Hanson | Skytrain: Delivering for Hanson Slide 1 North West Rail Link – John Hewitt 25/08/15
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Skytrain: Delivering for Hanson
Slide 1 North West Rail Link – John Hewitt 25/08/15
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Summary – NWRL SVC Project Works
• 4.6 km of precast segmental viaduct, 450 piles, 120 piers, 1,200 segments, 2300 parapets
• 230 metre cable-stayed bridge over Windsor Road at Rouse Hill – “An impressive structure set to become a distinctive local landmark”
• Station platforms • 3 Super T bridges
North West Rail Link – John Hewitt 25/08/15 Slide 2
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North West Rail Link
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Skytrain Contract $340 million contract awarded to ISJV on 17th Dec 13. Involves building a 4 km skytrain structure between Bella Vista and Rouse Hill, along with other surface works like bridges, embankments and railway cuttings. Skytrain contract is one of three major contracts for the construction and operation of the North West Rail Link.
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NWRL Project Team
Client: Transport for NSW (TfNSW) Contractor: Impregilo Salini Joint Venture (ISJV) Design: SMEC
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Impregilo Salini (ISJV)
North West Rail Link – John Hewitt 25/08/15 Slide 6
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Proportions considered • Width and depth ratios, edge design and column
supports to ensure its appearance blends in with the environment
Sustainability initiatives • Minimise the use of resources/materials - have a low
carbon footprint Rail infrastructure elements • Incorporated into the design holistically and be able to
be maintained – such as acoustic sound walls, downpipes and lighting.
Design Principles
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Environmental • Conservation of resources
Social • Individual and community wellbeing and safety
Economic • Economic prosperity and productivity
North West Rail Link – John Hewitt 25/08/15 Slide 8
Transport for NSW definition of sustainability
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Piling work and excavation - Concrete piles form the foundation of the Skytrain structure.
Pier construction - Erecting piers to support the precast box girders that will provide the overall support for the Skytrain structure. Girder installation - Installing precast box girders that will be joined together to create spans from pier to pier.
Parapet installation - Installing a parapet as a safety barrier for staff working on the Skytrain at the outer edge of the girder and be used to minimise noise impacts
Construction
Slide 9 North West Rail Link – John Hewitt 25/08/15
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Video – ISJV Tender Submission
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Supply all concrete: Circa 80,000m³ concrete: • 38,000 m3 for precast viaducts – Mulgrave batch plant • 35,000m3 ready mix concrete – Metro Concrete Supply all precast units: 4000 precast elements: • 2300 Precast parapets • Super T’s • Station platforms Lease: 22,000 m² at Mulgrave for approximately 2 years (no labour) Supply: 3000 m³ of gravel pavement Mulgrave plant: ISJV to fund all new plant assets and improvements
North West Rail Link – John Hewitt 25/08/15 Slide 11
ISJV / Hanson Agreement
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Mix Designs
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• Use AS3600 Special Class concrete and produce a consistently light colour concrete through use of cementitious material and aggregate only. No pigments or applied surface finishes.
North West Rail Link – John Hewitt 25/08/15 Slide 13
Urban Design Requirements
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• Achieve an Infrastructure Sustainability Council of Australia “Design” rating score of at least 65
• Use blended cement that contains waste industrial products such as flyash and ground granulated blast furnace slag
• Produce low carbon concrete • Achieve a minimum 1 point under the Green Star
Mat-4 concrete credit criteria for Portland cement, aggregate and water
North West Rail Link – John Hewitt 25/08/15 Slide 14
Sustainability Requirements
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The mix water for all concrete used in the project to contain at least 50% captured or reclaimed water (measured across all concrete mixes in the project) ISJV B80 specification added a new clause 2.7…all mixing water shall be tested daily at each source of supply for Chloride,Sulfate, Total Alkalis and Total solids
North West Rail Link – John Hewitt 25/08/15 Slide 15
Water
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TAFE NSW – Western Sydney Institute Precast Pre Employment Training Program to train the long term unemployed to be ‘Job Ready’ This is a requirement of TfNSW.
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Labour
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• High early strength for segments: 15MPa @ 14 hours, 26MPa @ 38 hours, and 59MPa @ 28 days
• Colour consistency throughout all elements • Sustainability objectives • Certainty of supply of materials • Some B80 mix designs have a very short lead
time from discharge to site – slump control
North West Rail Link – John Hewitt 25/08/15 Slide 17
Concrete challenges
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TfNSW preliminary construction program
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Concrete delivery schedule
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Mulgrave – ISJV leased land
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Construction phase
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New Factory Layout
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SHORT LINE - With this method, the form is stationary while the
segments move from the casting position to the match casting position
and then to the storage. This method requires a very accurate placement
of the match cast segment, for this reason a geometry control is used.
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Curing of the match cast segment just cast
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Hanson | North West Rail Link – John Hewitt 25/08/15 Slide 34
We made it happen!
10,000 m³ fill
decommission hollowcore
facility
remove batch plant relocate
crane
remove hollowcore
product
new carpark & amenities
new batch plant
council approvals
130 new employees
new workshop
new noise wall
contracts
concrete mix
approvals
agitators
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• Safety • Batch plant commissioning date • Ordering system for Precast • Invoicing • $1.2M Performance Bond – Continuity & Timely
supply • Quality • Brand exposure
North West Rail Link – John Hewitt 25/08/15 Slide 35
Challenges
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100m³/hr concrete batching plant. Upgrade of services. One level hard stand site. Two gantry cranes +. Relocated gantry crane. 7000 m² covered casting facility. Amenities for 130 workers. Extra heavy vehicle access. New maintenance workshop Noise wall 24hr manufacturing licence
North West Rail Link – John Hewitt 25/08/15 Slide 36
Legacy
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The first segment and pier
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Exciting times
North West Rail Link – John Hewitt 25/08/15 Slide 38
The Future for Hanson Precast?