Annual Innovation Report2017

02 / Annual Innovation Report

Message fromCEO’s

Welcome to our first innovation annual report. This initiative was driven by the increasingly competitive industry in which we have operated now for almost 85 years.

As we see more companies from outside New Zealand and Australia enter the market, we recognise the value of the relationships we establish with all our customers and the need to deliver our services to them in the most efficient way possible.

To achieve this, we know we must attract and retain the best people and demonstrate to customers our commitment to continuous improvement. So the Fulton Hogan Innovation Strategy was born.

It is a strategy with three key goals:

1. To offer customer-centric innovation by which we mean improving the processes around solving the problems that face our customers, our staff and the wider industry. To this end, we collaborate with alliance members, joint venture partners, small businesses, and our competitors to tackle challenges such as improving road safety and achieving zero harm on our work sites.

2. To deliver innovation projects across all three horizons so that we are prepared for changes

to industry and technology, therefore providing new diverse solutions for our customers as these changes occur. These horizons include:

• Horizon 1 – building on opportunities within existing business.

• Horizon 2 – investing in opportunities that are adjacent to our core business, increasing the range and scope of our portfolio.

• Horizon 3 – identifying potential areas for diversification, therefore laying the foundations for viable future opportunities outside of our core business.

3. Grow and maintain our connections with the global community, keeping pace with new and emerging technology, especially in Europe and the United States. We need to harness relevant technology and ensure it is embedded into our business for the benefit of our people, our customers and our long-term sustainability.

The strategic alliance we have entered into recently with the Dutch civil construction company Heijmans is one example of how we are tapping into the global community to bring innovations into New Zealand and Australia, which can then be shared with our customers. We have just installed our first Heijmans-developed product, Bikescout, for the Wellington

City Council. Bikescout is a new system which helps improve safety at intersections by warning vehicles that cyclists are approaching via a highly-developed sensor system and LED flashing lights.

One important way we are capturing ideas from within our business is via our innovation platform, Blue Skies. Developed as an interactive tool to streamline knowledge sharing and communication, Blue Skies is a complete database of all our ideas, innovations and technology solutions. Already installed in our regional offices, we are now offering Blue Skies kiosks to our customers, meaning new ideas and solutions are readily available.

We have also developed a customer challenge space within Blue Skies, which means we can pass on challenges from our customers and our people, using the collective knowledge of our business to problem solve. We are inviting our customers to send in their challenges, so we can upload these to Blue Skies.

In conclusion, our founders Jules Fulton and Bob Hogan weren’t afraid of change and were always looking at ways to do things better … the way ahead is exciting if we’re prepared to build constantly on their vision.

Graeme JohnsonNZ CEO NZ Regional Business

Graeme Johnson NZ CEO NZ Regional Business

Domenic De-Fazio NZ CEO NZ Construction

Domenic De-Fazio NZ CEONZ Construction

Customer-Centric Innovation

04 Blue Skies05 Blue Skies for our Customers06 PortPhalt®

07 Heijmans Bikescout08 Heijmans Brainjoint 09 Heijmans Fairytrail 10 MotoPhalt TM 11 Slurry Recycler Australia

Technology

11 VOC Lockout13 Virtual reality: Boil Out Procedure13 Fibre Optics 14 Halo Lights for Hard Hats15 The Mean Green Electric Lawn Mower16 Moving Plant Proximity Protection System17 Truck Safety Innovation 18 Load Alert System

Asset Management

19 Gatekeeper Smart Key and Intelligent Lock20 VisAbility21 Juno SCRIM22 OPM Tracker23 Laser Texture Meter

Maintenance

24 RUD ROTOGRIP25 Grip Tester

Traffic

26 Closure Breaches27 TMA Outrigger28 Solar Powered Traffic Management Attenuator29 'The Gibney' Horizontal Stop/Go Paddle

Operational Improvements

30 Vibrating Pneumatic Tyre Roller31 Footpath Machine31 Kerb Base Leveller32 Pile Starter Casing

Design Innovation

33 Sustainable Car Park – Tauranga Airport34 Diverging Diamond Interchange35 Upper Paskeville Recirculation System

Annual Innovation Report / 03

Contents

With 6,500 people spread across Australasia, one of the biggest hurdles we faced was improving communication and collaboration.

Blue Skies is a multi-faceted communication and interaction tool. Initially released via Salesforce as an idea dumping ground it has been redesigned with our partner, UiRevolution, to form a complete database of every innovation, big or small, that has delivered value for our people and our customers. Key benefits include:

• Blue Skies enables the ability to capture and share innovations, comment on and like ideas; upload photos, drawings and documents; apply for funding; and search through existing ideas to solve current issues onsite. Blue Skies can also be used to recognise individuals who conveyed an idea, or developed a new product or service.

• Blue Skies is unique in that it makes innovation accessible. Our teams can contribute, view or share at any time from multiple touch points where they work, rest or play. Blue Skies is on any web-capable phone, from every desktop, as an iPad application, available on kiosks in our lunch rooms and reception areas, and even formatted for the big screen televisions in our boardrooms.

• Blue Skies improves engagement around innovation therefore encouraging the development of a culture where innovation is seen as business as usual. Improved engagement means more ideas are developed and embedded in the business to improve productivity, safety, environmental sustainability, business performance, and delivers increased value for our customers.

• Blue Skies is also utilised to run our internal awards. It drives uptake of our awards by making them accessible to a wider audience and by providing real-time feedback directly from the judge to the entrant.

Blue SkiesFulton Hogan with UiRevolution has developed a new system to capture and share innovation.

Nicole Perry and Chloe Smith demonstrate the Blue Skies kiosk at the 5th International SaferRoads conference 2017

04 / Customer-Centric Innovation

Blue Skies for Our CustomersBlue Skies kiosks are located in Fulton Hogan regional offices and are now available for our customers.

Already up and running in the Invercargill City Council and Southland District Council, these kiosks give our customers direct access to all innovations that have been developed and trialled on site.

Enabling our customers to raise a challengeDo you have a challenge that you would like to put forward to our people to solve? Within Blue Skies we have added in a challenge space, where any challenge can be made visible to our people with the end goal of solving our customers' biggest problems. These challenges are visible for entry for a set period of time or until the challenge has had successful resolution, with the top entries being assessed by the business for development and trial. Challenge winners receive a certificate, presented by the regional manager, and a voucher for Mitre 10, as recognition of their idea.

If you have a challenge you would like to put forward or an innovation you would like to add to Blue Skies, email the innovations team at innovation@fultonhogan.com.

Russell Pearson, Invercargill City Council; Craig Stewart, Fulton Hogan General Manager South Island; Graeme Johnson, Fulton Hogan Chief Executive Officer – New Zealand Regional Business.

Craig Stewart, Fulton Hogan General Manager South Island; Hartley Hare, Southland District Council; Graeme Johnson, Fulton Hogan Chief Executive Officer – New Zealand Regional Business.

Customer-Centric Innovation / 05

PortPhalt®A highly modified asphalt designed for deformation resistance and load spreading capacity.PortPhalt’s® interlocking aggregate structure holds together under high loadings.

Why use it?PortPhalt® offers superior performance to these premium asphalts (A10E, A35P, C600) with double the deformation resistance and load spreading capacity.

How is it applied?PortPhalt® is applied like conventional asphalt, however is highly modified to meet the elevated specifications and customised for your particular project. This includes project specific pavement design, modified asphalt mix design for local materials, performance testing at our own laboratories and laying compaction by our experienced crews.

Midland Port, RollestonNew Zealand

Customer: Lyttelton Port CompanyCompleted: May 2016

Fulton Hogan’s PortPhalt® was speciallydesigned as a high modulus, deformation resistant product to stand up to theextreme conditions of heavy loads andchannelised wheel paths at the MidlandPort in Rolleston. Total area: 63,000m2

Deformation Resistance - PortPhalt® deformation resistance shows half the deformation against other premium asphalts in the market

06 / Customer-Centric Innovation

Cycling is becoming ever more popular, and not just with road users. Governments are keen to include the bicycle as part of their sustainable and inclusive transport policies.

But more cyclists on the roads places added strain on motorists, especially in busy urban areas. So, in this the United Nations’ decade of traffic safety, Heijmans is working on solutions to make cycling safer.

How Bikescout worksBikescout’s tracking radar technology is already being used by the automobile industry to provide signals to other road users. The radar measures the changing position of individual road users and continuously analyses this data, up to 50 metres in advance. By taking into account the speed of an approaching object (cyclist or pedestrian), Bikescout warns the motorist appropriately.

BenefitsEspecially in places with poor visibility of approaching cyclists, the Bikescout system increases traffic safety by giving timely warnings of cyclists crossing the road. Highly robust, dimmable LEDs, which can be fitted flush with the road surface, can provide signals in various configurations and are more effective and visually attractive than other safety measures.

Via mobile internet and an online web application, local traffic control can view the Bikescout’s availability and the traffic flow. This makes Bikescout a valuable management tool as well as making our city streets safer.

HeijmansBikescoutAn intelligent warning system that monitors the speed and distance of oncoming cyclists and warns approaching vehicles via LED indicators in the road surface.

Customer-Centric Innovation / 07

WATCH YOUTUBE VIDEO

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Expansion joints in overpasses and bridges are often the Achilles’ heel of the road network. Due to the combination of movements that occur, they can be difficult and time-consuming to construct.

These types of joints can require a great deal of maintenance. Their repair or replacement takes up a lot of time and requires lengthy road closures. In addition, the costs associated with damaged expansion joints are substantial for both the road owner and road user.

The most durable expansion joints have hard edges with a rubber profile between them. These often produce a considerable rumbling, pulsing sound when being driven across, which is often intensified by the “sound box” under the overpass. The pulsing sound when driving over the joints becomes an unacceptable nuisance and hinders the quality of life in busy urban areas.

The solution? Brainjoint The market has a need for silent expansion joints with a lifespan that corresponds to the surface layer. Heijmans has responded to this market demand with the Brainjoint, an

extremely quiet expansion joint that absorbs and distributes the movements of the bridge or overpass. This allows for the asphalt layer to be applied seamlessly over the joint. Brainjoint stands for “Buried Reinforced Asphalt Interlayer Noiseless Joint”. In other words, it is a concealed, invisible and silent joint based on special interlayers in the asphalt construction. The advantages of the Brainjoint are threefold: noiseless, easy to install and lower in maintenance.

Construction The most important feature of the Brainjoint is that it consists of several layers of asphalt. These layers can also be applied to the overpass directly. With this approach, there is no disruption of the surface layer of the asphalt construction before and after the joint. Moreover, during construction, application of the joint can be done by regular asphalt crews. There will be no hard edges in the driving lane that may cause pulsing noises. This way, there is no actual joint. Construction time is also considerably shorter compared to other types of expansion joints so the number and frequency of maintenance cycles can be significantly

reduced. Another advantage of the Brainjoint is that it can be installed both as an individual joint construction and as an integral part of a completely new asphalt package on and around an overpass. It can be used in both existing and new overpasses, integral and traditional structures with span lengths of around 50 metres and transitional structures at the end of baffle plates in integral structures.

Applications The Brainjoint was used on a major scale for the first time in September 2014, during the placing of a new layer of asphalt on the A27 motorway in the Netherlands as part of maintenance work. The bituminous joints in 56 expansion joints with a total length of 695 metres (2,280 feet) were replaced by the Brainjoint. This road has become quieter and more comfortable to drive on and, thanks to the use of the Brainjoint, there will be little to no need for more maintenance work on the joints over the next few years.

Since the first Brainjoint was applied, many more projects have followed, to the extent that other contractors have used the system to build and/or replace joints.

HeijmansBrainjointAn innovative expansion joint that absorbs and distributes the movements of the bridge, creating a seamless experience for road users.

08 / Customer-Centric Innovation

HeijmansFairytrailFairytrail is an interactive pathway with glow-in-the-dark effects developed by Heijmans. It makes walking and cycling a more memorable experience, while at the same time providing energy-efficient and sustainable illumination without disturbing the ecological environment.The first interactive path developed using this technology is the internationally renowned Van Gogh-Roosegaarde bicycle path (pictured left). It can be found near the city of Eindhoven, the Netherlands. It was designed by Daan Roosegaarde whose inspiration was Van Gogh’s masterpiece Starry Night.

During dark conditions the path is illuminated by thousands of twinkling stones, creating an experience of both poetry and art. This is a perfect example of cultural heritage and

innovation combined in a public landscape. Illuminated by additional LED lighting to ensure sufficient visibility and safety, the bicycle path is close to 1 kilometre (0.7 miles) long and part of the famous Van Gogh cycling route.

Economic BenefitsThe path adds value to the Eindhoven region as a tourist attraction. In order to experience the path in the evening, visitors are likely to spend more time in the area. Research shows that investing in cycling infrastructure specifically for

the purpose of tourism is highly profitable for municipalities. Cyclists spend up to three times more money than visitors who use other means of transport. Heijmans’ interactive pathway technology helps regions grow economically and achieve their sustainability goals.

Precast OptionsHeijmans has also developed other uses for the product, including specific designs set into precast concrete slabs (pictured above).

WATCH YOUTUBE VIDEO

Customer-Centric Innovation / 09

MotoPhalt™ A superior asphalt mix specifically designed for motor sport.MotoPhalt™ is an asphalt mix developed to perform under the extreme conditions experienced in motor sport racing, such as Supercars and Karting. These events tend to inflict the most damage to the surface by transferring the immense stresses exerted by vehicles through the asphalt, especially when cornering.

What is MotoPhalt™? MotoPhalt™ is a proprietary dense graded asphalt mix, specifically formulated to handle race conditions and minimise the potential for track surfacing failures. Race circuit failures include raveling or stone loss, rutting, shoving, cracking and delamination.

Any of these have the potential to damage cars, cause accidents, increase vehicle wear and tear, disrupt races and frustrate both drivers and spectators.

Fulton Hogan engaged the independent advice of the Australian Road Research Board (ARRB)

to test MotoPhalt™ against a range of leading alternative industry designs; with MotoPhalt™ proving superior performance.

What sets MotoPhalt™ apart?• Proven performance• Meets extreme racing conditions• Has a tight, smooth and durable surface• Performs on hot days• Produced with specially formulated bitumen

binder –MotoB2.117

How MotoPhalt™ works?Asphalt mixes for race track applications require specific mix design considerations. Extreme point loadings and shear stresses imparted to the surface from racing slick tyres and locked differentials spread extreme torsional forces across the pavement. For example, race cars tend to follow the racing line as close as possible and load up on one wheel as they pass through corners and particularly so on tight corners with rumble strips. This can lead to early

stress of the asphalt pavement, which in some cases has led to surface failure and disruption to racing events.

MotoPhalt™ is designed to perform• Mix design tailored to meet motor track

needs• Produced with a superior specialty bitumen

binder MotoBind™ tough enough to resist high shear and torsional forces

• Reaches high level of compaction for a tight and smooth surface

How to apply MotoPhalt™? • MotoPhalt™ is laid using conventional paving

equipment and processes, completed to the highest standard of finish. The team at Fulton Hogan use their expertise to provide the highest standards of quality, safety and environmental awareness, whilst ensuring minimal track disruptions.

WATCH YOUTUBE VIDEO

10 / Customer-Centric Innovation

Slurry Recycler Innovation removing the need for slurry ponds onsite.

The new purpose built slurry recycling machine reduces operating costs around slurry pond construction and management by approximately 60%. This innovative machine recycles 100 per cent slurry waste from national Airport and Defence runway grooving operations, airports from having to create slurry ponds on their land. This means that there is no need for slurry ponds, which often require large areas of land.

The new slurry recycler returns the leftover silt to Recycled Asphalt Product (RAP). This recycled product is currently being trialled for inclusion, instead of silicon sand, into Fulton Hogan's Jet Black® product for improved friction. When fully developed, this additional innovation will reduce the material cost of JetBlack® to Fulton Hogan and our customers.

A further innovation exists in the ability of the slurry recycler to detach the storage tanks during periods of standby so that the trailer can be deployed on other tasks. The unit is also equipped with purpose built telescopic lighting towers, therefore enabling it to operate during night works.

VOC LockoutVerification of Competency fob lockout

A cost effective and innovative solution has been developed and trialled that locks out an item of plant and will not allow it to start without a registered Verification of Competency (VOC) lockout fob and associated pin, confirming that the operator is competent to operate that piece of plant.

One unit can be fitted to each item of plant, linked through the ignition circuit that disengages the start signal to the starter motor. This means that without the VOC lockout fob, the starter motor will not engage.

As every individual is currently logged into our online professional development system, the plan is to utilise this system and issue everyone with a fob and a personnel code which can be used on every item of plant fitted with this unit. Once an individual has had relevant training and deemed competent to operate a piece of machinery, their VOC lockout fob will be logged into that machine, therefore allowing them to start it.

Customer-Centric Innovation / 11

Technology / 11

Fulton Hogan operates a fleet of bitumen sprayers and tankers, where skilled staff perform a highly dangerous procedure to decontaminate the tank and associated pipe work if water has been present – The Boil Out Procedure.

One of the most common causes of accidents associated with the use of hot bitumen results from the unintended mixing of water and bitumen.

In the event of a serious boil over, the vent will probably not be able to cope with the outflow of bitumen on its own and the hatch, if latched, may blow open, spraying bitumen over a wide area. If the lid and tank ends hold, bitumen will

be ejected out the vent with considerable force, and will possibly spray out from under tank hatch or other openings for some considerable distance, putting our people at great risk.

Amanda Lawrey from our Digital Team has been working with Warren Pickering (as a representative from the Bitumen Critical Risk Group) and Henry Lane from Corvecto to develop Fulton Hogan’s first Virtual Reality App – Boil Out.

Fulton Hogan has a written boil out procedure that outlines the requirements for bitumen product tanker decontamination and first loading procedure to minimise the risk of harm to personnel, the public and equipment. We

have taken this written Boil Out Procedure, and recreated it in a completely safe and virtual environment, navigating the user through a virtual simulation of the process. This enables the user to step through the procedure, as they would in real life, but also allows them to experience the consequence of their actions if they do not perform the procedure correctly (which is not possible in real life as it is too dangerous). We can also change the variables, like whether there is visible water present, so that each experience is unique. Users are tracked the full way through the process, recording all the decisions that were made, and how long users spent doing each task, which can be added to their training records.

Virtual Reality: Boil Out ProcedureVirtual Reality technology presents a new opportunity for Fulton Hogan to train our people by taking some of our dangerous and hard to recreate tasks and procedures that are normally only undertaken by very experienced staff and recreate them virtually.

WATCH YOUTUBE VIDEO

12 / Technology

Fibre OpticsThe Christchurch Northern Corridor is being built on soft ground that will settle during the construction of the new motorway.

Benefits to the Business• Safer: fewer people on site during

construction and maintenance measuring settlement

• Greater frequency: real time data for better decision making

• Cost effective: reduced survey costs• Early intervention: ability to respond to

unexpected settlement

To monitor the stability and settlement of the works during construction the CNC Alliance team is using a special fibre optic embedded geotextile.

The clever textile has been used in other countries as an early warning system to measure movement in stop banks during major flooding events and used in embankment construction to measure settlement. It is a world first to try the method on a large scale motorway project.

Two strings of buffered and two loose tube fibres are woven into a special strong erosion resistant textile that is being placed in the ground. Ground strain and temperature information is measured using lasers shone

along the fibres. The information from the lasers is converted to strain and temperature data which is transmitted via the 4G network to a Trimble 4D database.

The data is collected every 15 minutes to provide 24/7 information as the motorway alignment settles. All the data from several data recorders via the fibre optic geotextile is sent to a central telemetry station, called the interrogator.

The CNC Alliance team is confident other large projects will show an interest in this new settlement monitoring method, opening doors for more efficient, safer and cost effective monitoring applications.

Technology / 13

The Halo fits over a hard hat. It shoots out light 360° so drivers can see a worker who is up to 400 metres away. In just over a year, the Halo Light has won 12 Industry Safety Awards in the USA.

Benefits: The Halo light is visible up to 400 metres away.

It has different light modes, including: The halo mode, with bright light on all sides of the hard hat shining out 360°, to see and be seen by others on site. Use Halo mode while moving around and performing a number of jobs.

High alert mode, an attention-grabbing pulsing/flashing light to maximise the chance of being seen by others. Use Hi-Alert when flagging or signalling, while working around moving vehicles or machinery, or whenever you want to be extra noticeable.

The task mode, with 200% power to the front third of the Halo illuminating the wearer’s workspace out to the visual periphery. Use Task mode to fully flood your entire workspace right out to your visual periphery.

Dim mode, for when you’re working near others. Switch to Dim when working in close proximity to others or having a face-to-face conversation.

The Halo Light locks onto almost any hard hat so it stays in place, is lightweight and cordless.

The Halo Light uses a rechargeable battery that lasts from 4.5 hours, up to 34 hours, depending on what mode is used.

The Halo Light is built tough. It can withstand being dropped from 10 metres, driven over by a jeep, buried in mud, and immersed in water.

Halo Lightsfor Hard HatsThe Halo Light, made by Illumagear in the United States, makes sure all workers are visible at night. It’s not just for highway crews, the light is great any time workers and vehicles mix in the dark.

14 / Technology

The Mean Green Electric Lawn MowerOne key area for innovation is reducing the environmental impact of our works and therefore improving sustainability. The cordless electric lawn mower is powered by Mean Green Lithium Energy Modules, offering up to 7 hours of mowing at a fraction of the noise level of the traditional petrol powered mowers. The loudest this mower will get is 80 db. Petrol mowers sit around 95-100 db. For every 6 db difference in sound, noise doubles. So this 80 db mower is less than half the noise of an 86 db mower. Noise reduction for a maintenance job like regular mowing is a great benefit to our surrounding stakeholders, particularly when the mower is being used within the grounds of a cemetery.

The electric advantage over fossil fuels for outdoor power equipment is a substantially lower impact on the environment. According to an Environmental Protection Agency study in the United States, one 3hp petrol lawn mower emits the same air pollution as 11 cars driving at 88km/hr. The Mean Green mower requires no petrol and produces no emissions, charging overnight via a standard wall socket or specially designed fast charge station. Solar or wind turbines can partially or completely recharge this lawn mower if “off-the grid” charging is desired.

Minimal maintenance means the mower is always available to use. There is no internal combustion engine, so no spark plugs to clean or change, no carb/injectors to rebuild, no engine oil or filters to change, no hydraulics, no belts, no pulleys, no clutches, and no air filters... In fact, there are no oils or liquids to leak or spill at all on Mean Green Mowers. The only routine maintenance required is greasing the two grease fittings on the front wheels every 50 – 100 hours.

WATCH YOUTUBE VIDEO

Technology / 15

Moving Plant Proximity Protection SystemThe MPPP system alerts the operator and the person on foot, and captures the time, distance and location of the proximity breach.

There is a need in the business to better protect the people and plant who are in the proximity of moving plant, and as such we chose to develop a system which would help alert operators and people on foot within the proximity of moving plant that they are within an unacceptable distance of each other.

This data can be analysed to identify high risk operators in the business and can assist with incident investigation.

A majority of the activities in the road surfacing and construction business require the use of large items of moving plant. These are often in the vicinity of workers on foot, creating significant risk to cause harm to people and plant.

The aim of this project was not to create the primary system to prevent incidents between moving plant and people and/or plant, but to provide another tool which alongside existing controls, can help to reduce the risk of these events from ever occurring.

The main benefit to the business is to keep our people safe.

The concept developed so far:• We found a R2100 sensor scanner that is able

to identify and measure objects. A sample output was displayed via a laptop. As the roller moved forward we were able to see objects appear on the screen in the yellow and red zones. From here the focus then went to a display and acknowledge system for the driver. The 7” HMI would be enclosed in a custom case with a button to reset the sensors named the acknowledge button.

• By pressing this button it demonstrates that the plant operator is consciously aware of the object that has been detected. The acknowledge button also stops the LED ray that has detected an object from triggering the alarm. If the roller keeps moving towards the object, it will appear ‘larger’ the closer it gets to the sensor and the rays either side of the one that has been turned off will then sense the presence of the object and the alarms will sound again.

• For the sensor to reflect our standard terminology we created the red and yellow zones. The red zone is 0m to 4m away from the plant and the yellow zone is 4m to 6m away. As the scanner gets closer to an object the volume of the buzzer alarm increases and the operator can see the proximity on the HMI.

• The acknowledge button is designed to be next to the HMI, so the operator would be looking at the screen when he acknowledges the buzzer, encouraging the use of the HMI to gauge where the object that has been detected is located.

• All of this information for each incident is logged on the USB which can then be used for analysis.

• Further developments are currently underway with another new proximity technology.

WATCH YOUTUBE VIDEO

16 / Technology

Truck Safety InnovationFulton Hogan’s Auckland Transport Department is currently trialling two new safety innovations on the latest additions to its bulk truck and trailer tipper fleet.Inter-Lock SystemThe first is a trailer “Inter-lock system” which is an electric over air version of the mechanical Inter-lock currently used on Fulton Hogan trucks:

Whilst tipping, if the trailer gets to a pre-set angle and the system has not detected that the tail door trips have opened, the hoist will cease raising until the trips have physically opened.

This system will significantly reduce the number of incidents involving trailers tipping over, where the tail door not being released is a contributing factor. Up until now, connectivity challenges between truck and trailer have prevented a system like this being implemented on tipper trailers.

Fulton Hogan identified this as a significant hazard and together with the engineering company that designs and builds our truck and trailer bins and chassis’ (Transport Trailers) have developed a system that is an industry first for tipper trailers.

TailGUARDThe second safety innovation is “TailGUARD” . This is a system that reduces risks for drivers during reversing, by detecting small, large, static and moving objects in the blind spot behind the trailer. It also automatically stops the trailer at a safe distance.

This system provides stress relief for drivers during reversing and helps them to avoid collisions with pedestrians, vehicles and any other objects behind the trailer.

The combination of 4 features makes TailGUARD a unique solution. The integration of TailGUARD with WABCO braking technology provides unique functions: automatic stopping, forced slow down, distance programmability and truck-trailer communication via Power Line (PLC).

Technology / 17

The load alert system is a basic electric over pneumatic set-up. Connected into the airbag line, it runs as a separate line to a common manifold. On this manifold there are three separate adjustable air switches. From these switches, the desired switching range is set. One LED per switch is used to indicate certain weight levels have been reached. The LED light switches activate the initial amber light at 5T under maximum load, the flashing amber light at 3T and the red at 1T. This allows for load variance across the bin and ensures overloading will not be an issue.

The more product that is loaded into the bin the more the air bag pressure increases, activating the individual switches at their desired setting.

The LED alert lights protrude from the mounting base approx. 13mm to ensure visibility from the rear as well as the side with the potential of eliminating a load spotter.

There is a switch in the cab that activates the load alert system only when the truck is getting loaded. It is turned off once the maximum weight is reached, so that the alert lights are not illuminated whilst traveling.

Load Alert System One of the biggest issues facing our truck drivers is load control. A load alert system has been developed to warn when a load is getting near to the maximum, giving the driver an opportunity to stop loading.

Benefits • Prevents trucks from overloading,

ensuring they have safe loads within their legal limits.

• LED lights ensure clear visibility when a load is nearing the maximum weight allowed.

18 / Technology

Gatekeeper Smart Key and Intelligent Lock Innovation means achieving efficiencies and improvements to a system in an easier fashion. Fulton Hogan’s security policies, which are standard across all computer devices, ensure that after approximately 10 minutes all personal computer systems automatically lock when no user activity is detected. However, frustration has occurred among maintenance crews who have to reactivate their devices continuously throughout the day. With improvement in mind and a focus on keeping our employees happy and safe, it sparked discussions within the Asset Management team on how this process could be improved and the need for change. Liaising with IT we have come up with a solution that integrates seamlessly with our current systems and processes.

The Gatekeeper Smart Key and Intelligent Lock is a recent addition to the software that is issued to maintenance crews who use Pocket RAMM or other applications in the field.

At the core it is a proximity sensor that works by detecting whether the user is within a specified range of the tablet. If the user is in range then the device will remain unlocked, otherwise the timeout policy will apply as usual. The tag comprises of a USB receiver that gets plugged into the tablet and a separate tag that is kept on the operator’s key ring and communicates with the USB receiver. The benefits from its implementation are apparent

in terms of safety and efficiency. Initially rolled out to the Waikato region, we have received strong positive feedback and crews are able to focus on their current tasks without the constant interruptions. By implementing this simple solution, we are able to be more productive (no need to constantly re-enter passwords) and safe (focus is not taken from an activity to prevent the tablet from locking) while still meeting the necessary security requirements to keep our data and systems safe.

Asset Management / 19

VisAbility has been an initiative developed by Fulton Hogan on the Clutha District Council and Foveaux Alliance road maintenance contracts. Experience to date is showing VisAbility has benefits in a number of areas:

Ensures customer service teams have a reliable source of information they can relay to callers.

Provides council engineering staff and the contractor’s office staff with a good overview of activities on the network.

Contract staff are reporting the visual tool is providing them with better ability to prioritise and programme work across the network. Also helps supervisors to see what is on over the whole network.

VisAbility’s goal is to provide a quick visual snapshot of events on the roading network and their priority of resolution. This innovative technology integrates the customer’s Request for Service (RFS) information with Fulton Hogan’s field systems, including RAMM. Operators upload photos from RFS request dispatches, providing Council and Contract Managers back in the office with a reliable additional source of information. The system will also have the ability to display the planned grading programme, giving staff confidence in the information they are delivering to the customer. Future stages will include adding vehicle GPS locations to the map and a mobile application.

This application delivers a new standard for digital transparency around contracts.

VisAbility The VisAbility tool promotes better communication, providing a visual contract management and reporting tool, which is accessible for our customers and staff working on the contract.

Green means we have plenty of time left to complete the task indicatedOrange means we are nearing the due time / date for completionRed means we are overdue to complete the task

20 / Asset Management

Juno SCRIM Juno SCRIM is an asset management tool for analysing skid resistance results, developed using an existing platform, JunoViewer. It provides network and performance data in a spatial context, enabling fast and easy analysis which then feeds into our job management system.

Skid resistance results are recorded on a spreadsheet instead of being analysed manually with Google Maps and Roadrunner. Juno SCRIM automates this process, enabling you to scroll along the length of a road and look at all relevant data, turning on and off different features and data layers to narrow in on problem spots. The platform is set-up to analyse skid resistance results and crash history and compare this with the forward work plan to see if treatment has already been programmed. Juno SCRIM provides consistent and credible results with an auditable trail for tracking the decision process.

The new process is aligned with the T/10 requirements and the NOC risk profile.

Asset Management / 21

After logging in, past and current audits can be viewed, and new audits can be created. A random set of Audit Sections are generated for the field-based portion of new audits, and the audit is immediately distributed to the auditors' iPad once created. After both the office and field audits have been completed, an internal review is facilitated via OPM and Audit Section overview pages. This is followed by a review with the Maintenance Contract Manager, where scores can be amended, before a final report is automatically created and placed on Contract Workspace.

OPM Tracker The Operational Performance Measure (OPM) Tracker is a tool created by Fulton Hogan to manage our OPM auditing process for Network Outcomes Contracts (NOC’s). The tracker consists of a Salesforce web application and an iPad mobile application.

Benefits: • Ensures consistent practice • Provides a platform for evidence based

auditing and increases data quality • Reduces administrative overhead • Facilitates benchmarking through

business intelligence (BI)

22 / Asset Management

Laser Texture Meter The Laser Sand Circle Texture Meter replaces the current sand circle method. The electronic bar is attached to the back of a vehicle and operated from inside the cab. Road surface texture measurements are taken while driving at speeds up to 70km/hr.

GPS coordinates are recorded for location accuracy and traceability.

Collected data is used to determine if road texture is up to current standards.

The new system ensures accuracy is achieved with chip seal design which is required for a high quality chip seal surface - a core Fulton Hogan business.

Existing SystemsExisting systems for measuring road surface texture in New Zealand are unsafe, inefficient and unreliable, with results varying up to 20%.

A product is available for purchase in Australia however it costs around $120k per unit.

Product DevelopmentThe Ministry of Science and Innovation awarded Fulton Hogan a grant for the development of the Laser Sand Circle Texture Meter. Development from idea to prototype took 18 months. It included the investigation of another method using digital imaging that was also accurate, but inefficient.

The team completed a significant amount of data analysis and field testing. It was important to provide results which showed how the laser responded on different road surfaces.

The laser texture meter is now operational in Auckland and available throughout New Zealand at request.

Asset Management / 23

RUD ROTOGRIP The ROTOGRIP system, developed by RUD, provides automated chains for improved traction in ice and snow.Winter maintenance works require chains to be fitted to the rear (sometimes front also) of plant. Chains last well when being used continuously on roads covered with snow.

Plant may be required to travel on unaffected road sections to get to areas covered in snow

or ice, or to access grit stockpiles or yards. This poses a problem as the use of plant fitted with chains on roads not covered in snow, causes additional wear of the chains and requires the plant to operate at considerably below the posted speed limit.

Benefits Trialling ROTOGRIP has provided great value to the business across three core areas Safety, Operational and Cost:

Operational• Saves up to two hours down-time per

day when in winter maintenance mode.• Response times are quicker, meeting

KPI’s, customer satisfaction• Helps to achieve maximum productivity

and allows crew to respond more quickly ensuring roads are re-opened in shorter timeframes.

Cost• Great reduction: Manual chains

$1k a piece, ROTOGRIP estimated at $200 maximum.

• More life out of ROTOGRIP as they can be managed more efficiently by a flick of a switch on the dash of vehicle cab

• Reduced cost in down time to install.• A must for all winter maintenance

contracts, this methodology keeps us at the forefront of industry development.

Safety1. ROTOGRIP are already attached to the plant

and ready to operate at the flick of a switch in the cab of the truck.

2. Maximises keeping mobile and personnel safe when operational.

3. Eliminates down-time required to manually fit chains to plant to continue operations.

4. No exiting the truck in live traffic lanes to fit or remove chains to plant.

5. Reduced stress levels - one less thing to worry about in the process.

24 / Maintenance

Grip Tester Road safety for the end user predetermines the importance of correct testing and identifying of risk areas and solutions in our maintenance contracts. Skid testing can be undertaken using equipment such as the GripTester. Following skid testing, we can than compare the actual skid resistance with the skid demand that our customer assigned to that particular road segment. This highlights which sites we need to visit and confirm whether or not they do require treatment and if so, which type of treatment.

Main uses• To identify skid deficient surfaces in a

network.• Measuring airport runway skid resistance.• To retest sites that have been identified as

skid deficient.• To investigate accident sites.• To determine an accurate scientific measure

of surface friction.• To determine the surface friction variability

along a length of road.• To identify areas of road surface which need

remedial action to restore surface friction to safe levels.

• To be able to monitor road surface friction loss over a period of time.

• To assess road surface friction levels against TNZ T10 requirements.

• To assist in development of road safety strategies.

Features• Rugged compact and lightweight• Most versatile friction tester available.• Can be towed at standard test speeds up to

130 km/hr or be used in push mode.

• Continuous measurement of load and drag on a braked wheel fixed slip design.

• Information is easily connected to the highway referencing system.

• Data is collected on an IBM compatible lap top computer.

• Rapid and simple data acquisition and presentation.

• Machine has a simple onsite calibration system.

• Operated by IANZ laboratory staff.• Latest model machine tests accurately

around bends due to technological improvements.

• Operates as a Mobile Operation at 50km/hr• Low water usage.

Maintenance / 25

This occurs across all working environments including offices, sites, and depots. This has driven an innovative solution to provide more protection to the workforce within work sites, from a new dangerous phenomenon in Auckland - wrong way drivers.

Increasingly our network is being travelled by wrong way vehicles. Historically the drivers of these vehicles have been disorientated elderly, or impaired by drugs and/or alcohol. Death and serious injury crashes have resulted from wrong way vehicles. This is a major safety concern for the AMA and other road users.

X Net The heightened risk to our customers and our road crews drove the AMA to research different existing approaches to stopping wrong way vehicles and vehicles entering work zones. The preferred option was the X-Net vehicle arrest system which is light, portable, and easy to set

out. More importantly it brings vehicles to a controlled stop with minimal vehicular damage.

When an offending vehicle traverses the X-Net, uniquely designed barbed steel spikes on the net pierce and embed into the front tyres of the vehicle. The net then envelops the front tyres and is pulled tight under the vehicle undercarriage which stops the front wheels rotating, bringing the vehicle to a controlled stop.

It is designed to stop a vehicle weighing up to three tonnes at 60km/h. The retardation g-force is less than 1g, providing low risk to vehicle occupants. Speeds between 40–80km/h for conditions in both dry and wet environments have provided stopping distances between 15-75m. Speeds have been successfully tested up to 113km/h.

The AMA discussed the use of the X-Net with police (including operational guidance, advice

and feedback) and they have been supportive of its operational use. The police will respond to the arrest onsite and assume responsibility for processing the occupants and the removal of the vehicle.

The AMA consulted the NZ Transport Agency legal managing counsel (planning and network operations) and requested them to investigate the legal issues regarding the deployment of the X-Net vehicle arrest system. The AMA also entered into direct dialogue with the product manufacturer to fully understand the performance characteristics and the associated risks. Consequently, the AMA submitted a paper to the NZ Transport Agency to approve the deployment of the X-Net vehicle arrest system at work sites on the Auckland motorway network.

Intellicone The AMA recognised that there were no means of alerting our Temporary Traffic Management staff when a closure had been breached. As a result, we started to look into the ways in which this risk was managed in other countries. Their research took them to a device used in the UK named the Intellicone.

The Intellicone is an electronic perimeter management system that helps deter incursions by errant vehicles into work zones, and in a worst case scenario mitigate against the potentially fatal consequences of such events. The platform consists of Portable Site Alarms mounted onto road cones and contact based and contactless sensors which enables the rapid deployment of an electronic perimeter around a worksite. The intellicone is now used at a majority of full closures deployed by the AMA.

Closure Breaches The Auckland Motorway Alliance Leadership Team takes a comprehensive top-down, bottom-up approach to health and safety.

WATCH YOUTUBE VIDEO

26 / Traffic

TMA Outrigger One of the biggest issues facing the Auckland Motorway Alliance is how to prevent vehicles entering lane closures.

As a result, our staff are immediately alerted by a siren when a closure has been breached. A demonstration of the intellicone is included in the supplementary video.

Barrier Shaped Barricade In addition to the X-Net and the intellicones, our teams continue to look at ways to prevent closure breaches and reduce the risk that this places on our staff. We are currently refining an idea referred to as a ‘barrier shaped barricade’. The barricade is made from polystyrene with an acrylic coat making it reasonably light and easy to put in place. The idea behind the barricade was to place an item on the carriageway that has such high visual target value that any approaching vehicles are forced to make a decision, not to challenge the system, or enter the site. The drivers of the vehicles we were dealing with typically don’t concern themselves with running through standard COPTTM deployment, rather we need to deter them through means of perceived physical closure of the motorway. Whilst the barricade won’t physically stop the vehicles, they will discourage vehicles from entering the site.

Traffic Guard Worker Alert System The Traffic Guard Worker Alert System (WAS) is an additional system that we are currently trialing to help keep our workers safe. It consists of a lightweight, easy-to-transport trip hose and sensor assembly that wirelessly sends a signal up to 1000 feet away to a flashing rechargeable siren alarm and most importantly to an individual worker’s personal safety device. These personal safety devices vibrate and provide an audible sound through the included ear buds, giving warning of impending danger. The trip hose is placed ahead or behind workers on the road, far enough away to provide ample warning in the event that a vehicle crosses over the hose, so workers can be alerted and get out of harm’s way.

This is a similar system to the intellicone but allows for personal notification, meaning that you don’t have to be within earshot of the site alarm to be notified of an errant vehicle. In addition, this alert system is more cost effective than the intellicone and allows for multiple sites to be linked.

Traffic Management Attenuators use high visibility lights and colours to indicate that lanes are closed however only have the ability to cover one lane with their current design. By adding hydraulic arms to either side of the TMA, the team is now able to use them to prevent vehicles entering closures at critical points such as on and off ramps, and to close multiple lanes at a time.

Prior to the roll-out of the new design, in order to cover multiple lanes, the TMA was parked

sideways across three lanes. This meant that the specially designed cushioning pad at the rear of the TMA was ineffective for reducing the impact if a collision were to occur. The greatest benefit of the new TMA design is that when more than two lanes of traffic need to be closed, the vehicle can be parked as designed, with the crash cushion pointing toward the oncoming traffic, and brightly lit arms on either side folded down to indicate a wider closure than one lane.

Other uses for the TMA outrigger include rolling road or lane closures, on and off ramp closures, and protection for crash victims and emergency vehicles when attending incidents on the motorway. They can also be used to enable site access for construction vehicles where traffic needs to be stopped or rerouted.

WATCH YOUTUBE VIDEO

Traffic / 27

Due to the demands of Traffic Management, there is often a requirement for trucks to remain parked on site with arrow boards and flashing lights in full operation. This has the potential to cause the batteries to discharge, draining the vehicle of any battery power. In Canterbury, this issue was resolved by installing a small generator and battery charger that was automatically started when the vehicle was turned off. There were, however, resultant issues with this system such as: the ongoing cost of generator fuel; emissions from the generator exhaust; noise pollution at night; and the safety risk involved when operators must start the generator near a live lane.

Solar technology is continually improving; the efficiencies are increasing and the average cost is decreasing as the market expands. The idea of replacing the on-board generator with a small solar system was therefore investigated, especially given any solution would be applicable to the TMA fleet throughout Fulton Hogan.

It was decided that three 260 watt solar panels situated at cab roof height using a Fulton Hogan manufactured frame would generate sufficient energy to power the required signs and lights. A battery array of sixteen 60 amp-hour lithium batteries was recommended, complete with a charge controller and voltage sensitive relay (VSR) to recharge the battery while the vehicle is running. All of these calculations were performed based on the longest period of time that the TMA accessories had operated without any charge. The VSR is designed to ensure the TMA starting battery is always charged, the system requires no human input, it is self-managing.

Since the solar TMA installation, the feedback has been largely positive. The only question raised was why the solar panels had to be at the rear of the truck, instead of over the cab, as it has the potential to limit the number of cones they can

transport. When it was explained that solar panels over the cab would make truck maintenance more difficult and possibly add to wind resistance, the response was positive.

A common issue with the conventional TMA trucks is the drain of the truck battery to operate the signs and lights, such that the battery uses all its residual power. Since the solar installation, complete with the control system to manage the battery charging, there have been no instances of drained batteries onsite.

General feedback from operators is that the system is easy to use, it requires no operator intervention and manages itself effectively. No money has been spent on generator fuel, as it has not been required.

The solar TMA truck has prompted regular enquiry from internal staff, public and sub-contractors. The general interest of how it works and performs is superb, as it creates engagement and spreads awareness of alternative innovative solutions.

Environmental In order to run the generator, approximately five litres of petrol was required per week. This equates to 250 litres per year. Petrol is said to emit approximately 2.35 kilograms of carbon to the atmosphere per litre of petrol combusted, thus one TMA generator likely contributes around 590 kilograms of carbon to the Fulton Hogan carbon

footprint. If this is extrapolated out to the other TMA trucks within Fulton Hogan, and assuming 60% currently operate with generators, the carbon reduction is close to 36 tonnes per year.

Costs Due to the initial capital cost, the payback period is around ten years. As mentioned, the conventional generator uses approximately 250 litres of fuel per year so the payback period will depend on the cost of fuel. The real advantage is in reduced noise, safety risk reduction for operators, reduced carbon emissions, reduced operator time spent (no user intervention required as it is self-managed), increased environmental and innovation awareness and reputation. These successes are difficult to economically quantify but are significant nonetheless.

Solar Powered Traffic Management Attenuator Canterbury Traffic Management have developed a dual battery solar powered TMA's

28 / Traffic

The unit is positioned on the shoulder of the road much like a school traffic patrol type operation.

This concept was demonstrated to local RCA’s earlier this year and achieved permission from our local RCA at Tasman District Council to trial the paddle on a local job on the 13th September 2016. Results were extremely encouraging. Drivers questioned said it was:

Visible from some considerable distance away and being at eye level in the lane was impossible to miss.

The Gibney avoids the problem of a fatigued operator having their paddle on 'Go', when it should be on 'Stop'.

Certainly in a normal Stop/Go operation the MTC and paddle can sometimes be hard to pick up amongst the sea of orange cones and equipment onsite.

The paddle was easy to operate and did not take long to set up.

It is on wheels which means it can be moved along the road for a short distance if required.

It is probably more suited to long term day site where the MTC is in the same position for a considerable time.

*RCA Road Control Authority MTC Manual Traffic Control

'The Gibney' Horizontal Stop/Go Paddle The Stop/Go paddle is operated from the shoulder of the road, keeping our people away from live traffic.

WATCH YOUTUBE VIDEO

Traffic / 29

Vibrating Pneumatic Tyre Roller (PTR) Innovation means getting the best result the most practical way possible. The Vibrating PTR solves a gap in the market where a high quality finish is required for smaller domestic jobs such as footpaths and driveways. This innovation produces the flexibility of a small unit with sufficient compaction plus also the kneading benefits of pneumatic tyres.

Fulton Hogan Dunedin has developed a new product – a Vibrating Pneumatic Tyre Roller (PTR). This is a single drum walk-behind roller that uses the weight of the machine to compress the surface in combination with rubber tyres and vibration to create a kneading effect on the asphalt and therefore produce an improved

quality of finish for the customer. The invention consists of a metal drum with a smooth peripheral surface and rubber rings mounted around the metal drum.

The vibrating PTR has the ability to convert between a traditional compacting metal drum roller and a kneading roller design as the drum is interchangeable.

This Vibrating PTR was entered into the New Zealand Innovation Awards, was a runner-up in the Fulton Hogan Managing Director’s Innovation Awards and has been filed for a patent.

Benefits The PTR is a low cost method of kneading asphalt that avoids the need for multiple drums and ride on capability. It is a lighter weight (less than 1,000kg), compact unit that can be transported on light weight trailers or a vehicle deck. It is easy to manoeuvre about small work-sites.

It produces a comparable surface finish results to that observed from larger traditional pneumatic road roller devices.

• Asphalt is smooth, shiny and appears polished.

• No visible hairline cracks or imperfections.

• Reduces the amount of water ingress into the asphalt therefore surface lasts longer.

30 / Operational Improvements

FootpathMachineThe footpath machine is very easy to use. There is less manual work as concrete is spread by the machine instead of screeding by hand.

More lineal metres can be poured per day which makes this machine very time efficient. Previously under the traditional system of pouring concrete footpaths by hand, an average of 100 Lm/day could be achieved. With the new footpath machine upwards of 150 Lm/day can be poured. Timber boxing is not required, so resource and labour is reduced as well as the dump fee costs that go with timber boxing removal on completion. Waste is also reduced from having less concrete overspill on the edges.

The footpath machine has been successfully trialled and the team are now looking for other opportunities to use it.

Benefits • Saves time, labour, dump fee costs &

materials.• Increases lineal metres poured per day

by 50%minimum.• Perfect for subdivisions and other jobs

where new footpaths are being laid.

Kerb Base LevellerThis innovation supports sustainability by reducing material wastage and improves productivity by speeding up the kerb preparation process.

This innovation is an attachment that clips on under a grader moleboard so the GPS can trim out the kerb perfectly level and to exact grade.

The wings will hold material from spilling out the sides and enables carrying of that material along the kerb base for filling low areas. Utilising this attachment means less preparation area is required, just the right amount of area for the kerb machine to run.

Benefits • Enables the GPS to trim out the kerb

to perfectly level and exact grade• Reduces material wastage• Speeds up kerb prep process

Operational Improvements / 31

Pile Starter Casing Open bored piles are a constant safety risk onsite.The pile starter casing here has been developed to eliminate some of these safety risks. Firstly its bright colour makes it clearly visible onsite. Secondly the lockable gate at the top ensures no-one can fall in, if the working pile is left unattended.

After trialling the prototype in the field, Oakley Creek, a couple of improvements were made.

‘J’ locks were cut into the top of the casing so it could be driven/ screwed into the ground rather than lifted into position.

Environmental Compliance: The suction pipe was also increased in size from a three inch to a four inch. This enables better flow of water from inside the casing into the sucker truck, ensuring no water spills on to the ground in the transfer.

Benefits • Eliminates the risk of anyone falling

down an unprotected working pile • Clearly visible onsite• Lockable gate at the top of the pile • Light to transport• Design approved and certified

32 / Operational Improvements

Over the years Fulton Hogan has developed a strong working relationship with the Tauranga Airport Authority by providing maintenance, construction, surfacing and the operation of a clean-fill site over an historic landfill on airport land holdings; which is used to stockpile waste concrete from various projects around the Bay of Plenty.

When it came to designing and building a long-term car park for the Tauranga Airport, a low environmental footprint was a top priority for the customer. Project Manager David Kingham came up with a solution that used 100% recycled aggregate for the base course, derived from the stockpiled waste concrete. Concrete waste is a significant contributor to New Zealand landfills (12-17%), and using this recycled product saved 1,200t of concrete from landfill (and the cost of 1,200t of raw aggregate production).

Part of the construction build also involved installing certified Carbon Credit Environmental Services Triton Storm Water Chambers. These are soybean resin, a petrochemical resin substitute, that is made from a renewable resource (that is also cheaper to produce than traditional resin), and saved approximately 3t of concrete and plastic that a conventional drainage system

would require. These drainage chambers are a carbon neutral product that reduce greenhouse gases, CO2 emissions and energy utilised at the end users site by 15-30%. Triton Storm Water Chambers are used to capture storm water and disperse it slowly via soakage, creating a zero discharge to the already overloaded local storm water system. This steadily discharges stormwater, recharging ground water aquifers saving approx. 6,000,000L of annual runoff to the flood prone storm water system.

Vehicle emissions were also considered when planning and working on the project. Through logistical truck planning, savings were captured reducing fuel, CO2 (1700kg), costs and time by back loading trucks and not carting from the quarry. The team were able to take the cut sand to the airport clean-fill, while returning with crushed concrete to build the pavement instead of having to transport virgin material to site; 4,800m3 of sand and 900m3 of topsoil removed from site was used as fill to rehabilitate airport clean-fill for grazing.

Because this car park was designed in house, the team were able to use a 3D model in conjunction with grader control technology; saving over 100 man hours, creating a safer,

more efficient and less labour intensive construction methodology.

This project displays the importance of business synergies and is a great example of customer focused innovation which exceeded our customer's sustainability aspirations through reduced raw material use, reduced man hours & fuel burn, using carbon neutral products, and saving material from landfill.

Having a strong collaborative relationship with our customer, and with them in turn supporting the clean-fill recycling process, alternative storm water options, and then encouraging the use of these recycled materials in their infrastructure makes it a case study for other businesses and enterprises to follow.

Sustainable Car Park Tauranga AirportThrough eco-design, construction management, sustainable resourcing and logistics, the Fulton Hogan Tauranga team delivered a sustainable and innovative space for the Tauranga Airport.

Design Innovation / 33

Diverging Diamond Interchange An innovative design to reduce the footprint and cater for significant growth in the region.

Fulton Hogan was selected by the Department of Transport and Main Roads (DTMR) to participate in the Bruce Highway Upgrade Project (Caloundra Road to Sunshine Motorway) which is being delivered using the Early Contractor Involvement (ECI) contract model.

A key challenge for this project was to minimise the impact that the project had on the Beerwah State Forest adjacent to Caloundra Road Interchange whilst catering for significant future growth in the region.

The team collaborated with DTMR representatives and designers, including a worldwide search of innovative engineering solutions that maximised capacity whilst reducing the impact footprint compared to a

traditional interchange design. The result was a Diverging Diamond Interchange (DDI), which when implemented, will be the first in Australia. Over 50 DDI’s have been implemented in the USA.

The Fulton Hogan team quickly recognised the potential benefits of a reduced footprint and increased functionality of the DDI solution for the Caloundra Road Interchange. However, DTMR were initially reluctant to embrace it as this was very different to their established approach to interchange design. In recognising the significant change that the DDI solution represented for DTMR, Fulton Hogan worked with them and brought them along the journey of understanding of how they worked and how to engage with the public. This

included identifying additional safety benefits of a DDI solution with a reduced number of traffic points.

The DDI solution for the Caloundra Road Interchange developed by the Fulton Hogan Bruce Highway Upgrade Project team is an excellent example of engineering innovation. It achieved the customer's objectives of reducing environmental harm whilst catering for future growth, all with improved safety outcomes for the travelling public, and it reduces cost of construction compared to a traditional solution. The Fulton Hogan Bruce Highway Upgrade Project should be particularly recognised for bringing DTMR along the journey of understanding so that they can also embrace the outcome.

34 / Design Innovation

Upper Paskeville Recirculation System Benchmark for future mixing systems saves running pumps 24/7. Historically, mixing systems inside storage lagoons consist of static horizontal or vertical mixers which are largely ineffective, run 24 hours a day, 7 days a week, and use considerable power. Inside large reservoirs, their sphere of influence is relatively small and therefore multiple mixers are usually required at a large capital cost. Water traditionally stratifies and the quality can rapidly deteriorate in summer months requiring great intervention by our customer – South Australia (SA) Water.

At the project kick-off for Paskeville, the project team decided to proceed with the concept of a recirculation system, which could potentially offer many savings to our customer and if proven successful, would become a benchmark for future mixing systems in lagoons across the SA Water network.

The installation of the recirculation system at Paskeville is considered to be a trial, however so far to date the test results that have been achieved are proving that the system is able to provide a much faster, flexible and more efficient mixing system for SA Water. This has the direct effect of providing far greater water quality within the storage lagoon due to the better mix of chlorine and water treatment.

Throughout the design process it was also established that rather than running the recirculation pump non-stop, the water flow into the storage lagoon could also be utilised to provide mixing as well. This is achieved by running the inlet flows through our recirculation manifold and utilising the upstream head pressure to achieve mixing within the lagoon. In effect, this provides SA Water with free mixing!

The recirculation system also requires significantly less maintenance. Furthermore, all maintenance activities are located outside of the storage and so this offers a safer solution for SA Water operators because they do not need to walk on the covers of the storage lagoon or employ divers to access the inside of the lagoon.

Based on the results achieved to date, SA Water has been using the system and is extremely happy with the far greater mixing performance being achieved. This style of mixing is therefore likely to be rolled out for all future projects involving storage lagoon upgrades.

Design Innovation / 35

Alan Peacock General Manager,

Engineering & Technical Services. Alan.Peacock@fultonhogan.com

Chloe Smith National Innovation Manager

Chloe.Smith@fultonhogan.com

Nicole Perry Innovation and Blue Skies Co-ordinator

Nicole.Perry@fultonhogan.com

Please note: The information stated in this document is to the best of our knowledge at this time. Since the conditions of use and application are beyond our control, no guarantee beyond that of the quality of the product at the time of despatch can be implied.

This document can be updated at any time. © Fulton Hogan, June 2017.