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Newcastle K10 Berth coNstructioN

wiNNer2013 Master Builders australia NatioNal excelleNce iN BuildiNg aNd coNstructioN award – toyota NatioNal civil/iNfrastructure award – over $25 MillioN

wiNNer2013 Nsw Master Builders associatioN excelleNce iN coNstructioN award – civil eNgiNeeriNg Projects ($20,000,001 & over)

“One of the key to success was to accurately manage information flows to and from the client, providing expert advice where required, and to develop new ways to work with operations and other contractors.” Greg cook Project Manager, Newcastle K10 Berth construction, laing o’rourke

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PROJECT DESCRIPTION

the Newcastle K10 Berth construction project for Newcastle coal infrastructure group (Ncig) involved the construction of the new coal loading wharf at the world’s largest coal export port, Newcastle’s Kooragang island. the project involved delivery of a new 465 metre wharf, adjacent to Ncig’s existing K8/K9 wharves – which were built by laing o’rourke 18 months earlier. land and marine piling, concrete structures, rail works for the shiploader, and all associated drainage, road and civil works were included in the project.

construction of the K10 berth increased the length and output of the existing K8 and K9 berths enabling up to three vessels to be loaded at any one time. this increased the outflow of coal through the new shipping berth helping alleviate current bottle-necks. the berth allows handy through to cape class vessels (the largest categories of dry bulk carriers, from 60,000–200,000 dry weight tonnes) to berth and load, helping to deliver a coal export volume of 66 million tonnes per annum.

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ProJect Details

Project title: Newcastle K10 Berth construction

location: Kooragang island, Newcastle, New south wales

client: Newcastle coal infrastructure group

date commenced: 26 september 2011

date completed: 19 december 2012 (2 months ahead of schedule)

contract completion date:

9 february 2013

type of contract: construct only

the a$110 million K10 Berth construction is part of the overall Newcastle coal infrastructure group (Ncig) coal export terminal 3 project. the 465 metre composite steel and pre-cast concrete structure plays an integral part in Ncig’s export terminal achieving a coal export volume of 66 million tonnes per annum. the construction of the berth commenced in september of 2011 and was completed in december 2012, some two months ahead of the planned schedule. the project involved over 400,000 work hours without a single lost time injury and was delivered to a standard that resulted in all stakeholders being extremely satisfied with the outcome. the project was delivered in a challenging marine environment and involved the installation of over 200,000 tonnes of revetment and armour rock, 150 steel tubular piles, 4,000m3 of in-situ concrete, 500 pre-cast elements and 2,000 tonnes of structural steel. the project was delivered on the back of work successfully completed for the same client. due to the performance on the K8/K9 project, Ncig afforded the laing o’rourke team the opportunity to exclusively bid the K10 project. the bid was contingent on value for money being demonstrated, but also the ability of the laing o’rourke team to effectively work with the client through the procurement process.

the challenges in constructing this project included several key elements:

• difficult geotechnical conditions for installation of piles requiring passive anchors;

• interfacing with other contractors;

• a sensitive marine environment; and

• complex logistical movements.

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out of these challenges was born the innovation, robust controls, focused leadership and governance at each stage of the project to ensure a successful outcome. the solutions to solving these issues were technically led and highly focused around our core value of safety. one such area of innovation was the development of the temporary jetty. laing o’rourke purpose designed, fabricated and erected a 75 metre modular temporary works structure to:

• limit the risks around shipping channel dredging operations – the temporary structure was designed to remain within the permanent berth envelope;

• Provide a stable guide to enable pile installation tight tolerances in order to remove the need for post installation manipulation;

• support the piles during the drilling, concreting and anchoring activities;

• support piling equipment of more than 50 tonnes, transferring the loads away from the permanent structure back to the shore; and

• Prevent the ingress of contaminants from the wharf installation into the Hunter river.

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By effectively mitigating these issues, the temporary works structure enabled a safe work environment for multiple operations to be carried out from the one platform. it enabled predictability in the programming, delivered time efficiencies by limiting interfaces with other contractors, and enabled increased accuracy of pile positioning and lessening any costly post-pile installation manipulation. while this is an example of innovation implemented to facilitate time, safety, quality and environmental benefits, the entire project was predicated on the philosophy of safety at the core of the construction methodology.

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oVerView oF wharF worKs

• 81 steel tubular piles screwed into the river bed, drilled out and anchored (passively)

• 2,000 tonnes of structural steel superstructure installed, welded and the connections then painted

• installation of 182 Pre-cast concrete deck panels (10 tonnes each)

• installation of 149 prestressed concrete beams (10 tonnes each)

• 465 metres of fit out work, including installation of mooring hooks, rail, handrails, grating, brackets and drainage.

• 150,000 tonnes of revetment stone installed

• 56 steel driven tubular piles drilled out and anchored (passively)

• 32,000 tonnes of armour material placed on the front face of the revetment for scour protection

• 1,300m3 of in-situ concrete works fixed, formed and poured for the thrust blocks, crane beams, maintenance bay abutment and maintenance bay platform

• 465 metres of rail installation and minor finishing works to the shiploader beams.

laing o’rourke is committed to the use of our innovative design for Manufacture and assembly (dfMa) methodology. this technology recognises the need for innovative construction techniques that are safer, cleaner and more efficient, and which minimise disruption, guarantee quality and cost, and save time. dfMa maximises the size of components fabricated off-site in a controlled factory environment to limit the work on site and hence reduce the installation risk on these critical elements.

oVerView oF laND worKs

laing o’rourke approached the construction of the wharf from the perspective of working from the land and not the usual scenario of working from the water. the key differences and benefits of this technique were:

• the 1,000 tonne barge and 150 tonne crane usually used on the water (erecting the temporary jetty) were replaced by a 280 tonne crane on the land.

• the 2,000 tonne barge and 200 tonne crane on the water (dismantling the temporary jetty and erecting structural steelwork) were replaced by a 350 tonne crane plus superlift on the land.

• the 1,000 tonne barge and 100 tonne crane on the water (fitting out the steelwork) were replaced by a 280 tonne crane on the land.

• the 280 tonne crane used at the barge load out facility was not required.

• the workboat used to manoeuvre anchors was not required.

• the dumb barge used to ferry materials back and forth to the barges was not required.

• the barge load out facility was not required.

• the steelwork could be lifted out in larger sections due to the larger capacity of cranes on the land. this meant less connections and less welding and painting over the water which also had a tangible programme advantage and posed less safety and environmental risks.

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the project achieved consistently high rates of productivity for all work faces, but importantly ensured that the correct controls were in place to avoid re-work. this diligent and consistent approach to achieving the highest level of quality resulted in the lowest overall number of outstanding works items upon issuance of a practical completion certificate in the Ncig project history.

the K10 team also implemented a range of ecologically sustainable initiatives associated with the site shed establishment including rain water harvesting; solar panel roof ventilators; timed light switches for meeting rooms; glazing panels to meeting rooms to increase natural light penetration; low wattage light fittings and globes, split air conditioning and removal of sinks to restrooms.

all of these sustainable initiatives are part of laing o’rourke’s industry-leading ePic sustainability agenda. ePic demonstrates our commitment to a sustainable future through nurturing our environment, caring for our people, supporting our industry and enriching the communities in which we are working.

the K10 project also incorporated community initiatives such as a red cross Blood drive; a shipping container foc for a local rugby club, a footpath for redhead surf club and a retaining wall and slab for windale st Pius school.

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one of the factors that distinguishes laing o’rourke from other construction companies is the direct employment of our workforce and our capacity for self-delivery. our clients benefit from our direct delivery approach and the security and reliability a directly-employed workforce provides.

the retained knowledge of our staff is one of the key reasons we confidently deliver successful projects and maintain ongoing relationships with our clients.

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SubCONTRaCTOR lIST

all tasks were self-performed, except:

onsite Painting subcontractor: capeonsite land Piling subcontractor: Piling contractorsoffsite steel fabrication subcontractor/supplier: j steel/Pt Hanjung (indonesia)offsite Pre-cast fabrication subcontractor/supplier: Hansononsite Non-destructive testing subcontractor: Bearu veritasonsite welding Howard welding & constructionconcrete works supply of labour john clayden constructions & team dreegan

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SafETy RECORD

K10 was identified at its launch as a Mission Zero flagship project, showcasing laing O’Rourke’s unique behavioural safety campaign that aims to drive all incidents from our construction sites by 2020.

The safety record achieved was approximately 400,000 Mhrs lTI free.

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SuMMaRy

K10 is the third consecutive project laing o’rourke has successfully delivered at Newcastle’s Kooragang island. our innovative approach to design for Manufacturing and assembly (dfMa) methodologies and our Mission Zero safety programme saw this project successfully completed with an impeccable safety record and programme completion two months ahead of schedule. the high-quality composite steel and concrete wharf was realised by the forward-thinking techniques and the hard work of the team involved. this outstanding project will play an integral part in boosting the Port of Newcastle’s export capacity – a critical mainstay for the economies of the Hunter valley, Nsw and australia.

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site PlaN

PlaN View

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diagrammatical representation of wharf

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eND eleVatioN

with the shiPloaDer imPoseD oN DrawiNG

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diagrammatical representation of wharf

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ProGress imaGes

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