The project team established a procurement system on site that significantly increased rock delivery.

Overview
APLNG Materials Offloading Facility is located on Curtis Island, which is within Gladstone Harbour.

Project Scope
BMD Constructions is engaged to design and construct the Materi als Offloading Facility. The work involves the design and construction of a Roll-on Roll-off (Ro-Ro) and Lift-on Lift-off (Lo-Lo) wharf on Curtis Island and is part of early works to facilitate the delivery of materials for the construction of the LNG plant.

The scope of works includes:

• Marine based piling construction of a 230m long HZ combi wall;
• Installation of 30m anchor ties between walls within tidal zones;
• Supply and transport of 300,000 tonnes of rock fill;
• Placement of the rock fill behind the walls together with associated earthworks;
• Potential acid sulphate soils excavation and management;
• Heavy pavement construction;
• Concrete construction of capping beam and slab over water;
• Marine based piling and installation of berthing dolphins and fenders; and
• Installation of navigation aids within shipping channel

LOCATION: Southern Adelaide, SA
CONTRACT VALUE: $407 million (total project value)
CONSTRUCTION PERIOD: Dec 2011 – June 2014
PROJECT DELIVERY: Design and Construct
CLIENT: Department of Planning, Transport and Infrastructure
REFEREE: Lou George, Department of Planning, Transport and Infrastructure

The Southern Expressway is in one of the most significant transport corridors in the fast-growing southern suburbs of Adelaide.

The Southern Expressway Duplication project will do much more than increase the capacity of the expressway: it will provide the infrastructure for transforming Adelaide’s southern region and create opportunities for local people and businesses.

The project will include the design and construction of 18.5kms of roadway alongside the existing expressway carriageway to provide a two-way road from Darlington to Old Noarlunga to the south of Adelaide. The new carriageway will have four city-bound lanes from Darlington to Reynella and two lanes from Reynella to Old Noarlunga.

The project will also include the duplication of existing interchanges, road and pedestrian bridges. Construction started in December 2011 and is scheduled for completion by mid 2014.

The Southern Expressway Duplication project is being delivered through a 50/50 joint venture between Baulderstone and Abigroup (BAJV).

Designers KBR and Hyder are a fully integrated part of the BAJV team. They have extensive roads and structures experience, particularly in the design and construct space and have strong, existing relationships with our construction team.

The narrow and constrained site adjacent to the live motorway presented unique challenges when it came to safe pitching of the very long single lengths of PSC piles in a way that ensured zero harm to workers and commuters, while minimising delays on the busy motorway. This challenge drove the team to develop and implement a new and innovative mechanical lift connection using cast in block-outs in the pile (a TMR approved deviation from the rigid rules on standard pile design).

The project team worked collaboratively with temporary work designers to devise an elevated temporary structure which allowed its assembly from behind creek banks with crawler cranes. This elevated structure allowed for 13 piles to be pitched in one work shift, which greatly reduced temporary traffic closures and disturbance to the marine environment.

The Curtis Island LNG projects each have joint procurement, human resources, travel, accounting, legal, and community relations teams servicing them. This ensures efficiency and a quality service to our clients, reducing costs and streamlining processes and procedures. We work closely with the community, clients, key stakeholders, and government representatives to ensure a positive social impact for the duration of these projects.

At the peak of construction, the workforce will be 8,800 strong. These projects are also delivering a range of training and upskilling programs for the workforce. Bechtel will intake 400 adult apprentices through the National Apprenticeships Program (NAP) to work on the three LNG projects.

NAP targets experienced workers who may have many of the skills required to fulfil an apprenticeship, but may not yet have the formal qualification. This program will provide opportunities now and into the future for many Australians.

Part of the construction process for the three LNG plants is the construction and delivery of 260 modules from around the world. The modules are pre-fabricated steel structures that are built as a single component and transported to Curtis Island. The modules will arrive in Gladstone between August 2012 and mid-2014. When they arrive, they will be put into their permanent position to make up the key components of the LNG plant.

The delivery of the Curtis Island LNG projects will help position both Gladstone and Queensland, as one of Australia’s leading industrial centers.

Source: http://www.bechtel.com/curtisisland_lng.html

Macmahon’s site civil works on the project will include clearing, bulk earthworks, pavements, roads and drainages for a 160 hectare greenfield site on the south west side of Curtis Island. Access to the island is via water transport and there are no construction facilities on the island. Macmahon will pre-cast most concrete formations and other concrete structures on the mainland and barge these across to the island.

As there is no land access to the site Macmahon will undertake rigorous planning to ensure all plant, equipment and materials can be mobilised to site when required.

The GLNG project will create more than 5000 jobs during construction, stimulating business development and employment opportunities in the Gladstone and Roma communities.

Source: http://www.macmahon.com.au/construction/curtis-island-glng.html

The contract will involve upgrades to Gladstone-Mt Larcom Road, as well as construction of the terminal’s rail receival facility.

The rail receival facility is designed to handle 7,600 tonnes of coal per hour and is connected to the terminal stockyard by a 5.5 kilometre overland conveyor. BMD will undertake civil and concrete works for the rail receival facility and overland conveyor, mostly to the south of Gladstone-Mt Larcom Road.

BMD will also undertake civil and structural works within the Gladstone-Mt Larcom Road corridor including roadwork and bridges for public and project related use.

The contract will occur in three phases, with first phase focusing on construction of the terminal access road contained on the WICET site. Construction is expected to be complete on this phase by mid-2012.

Work will then commence to upgrade 2km of the northbound carriageway of Gladstone-Mt Larcom Road from mid to late-2012, followed by southern carriageway upgrade that is expected to be completed late-2013. This work also includes a number of service installations including water, fibre optic and gas lines.

The upgrade to part of Gladstone-Mt Larcom Road will improve safety for workers accessing the WICET site during operations, together with the travelling public.

Source:  http://www.bmd.com.au/News/BMD-awarded-major-coal-terminal-project.aspx

The delivery of the 36” and 42” diameter gas pipeline and associated facilities from the coal seam gas (CSG) fields in the Surat and Bowen basins in south western and central Queensland to Curtis Island, off Gladstone, follows MCJV’s completion of the Front End Engineering Design (FEED) and early works contract awarded in December 2009 by Australian Pacific LNG.

Mark Twycross, General Manager – Pipelines, McConnell Dowell Constructors (Aust) Pty Ltd said the project was a significant and strategic contract win for the MCJV.

“MCJV will have a peak workforce of more than 1000 people and will deliver the large diameter gas pipeline and associated facilities over a two year construction programme,” Mr Twycross said.

Moujally Jabara, Regional Managing Director Operations – Africa, Asia and the Pacific, Consolidated Contractors Group Holding Company added: “The addition of this scope of works for MCJV demonstrates our ability as leaders to help shape the future of Australia’s resources industry by delivering on one of the LNG projects in Australia.”

Major site works will commence in mid 2012 with completion due by the end of 2013.

Source: http://www.macdow.com.au/news/mcjv-commences-construction-of-export-pipeline-and-facilities