Civil Infrastructure

The Butler Rail Extension Project is a $240 million project to extend the Joondalup rail line to Butler. This project is to extend the Joondalup Line to Butler and involves extending the existing rail line approximately 7.5km north of the existing Clarkson Station, to service Perth’s rapidly growing north-west suburbs. With more than 2,000 passengers expected to board at Butler Station every day, the project will also help ease pressure on the Mitchell Freeway and major road corridors.

Passenger services on the new line started in 2015.

Features of the overall project include:

• A park ’n’ ride station with approximately 930 car bays
• 11 new buses to provide feeder services into Butler and Clarkson stations
• Opportunity to positively influence land use around the station as a Transit Oriented Development
• Four additional railcars have been acquired to accommodate the extra passengers

A significant factor affecting the project was the complexity of operations due to restricted access and limited work area, and a project requirement to complete the works as close as possible to the allocated timeframe. This was further completed by PTA adding a series of contract amendments to the project that resulted in the required work tripling in scale. Included in the additions was a requirement for: 

• Under-track boring at the Nowergup Depot – during liv railcar operations
• Butler Transit Station Forward works
• Earthworks to Nowergup Depot yard – 200,000m³
• Additional up main re-alignment (additional rail track) – bulk earthworks 167,000m³
• Nowergup access road – bulk earthworks 30,000m³
• Supply and installation of HV electrical pit and pipe at Nowerguy Depot
• Supply and installation of HV cable works and services relocation at Nowergup Depot
• Supply and install tech span arch underpass and reinforced earth walls to Nowergup access road

The magnitude of the civil work required achieving the original contract within deadline, plus the additional project works, with changing design requirements within the original deadline was immense.

RJV was the winner of the Civil Contractors Federation ‘2012 Earth Awards’ (WA).

The Butler Railway Bridges Project involved the construction of 3 road-over-rail bridges (Butler Boulevard, Benenden Avenue and Landbeach Boulevard) and the associated road works to connect Subdivisions previously built by RJV with each other across the railway. The works also included the completion of the communications and traction power conduit and pit system along the length of the railway cut, the construction of approximately 1.8km of asphalt public shared path (PSP) along the embankment of the railway cut as well as the installation of the limestone capping layer to the cut foundation in preparation for the subsequent laying of track-work and ballast material (completed by others).

The project was completed as part of a joint venture with Bocol Constructions PTY LTD. The Joint Venture saw Bocol complete the bridge construction works and concrete wing wall structures whilst RJV completed all road construction, earthworks, diversion works and services. The road works included the constructions of approximately 8000 square metres of pavement along with earthworks to tie in the adjacent subdivision roads with the newly built bridges. Minor works also included noise wall construction, landscaping, fencing and PSP lighting along the railway alignment.

Each of the bridges involved the construction of a cast in-situ concrete bridge deck with cantilever wing wall abutments, removal of existing services (water, sewer, power, lighting , gas and Telstra) contained within the diversion “bunds” crossing the railway cut, removal of the bund material and its use in backfill to the abutments where possible.

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The Butler Railway Bridges contract demonstrated RJV’s ability to perform a multi facet high-profile contract as part of a joint venture arrangement for a government client.

The contract involved considerable community interaction to ensure local residents were made aware of the works as well as kept informed of any delays that may be caused. RJV was able to effect community consultation through letter drops, community and stakeholder meetings, effective communication and signposting for site contacts and through our approachable presence onsite in Butler. RJV and Bocol, in conjunction with the PTA, developed comprehensive construction management plans to ensure that the potential environmental impacts of the project on the surrounding areas were inimised. Some of the environmental issued addressed by the plans were noise, dust, traffic and vibration.

The project also saw RJV and Bocol engage in value-engineering for the bridge design. Bocol’s experience in cast in situ concrete works and RJV’s experience in the ground conditions at the location of the footings for the bridges (RJV had previously completed the railway cut earthworks for the PTA two years prior) meant that through consultation with the PTA the bridge design and cantilever system originally tenderer on was modified to better suit the surrounding conditions and ensure that the final design was constructed with ease.

Throughout the contract period, RJV managed reporting on both Bocol and RJV QA aspects of the works to meet the requirements of the PTA. RJV completed quality assurance tasks such as RJV’s inspection and testing plans as well as  integrated the reporting of the bridge deck construction (ie. concrete testing, reinforcement schedules, survey and backfill compaction of the abutments) for the project as a whole.

RJV implemented detailed traffic management plans during the construction of the 3 bridges to ensure that disruption to the local residents was minimised. Part of the works included the temporary closure of Benenden Avenue and the realignment of both Benenden Avenue and Landbeach Boulevard. The location of adjacent schools had to be considered during works and works were schedule to ensure that morning and afternoon school drop off periods were kept free of major works associated with the realignment of the roads leading to the bridges.

The 2km Bertram Road Duplication Project involved the construction of a duplicate northern carriageway for the existing Bertram Road alignment from the Kwinana Freeway to a tie-in point 300m West of Challenger Avenue Intersection with Bertram Road, as well as the upgrading of road infrastructure and existing pavements on Bertram Road. RJV was required to undertake tie- in works with existing pavements and intersections connecting into the existing Bertram Road carriageway as well as the offline construction of the Bertram Road northern carriageway.

The complexity of the project was significant, owing to the need to adjust levels and cross falls of the existing carriageway in sections as well as retain as much of the existing pavement alignment as possible. A new dual-lane roundabout was also constructed under traffic conditions with RJV also constructing a culvert extension under Bertram Road for the Peel Main Drain crossing. RJV removed and rehabilitated existing road seal and pavements from basecourse level, built up existing pavements to new levels through reconstruction of basecourse layers as well as constructed full–depth pavement installation from subgrade. The project required installation of new pit and pipe drainage and culverts for the existing and new carriageways, modified and installation of full new lighting and electrical services and completion of all earthworks and road pavement construction including new sealing and asphalt, kerbing, footpath, lines and signage and roadside infrastructure.

RJV also converted all overhead electrical to underground power requiring significant liaison and coordination with Western Power. RJV also liaised with MRWA regarding the tie into Mortimer Road Freeway Bridge at the freeway on ramp and completed this section under night works. RJV also relocated existing bus stops and shelters requiring liaison with the PTA.

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RJV conducted significant community consultation throughout the project’s duration. This included letter drops and signage to inform the community of the impending works, as well as attendance at community meetings. A comprehensive traffic management plan was implemented to ensure that local residents were able to utilise the road whilst maintaining safety on site. With the different sections of the works requiring differing methodologies for construction the traffic management process continually changed, from stop-go single lane restrictions, to roadside lane-narrowing to full detours, depending on the level of management required for the project.

Access for existing residents facing Bertram Road was a consideration in all works, as well as the particular issues surrounding the location of the local school midway along the length project. Access was maintained during peak school-traffic periods, and RJV was required to ensure normal bus services were able to continue to use portions of the existing carriageway.

RJV was able to plan and execute the works so that existing lighting at intersections was kept in place for as long as possible to minimise the need for temporary lighting towers at intersections. The works progressed with minimal disturbance to the daily activities of local residents.

RJV’s project management team on the project completed works to the specifications required by the client. This involved continuous engagement with stakeholders to ensure that everyone was informed and their needs were met.

The Lenore Road Realignment and Upgrade involved the construction of a new single carriage way roadworks of Lenore Road from East Road to High Road and the associated service asset relocations. The works were divided into three Separable Portions as follows.

·Separable Portion 1 involved the construction of a Bypass Road to allow the relocation of both Western Power and Water Corporation assets. This was an 860m section of road which was constructed offline to the final alignment to allow works to be carried out without disrupting the flow of traffic.

·Separable Portion 2 involved the relocation of Western Power and Water Corporation assets and earthworks in the vicinity of the Nicholas Road intersection. Existing Overhead HV power lines were removed with the new lines being installed underground. Construction of a new DN600 MSCL water distribution line was carried out to allow the removal of the old line which, along with the removal of the overhead power, enabled bulk earthworks to proceed in order to lower the intersection by approximately 3m to its new design levels, increasing lines of sight for traffic in all directions.

·Separable Portion 3 involves the online upgrades to the existing road alignment including clearing, pavement construction, drainage, shared paths, tie-ins to existing roads, landscaping and associated works. Upgrades were also completed to the intersections at East Road, Nicholas Road and Elliot Road.

RELEVANCE: The Lenore Road Realignment & Upgrade contract is a current example of RJV’s ability to complete road construction projects involving precise traffic management and a high level of planning. Originally a 66 week program at tender, upon commencing works RJV was able to identify areas where this could be reduced by carrying out a large number of operations concurrently. This involved accurate planning of operations and resources along with close monitoring of on-site activities to ensure these dates were both achievable and met. As a result of this our client benefited from an 8 week reduction in the overall duration of the project.

The large volumes of traffic encountered on Lenore Road during morning and evening peak hours also required a high level of management, with numerous Traffic Management plans utilised over the construction period to ensure the road remained open to the public at all times. RJV coordinated their works so that operations that required STOP-GO on Lenore Road were carried out during off-peak traffic hours to avoid potential delays or hazards for road users. This was carried out successfully by utilising our own Traffic Management Controllers who are fully accredited by MRWA.

Using our knowledge from previous works, RJV also approached the client over the course of the contract with design ideas for different aspects of the job which were in their benefit. An example of this would be the design proposed by RJV for the construction of the Bypass Road which resulted in a substantial saving for the client as opposed to the original tender design. RJV’s proposal also gained the client a week on the program in this case.

The project also involved interaction with a large amount of existing services. HV Power, MP Gas, Sewer, Water, Gas and Telstra were all located within the work zone. The largest portion of our service relocation works involved the installation of the DN600 MSCL water distribution main. Due to the size of this water main and the nature of the inspections and tests associated with it, regular correspondence was required with Water Corporation. RJV were contractually committed to achieving a completion date of the 31^stof July 2015 which was achieved and allowed the connections to be carried out mid-August during the Water Corporations shutdown period as was specified in the contract.

This contract is currently ongoing with SP1 100% complete, SP2 100% complete and SP3 20% complete. All works are on program and within budget.

The Marmion Avenue Extension involved the construction of Marmion Avenue from Butler in the south, through coastal dune areas to Yanchep in the north. The link opened up the northern suburbs corridor through the Alkimos, Eglington areas and has significantly reduced travel times for residents of Yanchep and Two Rocks in travelling to Joondalup and Perth. The extension was approximately 13 kilometres long and involved clearing and bulk earthworks for the ultimate formation, pavement construction for the single carriageway stage 1 formation, drainage and street lighting. The alignment through coastal dunes also required tying into existing pavements at Yanchep Beach Road as well as the existing extent of Marmion Avenue at the time.

RJV also constructed three roundabout intersections for future roads at Romeo Road, Pipidinny Road and Santorini Promenade, as well as constructed wildlife crossings in strategic locations under guidance from Principal-Engaged Environmental Consultants and erected wildlife fencing to the extent of the project.

The Marmion Avenue works linked two projects being undertaken concurrently by RJV, Capricorn Village at Yanchep and Brighton Estate at Butler.

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The project involved the cut to fill of nearly 1,000,000 m3 of sand and rock. Rock was excavated through ripping with D10 and D11 dozers. RJV was able to efficiently rip all rock encountered to the extent that rock blasting provisional allowances were never utilised on the project. Excess rock was earthworked into deep fill areas and blended with sand to provide a suitably graded fill mixture. RJV used its fleet of scrapers to perform earthworks cut to fill operations within short to moderate haul distances. Larger haul cut to fill operations utilised 50T Articulated Dump Trucks loaded by 988 Loaders and 85T Excavators.

The pavement works for the project comprised of 225mm thick 75mm graded limestone subbase, 75mm thick Emulsion Stabilised Limestone basecourse, primer seal and 30 mm AC or 40mm AC intersection mix wearing course.

The project demonstrated RJV’s capability in planning and executing large scale road alignment projects over long distances, as well as an ability to coordinate multiple working fronts over an alignment of approximately 13km to ensure that program timeframes were met.

Proper planning and coordination of site activities meant that RJV was able to maximise efficiencies with haul distances and minimise wastage for cut to fill along the alignment.

The size of the project also demonstrated RJV’s ability to coordinate the delivery of large quantities of road pavement materials, asphalt and sealing works as well as ensure that quality of materials was kept consistent across the project.

On the doorstep of the Swan Valley, RJV commenced work at Vale in mid-2012 and has since completed over 90 separate works contracts for Stockland, totalling in excess of $110M and providing housing lots for over 2,500 new homes in Aveley during this time. The main area of the works has been situated on farmland predominantly used for the training of racehorses. Prior to works commencement there was a significant demolition contract awarded to RJV for the demolition and disposal of structures, both above and below ground, including the cataloguing, removal, and disposal of large amounts of building materials including asbestos and other contaminants.

Subsoil conditions at Vale range from sand through to significant clay layers and occasional laterite. The management of acid sulphate soils and groundwater infiltration and acidity are daily tasks undertaken by RJV, along with the blending of site based topsoil with imported sand, providing a fill material that meets the strict permeability requirements of the development.

In May 2015, RJV commenced construction of the Ariella Private Estate in the suburb of Brabham, on the fringe of the Swan Valley. When complete, the 40 hectare development will comprise 500 residential lots developed in seven stages, and will include 11 hectares of community recreational facilities and a primary school. The development area includes a sensitive wetland and sits above an extremely high water table, with the treatment of acid sulphate soils, strategic dewatering and close monitoring and management of groundwater infiltration being part of the RJV daily operation.

The estate requires a large volume of imported fill sand to bring the site up to its design levels. This has required targeted planning and management in consultation with local authorities to ensure that existing residents and infrastructure are not adversely affected by high volumes of truck and machine movements occurring in the rapidly developing area of Brabham.

The development is adjacent to the Dampier to Bunbury Natural Gas Pipeline, one of WA’s most important pieces of energy infrastructure. Part of the works required the filling of parts of the PBNGP corridor to suit the estate levels, due to the sensitive nature of the works these earthworks are being completed by RJV in close consultation with DBP.

In August 2011, RJV commenced construction of the Whiteman Edge development in Henley Brook, 20km NE of Perth CBD (adjacent to Whiteman Park). When complete, the development will comprise over 1,500 residential lots and will include in excess of 22 hectares of community recreational facilities, a neighbourhood shopping centre and schools. The development is a joint venture between Stockland, Department of Housing, and Whiteman Edge Developments.

Construction at the site presented a number of environmental challenges for RJV, which prides itself on its commitment to environmental management. The development area is flanked by sensitive wetlands and sits above an extremely high water table. Treatment of acid sulphate soils, strategic dewatering and close monitoring and management of groundwater infiltration are part of the day-to-day operations being undertaken by RJV at the site.

Large volumes of imported local sand have been required to bring the site up to its design levels. This has required target planning and management in consultation with local authorities to ensure that existing residents and infrastructure are not adversely affected by high volumes of truck and machine movements.

To date, RJV has completed contracts in excess of $80m since commencement.

RJV commenced Stage 1 & 2 BEW in November 2014 with completion in June 2015.  Works consisted of bulk earthworks spanning two large commercial civil stages ranging from underground services, roadworks and retaining walls.

Particular attention was given to the bulk earthworks in that a considerable amount of unexpected finds were uncovered in this post demolition site. Furthermore, asbestos was exposed and very stringent environmental requirement had to be met in the handling of both these unexpected finds and asbestos materials. At the request of the client, RJV were actively involved in the overall post demolition remediation requirements.  Large areas of fill were excavated, unexpected finds removed and then selectively backfilled. RJV played a pivotal role in the client attaining all post demolition approvals allowing the civil works to commence.

The civil component of this stage encompassed a significant amount of underground services.  In particular, the sewer installation involved substantial dewatering, handling and treatment of acid sulphate soils (ASS) together with the installation of both infiltration and sedimentation ponds. Additionally, in line ASS dosing treatment plants were installed to effectively manage the acidity of the pumped water. Stringent environmental control measures were implemented with daily compliance checks being carried out by the Environmental Engineer.  

Another key component of the underground services was the substantial sewer boring being carried out very closely to existing properties, adjoining the overall development area. This involved meticulous boring techniques to ensure numerous factory buildings were not compromised during the deep boring operation. Specific boring techniques were also implemented to cater for numerous other existing services located within Baile Road covering, high voltage power, optic fibre communication cables, water and gas services.   

Following the successful completion of Stage 1 & 2 BEW together with the integral part RJV played in assisting the client in the overall Stage 1&2 demolition delivery, RJV were then awarded the contract to carry out the demolition and associated earthworks of the existing Bevchain facility. This involved the direct supervision of the demolition, removal of unexpected finds, exposure and disposal of both asbestos material and completion of the bulk earthworks. Works commenced in April 2015 and was successfully delivered in September 2015.

Stage 3 Civils was then awarded to RJV in September 2015 with an anticipated completion in January 2016. Again, this stage included for underground services, roadworks and retaining walls.  Whilst on a smaller scale than Stage 1 & 2, RJV again had to deal with very deep sewer excavations, extensive dewatering, treatment of ASS material and working in close proximity to existing buildings.           

The estate is situated on Yanchep Beach Road between the Sun City Country Club and the Yanchep National Park. RJV commenced construction with Stage 1 of the Yanchep Golf Estate in late 2011 which included bulk earthworks, underground services, retaining walls and road construction, along with the roundabout and main entry from the existing Yanchep Beach Road.  The interface between the development and the golf course has been successfully created with the use of naturally occurring limestone, along with the preservation of existing trees and vegetation to provide an aesthetically pleasing link between the property boundaries and the golf course fairways.

Throughout construction of the development, RJV has worked closely with both engineering and environmental consultants to ensure delivery of an impressive residential estate that co-exists with native flora and fauna species.  The implementation of strict guidelines for the protection of native species such as the Carnaby Black Cockatoo, combined with diligent monitoring of machine hygiene and movements to stop the spread of dieback has allowed RJV to present the Yanchep Golf Estate as a residential development that exists harmoniously within its natural surroundings.