislation in regards to health and safety but ensuring Rocla are leaders in the industry in safety initiatives and best practice will be what sets us apart he explains. My goal is to develop a strategic and individual approach for every site. Effective communication with both site management and workers enables them to have a voice and highlight areas where we can improve. The aim is to deliver the Fletcher Building groups values and bring a high level of safety maturity to every part of the business. Rocla has given me the chance to develop my knowledge and experience and in turn Ill be able to help the company develop as well. To find more opportunities to develop and grow in the industry contact Fletcher Building or Rocla. 06 Principal Mackay Regional Council Contractor Vassallo Constructions Consultant Aurecon The revitalisation project is a 50-50 joint venture funded by the Australian Government and Mackay Regional Council and in addition to beautification initiatives such as street furniture landscaping lighting and public art involves a significant underground and surface stormwater drainage upgrade. Chris Andersen Project Manager for Vassallo Constructions says Mackays old infrastructure has presented a few challenges. Currently in place is an old 600mm hand-laid brick arch pipe which runs down the centre of Wood St and is up to 100 years old he says. Were now duplicating that system on a different alignment installing a 1200mm rubber ring joint reinforced concrete pipe ranging from 3.8m 2.2m in depth. But before we could install the new line the existing watermain which runs right in the alignment of the new drainage line had to be replaced on a new alignment. Then we also had to relocate and upgrade all the existing street lighting because it was located where the new watermain was going The complexities of the project meant using a reliable quality product from a trusted supplier was paramount. Roclas product has always been a good product their quality is always spot on said Chris. Jim Carless Project Manager of the City Centre Revitalisation Project for the Mackay Regional Council says the new trunk drainage line designed by engineering consultants Aurecon provides for greater underground stormwater capacity taking it from the current Q2 rating up to Q5. It supplements the existing stormwater system and ultimately will replace the clay brick constructed drain which services large portions of the city centre out to the river. Its still operable and will still be used but ultimately the new 1200 line will futureproof it. Once the underground civil works are complete the city centre will have a robust safe and sustainable base for the beautification aspects of the project which will eventually extend as far as historic building restoration improving building facades and working with local businesses to promote the region. ITS WHATS UNDER THE SURFACE THAT COUNTS In a classic example of not knowing what youre going to get until you start digging Vassallo Constructions who were tasked among other things with the drainage component of the Mackay City Centre Revitalisation project have had to deal with a number of complexities in the 18m venture intended to cement Mackay as a destination of choice. The relationship with Rocla is all about the technical support the people we are in contact with and also the convenience. We were able to have the pipes delivered to a location suitable to us to avoid double handling. Its all about convenience. Jim Carless Project Manager Mackay Regional Council City Centre Revitalisation Project The figures 33m of 1500mm x 750mm Rocla reinforced concrete box culverts 138 x 1200mm dia rubber ring joint Rocla reinforced concrete pipes class 2 and 3 88 x 375mm dia Rocla reinforced concrete pipes 2 x 22 degree bend 1200mm dia Rocla reinforced concrete pipes 20 x 900mm x 600mm Rocla reinforced concrete box culverts For more information about the project visit 07 The Gateway WA Perth Airport and Freight Access Project Gateway Project is the largest infrastructure project ever undertaken by Main Roads WA. Australian Construction Products ACP took on the largest barrier project in the state since the Perth Bunbury Highway was constructed in 2009. The need for the project has been driven by the expected doubling of passenger air travel and the road freight task over the next decade coupled with proposed consolidation of the Perth airport terminals. It is being jointly funded by the Federal and State Governments and will cost more than 1b with completion expected by 2016. The project involves a major upgrade to the road network surrounding Perth Airport and the freight and industrial hubs of Kewdale and Forrestfield. It focuses primarily on Tonkin Highway between Great Eastern Highway and Roe Highway and Leach Highway between Orrong Road and Perth Airport. According to Main Roads WA this area of Perth is arguably WAs most important transport interchange where road rail and air services meet to facilitate the movement of people and goods that are essential to the economy of both the state and the nation. The project is the largest ever supplied by Safety Barriers WA SBWA who have installed over 260km of barrier over the past seven years and won the tender to supply all road barriers based on their track record of reliability and previous work with contractor Leightons. Cyndie Woolcock Director of SBWA said it is the longstanding relationship with ACP and the trust they have built over the years that keeps them working together and that it was a joint effort to win the work. Wed made a commitment to SBWA from the start says Paul Kelly from ACP. We wanted them to win the job so we worked hard on pricing and with the Gateway guys on specification and supply. Its a partnership with SBWA were here to support them. With the project ramping up from around July 2014 15 of the barriers were installed by early 2015 with the remainder to follow during 2015 requiring up to four installation crews on the project at its height. 54KM OF BARRIER IN BILLION DOLLAR WA GATEWAY PROJECT 08 ACP is a Rocla business. 09 Rocla Poles are Tested year after year in severe bushfire conditions Impervious to termites corrosion and rot Engineered to meet the strict requirements of transmission line construction Manufactured from reinforced or prestressed concrete at heights of up to 55m Integrated fittings with a wide range of footings available. For further information call 131 004 W E R E TA K I N G P OW E R TO N E W H E I G H TS. Rocla is the proven name in concrete pole durability flexibility and strength. Advanced separation technology The Rocla Downstream Defender separator is an advanced hydrodynamic vortex separator. Rotary and shear forces are generated to augment gravitational forces and remove settling solids using a much smaller area than sedimentation basins. An oil and floatables trap within the vessel provides a compact solution for non point source pollution. With the addition of a spill tank the Rocla Downstream Defender separator provides an effective spill control system as well as removing sediments fines and litter. This is an ideal solution for major road projects where there is a requirement to control potential hydrocarbon spills. BIG IS BEAUTIFUL FOR GATEWAY Rocla was chosen to meet the challenge of a very large storage requirement within a small footprint faced by the Gateway WA project and many other road corridor projects like it. The largest Rocla Downstream Defender separator system in Australia was recently installed at the corner of Leach Highway and Abernethy Road on this 1b project. Rocla Regional Sales Manager Craig Donaldson says the system a Rocla Downstream Defender 3000 with grit chambers and in line storage tank weighs about 70 tonnes in total and was dropped into position by crane at the end of April. The role of the system is to remove accumulated oil and sediment from the stormwater discharge of a main transport corridor as well as provide emergency catastrophic oil spill control for a fully laden 24000L petrol tanker. Stephen D Baker Manager Water Quality for Rocla says the unique quality of the Rocla Downstream Defender is that pipe geometries can allow complex inletoutlet pipe configurations. Alternative solutions could have involved catchment splitting over several sites which would have meant more complex maintenance regimes and long term costs he says. Rocla Downstream Defender bypass upstream manhole inlet pipe weir wall outlet pipe 11 ROCLA PLASTREAM DETENTION SYSTEM HELPS MANAGE FLOW When the City of Charles Sturt SA needed a solution to prevent ooding in Findon Road they looked at a number of alternatives for a detention system at Don Klabe Reserve eventually settling on Roclas Plastream steel reinforced polyethylene pipe. There were signicant ooding issues further upstream which dictated an upgrade to local underground drainage but it was going to produce ows in excess of the capacity of the downstream drainage network says Tim Kerby Senior Engineer for Tonkin Consulting. The Plastream system has been used to detain ows so they will now match the capacity of the downstream system. Tim says hed never worked with Plastream before but this was a unique project in terms of the site constraints meaning Plastream t the bill. We identied that the original concept design to detain ows within a basin wasnt going to be viable given the site constraints he says. We had issues of proximity with buildings reactive soils underground services management of existing trees and a tight footprint. Ultimately three interconnected 1350mm diameter storage chambers were specied to provide the required 600m3 of detention storage. With Plastream being a watertight solution and able to detain a large volume of water in a fairly small space it was considered the ideal option and installation took place in February to April this year. Rocla Plastream steel reinforced polyethylene pipe is lightweight making it ideal for sites with limited or 12 Roclas CDS Unit P3000 series is now available with a fully pre-fabricated bolt together on-site screen assembly. For more information call your local Rocla representative or phone 131 004. oooonnn-sssiiittteee ssscccrrreeeeeennn aaasssssseeemmmblyl .yy FFFor more information call y Rocla Water Quality along with the Product Application Design PAD team have been working for some time on improving the product offering for the large 3000 series Rocla CDS units. Traditionally the Rocla CDS Unit P3000 series screens have been offered as at pack screen sheets requiring signicant on-site stainless steel welding in a conned space. The development of the new CDS Unit Segmental Screen means the conned space entry risk assessment and controls required are minimised by no on site welding no gas no hot work and no manual handling of welding equipment including gas bottles. This reduces the risk of HSE incidents signicantly. By manufacturing the screens and associated assembly details prior to delivery to the customer we can make sure the durability of the CDS Unit Segmental Screen is at its highest. Each screen is pre-fabricated under factory Quality Assurance. There is no loss of functionality to the screens performance and there are no special skills required to assemble the CDS Unit Segmental Screen welders etc.. The new screens take less time in assembly which means it is estimated a Rocla CDS Unit P3024 could now be fully assembled by a standard site crew easily in one eight hour day. If the screen is damaged panels can now be removed and replaced separately as part of lifecycle maintenance. All of the above benets have been veried by a trial assembly at Roclas Canberra factory prior to the new CDS Unit Segmental Screens being installed on several recent projects with great success. 13 PREMIUM POND PROTECTION FOR NEW DEVELOPMENT A large-scale Rocla water quality solution capable of managing 24000L of water per second is providing industry-leading protection against urban generated stormwater pollutants for Australands Fairwater Residential 800-lot stage one development in Blacktown Western Sydney. With the development set around 9.5 hectares of parks and waterways to provide attractive open areas for families the central pond is a key aesthetic feature of the development. The brief to engineering consultant Craig Rhodes by the developer was to provide the highest level of pollutant capture so that litter and sediment were captured from upstream urban catchments before stormwater entered the pond. Henry Ha Water Quality Specification Engineer for Rocla said the Rocla Product Application Design PAD team worked closely with Craig and Rhodes to overcome a number of technical challenges. The system had to be able to treat and bypass stormwater flows from a wider catchment outside of the development being some 78 hectares supplied by twin 1500mm diameter pipes. At peak flow the twin 1500mm diameter inlet pipes will supply 24000L per second through the gross pollutant trap GPT unit. At this rate youd fill an average backyard swimming pool every two seconds he said. A cast in situ diversion chamber the size of a large living room was installed to handle peak flows from the catchment along with a Rocla CDS GPT and a Rocla Downstream Defender 3000 separation unit. The CDS provides an industry leading engineered solution to capture gross pollutants such as litter leaves and sediments. It is efficient and robust due to its ability to self clean its capture screens said Henry. The Downstream Defender was installed in addition to the CDS unit to provide further polishing of the stormwater to filter out free oils and sediment. The two Rocla units combined will ensure that the pond stays clean playing its all-important role in the ongoing desirability of this important new urban space. Roclas PAD team of Darren Cook Peter Warnock Stephen D Baker and Chris Bordignon specialises in assisting customers and consultants to ensure Rocla products are used to best effect within the requirements or constraints of a project and more importantly that nothing is left to chance. In some cases such as the system for Fairwater Residential this means making modifications to the product to produce the desired result. In this case the complex detailing of the treatment train configuration multiple treatment units and associated levels had to fit within a tight hydraulic profile in order to avoid upstream flooding during peak events said Stephen D Baker Manager Water Quality for Rocla. PAD produced a full set of detailed drawings to ensure no information was overlooked. Frank Carrozza Urban Development Project Manager from Craig Rhodes says his consultancy tends to work with Rocla in Blacktown because the council trusts the performance and quality of Rocla product. Roclas service and assistance to meet both our requirements and council requirements was really good he said. They ran a number of scenarios and offered solutions to get it to work. Frank says the Rocla team helped minimise delays by working closely with Craig Rhodes during the drafting phase to expedite the design development and by providing access to a number of people throughout the process. 14 The upgrade is also one of the largest reinforced concrete box culvert projects Rocla has supplied in the Southern region and includes five major road crossings where Rocla reinforced concrete box culverts designed for acid sulphate soils in a salt-water environment have been supplied. The higher spec product means a lifespan of 100 years is still expected regardless of the corrosive circumstances. Rocla representative Robert Burns said that in addition to these special requirements traffic management was essential to maintain access to the industrial estate. Coordination of deliveries was critical as the base slabs had to be poured and culverts installed as quickly as possible he said. Rocla manufactured and kept the culverts stored until they were required progressively delivering them to site when we needed them said Gordon Charles Senior Project Manager for East Gippsland Shire Council. That was exceptional in my view. It meant we managed to keep road closures to a minimum which was appreciated by Council and the local residents. Gordon says Roclas willingness to accommodate the demands of the project was also evident when a discussion with homeowners about installing drainage through their properties revealed a preference for a flat surface over the top rather than an open drain above circular pipes after the pipes had been manufactured. Rocla allowed us to modify the order to box culverts. We were very impressed with their flexibility and sympathetic approach to our circumstances said Gordon. HI-SPEC CULVERTS FOR SALTWATER ENVIRONMENT The Eastern Creek Upgrade in the town of Lakes Entrance is the largest drainage project that the East Gippsland Shire has undertaken to date and is intended to improve the capacity of Eastern Creek which runs through industrial areas of Lakes Entrance and to assist in eliminating flooding in the coastal town which lies just two metres above sea level. Lakes Entrance is situated 320km east of Melbourne on the coastline of 90 Mile Beach and is one of the largest tourist areas in Victoria with access to the states largest inland waterways. 15 The new 520m long pipeline and associated services installed by Mt Hotham RMB and pipeline contractor Extons replaces the steel pipe originally installed in the 1980s which was found to have deteriorated. Rocla provided more than 200 x 2100mm dia Class 3 reinforced concrete pipes 8 of which were fabricated with 5 degree bends 4 x 3000mm dia reinforced concrete pipes plus 900 x 900mm reinforced concrete pits plus grates and accessories for the project. Rocla also supplied 400m of 600mm dia Plastream steel reinforced polyethelene pipe for the surface drainage and 1350mm dia reinforced concrete pipe for a separate creek also with fabricated bends. Project Manager for Mt Hotham RMB Mick Cherry has worked with Rocla for a long time and certainly knows the history of the resort having worked there for more than thirty years. However he says this project presented a whole new set of challenges that required a fair amount of good old Aussie ingenuity. One of the main challenges was the limited access around the site says Mick. Rocla transported the pipes to Mt Hotham to the top of the mountain in semi-trailers in convoy three pipes per semi. We then used a specially modified forklift to load the pipes onto a specially purchased 6-wheel drive Mac truck fitted with a pipe cradle. The pipes were transported on the truck from the stockpile at the top of the mountain one at a time a total of 204 trips down the fairly steep 3.5km into the valley. The other challenge was the narrow valley floor - its around 25m wide and about 500m long. Due to the size of the pipes and the length of the pipeline there was a massive amount of earth to move in a very limited space. A lot of things were pre-planned and constructed specially for the job to enable it to happen including customised equipment for laying the pipes and compacting the fill. There was a lot of coordination between the contractors and other allied services to work in together. With the toughest part of the project well and truly complete the focus now moves to revegetating the valley and making final preparations for the winter snow season. With the countdown to the ski season well and truly underway the Mt Hotham Resort Management Board Mt Hotham RMB can breathe a sigh of relief having successfully completed a major stormwater pipeline upgrade through the Swindlers Valley ski field despite very challenging conditions. AUSSIE INGENUITY HELPS TACKLE TRICKY TERRAIN 16 17 A FAST NO-FUSS SOLUTION FOR NEW CROSSINGS In its continued drive to upgrade and improve road access and improve water ow has completed three further replacement road crossings this time using Roclas M-Lock precast concrete bridge system. p p g g M-LLoocckk kk ppprreeccaasstt ccoonnccrreettee bbrrididgggee ssyyysstteemm. The three bridges are identical 15m long and 10.8m wide and are within a 2km area. Jody Rudd Delivery Executive for Murrumbidgee Irrigation says they were just the right size for a single span allowing the construction team to work out of the waterway and maintain levels of service during the construction process. He says they would denitely use Roclas M-Lock precast bridge system again. We predominantly use pipe and box culverts in these situations. This was the rst time we have used a place and drive over structure. You place the decks and its ready to go there is very little nishing. As far as limited interruption to our levels of service and neighbourhood in terms of closure its a much better option. The crew from Ladex Construction Group Ladex tasked with construction are no strangers to the Rocla M-Lock precast bridge system having installed a number of them in recent years. From go to whoa knocking down the old bridge removing electric lines out of the road completing the civil works to get to the stage of piling and then getting the new bridge installed and the road open is about is there the bridge itself is up in three days. We obviously found them far easier to use and put together whereas with culverts there is a need to precast bridge system its just a matter of drilling either side of the canal putting pilings down and building the bridge like Meccano. There is no water diversion the guys and machines didnt even get wet. Its denitely an easier option. 18 Pile holes bored piles lifted into place and driven into the ground minimum 2m. Tested by registered authority to achieve the accepted standard as required by the specications. Piles trimmed to exact height required for the headstocks to be placed on top. Headstocks and end beams placed and rock lining protection of the channel banks undertaken. Plank placement using two cranes simultaneously lifting the planks into position between the headstocks. Planks bolted together and all open voids grouted using recommended and approved product. Guard railing and approaches nalised. 19 Rocla customer Sure Constructions has been engaged by Tarago Gardens Pty Ltd to develop the property purchased in 2013 into an over 55 lifestyle village. However due to the fairly steep slope of the site they needed to build a substantial retaining wall across the whole development in order to fully utilise the land and make it as flat as possible for the future residents. The project involved moving 25000m3 of earth and placing 173 standard 193 base 6 corner and 2 half blocks. Kyle Taylor from Taylor Miller consulting engineers says the Rocla MassBloc retaining wall system was the only option considered thanks to the previous experience of Sure Constructions Director David Muir. The benefits are the size of them and the ease of construction he says. Their weight and size gives surety they will retain the amount of material behind them. And they are easy to place compared to other options. A short construction time was required as the cut and fill operation of the land was a critical part of the project says Rocla Sales Representative Robert Burns. Therefore a quick solution for a retaining wall was the key and the MassBloc retaining wall system proved a winner on all fronts. Kyle says as someone who hadnt worked with the Rocla MassBloc retaining wall system previously hes impressed particularly with Roclas ability to get designs completed and provide construction advice. ITS GOT TO BE THE ROCLA MASSBLOC RETAINING WALL SYSTEM A property development at Neerim South about 160km east of Melbourne at the foothills of Mount Baw Baw can now boast the longest Rocla MassBloc retaining wall in Victoria and the largest number of blocks ever supplied to a single project. The challenging terrain proved a significant challenge to best utilise land space. Steep blocks and loss of land in batters was not a preferred option. Rocla helped us get to a fast and efficient solution. Delivery was timely and construction ran smoothly. The fast installation enabled significant earthworks including behind the blocks up to 3m to continue in a timely manner to beat the Gippsland Winter Weather. David Muir from Sure Constructions 20 21 REPLACEMENTBRIDGEIMPROVES FLOOD IMMUNITY 100-FOLD Another Northern Queensland community is now beneting from vastly improved ood immunity with the replacement of a low-level 1930s timber bridge on the Kennedy Highway in the town of Innot Hot Springs with a new higher-level Queensland Department of Transport and Main Roads QDTMR pre-cast concrete bridge manufactured by Rocla. Rocla supplied 26 x 15m pre-stressed piles and 57 x 21m deck units for the new 3-span bridge which will improve the ood immunity to annual exceedance probability of 1 - which under the old terminology is equivalent to a 1 in 100 year ood event said Philip Pearson Engineer Civil for the QDTMR Far North District Program Delivery Operations. The project is funded by the Australian Government and is part of a major push for continued works to improve the inland route that is used as an alternative to the Bruce Highway. With a very low ood immunity the original bridge had ooded a number of times in recent years isolating the communities it served and putting a stop to heavy vehicle transport. Philip says the QDTMR looked at a variety of replacement options. We undertook a geotech analysis of the ground strata and cast insitu piles were considered but it was found that we could achieve the required capacity from pre-cast driven piles which is a quicker method of construction with less risk when considering the close proximity of Roclas depot he said. The project also involved upgrades to the bridge approaches and associated intersections plus lighting and a pedestrian walkway on the bridge meaning big benets for Innot Hot Springs residents and heavy vehicles looking for alternatives to the Bruce Highway during the wet season. Bryan Vance from Brisbane-based contractor Decmil Engineering had worked with Rocla precast piles before. He agrees that you cant ask for more than a project to go to plan and for everything to t together. It went smoothly everything arrived on time and there was minimal hassle he says. The units were good quality the post stressing holes lined up well and the lengths were all good. Rocla in the past has provided The Department with very good pre-cast piles and deck units and we were able to continue that strong relationship said Philip. Everyone worked well together to ensure the piles and deck units were delivered and installed on time and safely. This project is another example of quality improvements to QDTMR infrastructure delivered by Far North Queensland suppliers. 22 BIGGER AND BETTER BRIDGE FOR WA A new bridge constructed late in 2014 and intended to make crossing the Greenough River on the Brand Highway in WA safer is around twice the length and 1.6m higher than its 60-year-old predecessor which was possibly the oldest reinforced concrete bridge still in use prior to decommissioning. The new bridge is situated 25m upstream of the original bridge is 90m long and has a width between kerbs of 8.2m. It features 202m of Thrie-beam guardrail on fabricated bridge posts over the river itself and a further 320m of modied Thrie- beam guardrail on the approaches all supplied by Australian Construction Products ACP - a Rocla business and installed by Safety Barriers WA. Safety Barriers WA installed all guardrail materials supplied within ve days on site says Chris White from ACP. It was a very smooth installation process which was helped by the good quality of the ACP guardrail materials. Safety Barriers WA and ACP have enjoyed a long partnership which has seen them successfully complete many of the Main Roads WA rural and main highway bridge guardrail upgrades and major infrastructure projects in WA over the past 10 years. The new Greenough River Bridge Brand Highway WA is designed to remain usable in the event of a one-in-100 year ood and was part of an 8.1m Main Roads project. 23 IN AND OUT IN 30 HOURS IN NT As a critical conduit for freight and tourism the Adelaide-Darwin railway carries freight trains operated by Genesee Wyoming Australia GWA and the Great Southern Rail operated passenger train The Ghan.operated ppassengger train The Ghan. So when one of the culverts on the newer section of the line from Alice Springs to Darwin washed out in heavy rains in January 2014 and the replacement solution of a concrete box culvert bridge was decided GWA needed to identify a suitable gap between trains to undertake construction. With a 36-hour window identied requiring just one train cancellation planning for the installation began in earnest and an order was placed with Rocla for 24 x 2400 x 2400 x 2.4m 300 LA steel reinforced concrete box culverts each weighing 10t along with pre-cast base slabs rather than pouring in-situ to ensure the speediest possible construction. Roclas Rob de Nys was on hand during installation There were two 12 hour shifts with 50-odd people on the job he says. They had to take out the line put the base slabs down and the new culverts on top backll and put the track back in and they did it all within 30 hours. Whilst the project faced a few challenges including being 30km from the highway the track was handed back six hours early because everything went according to plan. With a lot of pre-work undertaken the construction work during the track closure was centred on the track and formation and getting the track back in place there was no outlying work to be done. 24 About GWA GWA owns over 3500km of track in South Australia and the Northern Territory including the 2200km Tarcoola-to-Darwin railway. An accredited rail-service provider in six states GWA provides intrastate haulage of bulk commodities including grain steel gypsum and minerals as well as short-haul shunting and terminal operations. GWA is also a major supplier of contracted services such as locomotives wagons and crews for freight forwarding on the interstate and Tarcoola to Darwin rail network. 25 A longstanding source of annoyance for residents in Canada Bay NSW has nally been resolved. In the once quiet street of Barnstaple Road the rattling of the lid over a P2018 CDS unit installed in 1999 has been silenced using the latest technology. Engineering Supervisor for Rocla Peter Warnock says he rst investigated the site in 2006 to see how the six part Gatic lid could be secured to prevent it background to why the lid was installed. The location was in the middle of a quiet access road that leads down to the water of Iron Cove Sydney Harbour. Using the existing technology for the conditions which included tidal inuences and tail water the grab clamshell cleaning method for the CDS was the preferred option. This requires the opening of the unit to gain complete access for the apparatus the existing technology in 1999 was the multi-part Gatic lid system that comprises multiple rectangular sections of lid supported by a mid-span lintel. By 2006 the waterfront had been developed with the road providing access to more residential properties. increased with the lid generating a low-key but penetrating clunking noise. With budgetary considerations of council a key factor a number of solutions were attempted. Eventually some eight years after the issue was rst raised the new consolidated Canada Bay Council approved the design of remedial works proposed by Optimal Stormwater in conjunction with Rocla to be completed by H2O Civil. Conducting any project in the middle of a high and these remedial works were no exception. A out utilising safety barriers lighting fencing and signage. On the completion of the works Rocla the site observing and listening to high speed high It was agreed that after the completion of the works the result was a vastly reduced noise level and minimal visual impact which has naturally met with the approval AAAAA llllooonnnggggssstttttaaannnnnddddiiiinnnnnggggg ssssooourururccceee ooofffff aaannnnnnoooyyyyaaannnccceee ffffoooorrrr rrrreeeesssssiiiiidddddeeeeennnnntttttsssss iiiiinnnn CCCCCaaaannnnaaaadddddaaaaaa BBBBBaaayyyyyyyyyy NNNNNSSSSSWWWW has nally been resolved. In the once quiet street off Barnstaplle Roadd the rattling of the lid over a P2018 CDS unit installed in 1999 has been silenced using the latest technology REMEDIAL WORKS REMOVE RATTLE FOR RESIDENTS out utilising safety barriers lighting fencing and signag THE SOLUTION Rocla supplied a 600mm P2000mm riser section and a P2000 Davo Lid - which is a concrete encased CDS swirl lid format of conversion slab. The rating on these components is the road usage requirements. The methodology required the unit to be excavated down to the top hat removing the existing riser section. The replacement P2000 riser section was cut down to approximately 430mm and chamfered to suit the camber of the road. This section was xed to the existing top hat complete with Rocla branded primer and black mastic to seal the join with 90 stainless steel brackets dyna- bolted into both sections. The Davo Lid was placed on the riser section with a layer of interlocking rubber material underneath to prevent any movement. 26 A cast-in-situ collar was formed up around the lid and concrete placed to prevent any of the surrounding material from falling into the unit when the lid is removed for cleaning. During this process a band of able-ex was placed around the circumference of the lid to establish a 10mm gap to enable the removal and replacement of the lid for the cleaning process. The surrounding excavation was backlled and mechanically compacted to the required compaction rate with the level of backll 100mm from the top of the lid. The councils asphalting crew placed and then compacted the asphalt to a level exactly marrying into the camber of the road surface. Throughout the process RPP personnel monitored the methodology and provided advice. From an aesthetic point of view the result was the typically minimal CDS footprint. 27 FOR FURTHER INFORMATION Call your local Rocla representative 131 004 The contents of this publication are copyright and may not be reproduced in any form without the prior written consent of Rocla Pty Limited. Product applications described in this publication are to be taken as illustrations only and are provided without liability on the part of the company or its employees and agents. Trademarks of Rocla Pty Limited. ABN 31 000 032 191. A member of the Fletcher Building Group. MassBloc trade mark used under exclusive licence from MassTec Industries Limited and Fletcher Concrete and Infrastructure Limited. TAU-II trademark and ABSORB 350 trademark used in Australia under exclusive licence from Barrier Systems Inc. Super-Cor registered trademark used under licence from AIL International Inc. Downstream Defender trademark used under exclusive licence from Hydro International PLC. Rocla Pty Limited May 2015.