Ballast Supply – Cape Lambert Expansions, Rio Tinto
Location
Cape Lambert, Rio Tinto
Commencement
May 2013
Completion
November 2015
Type of Contract
Lump Sum
Contract Value
AUD $6.5million
Overview
Norwest Sand and Gravel was commissioned on behalf of Rio Tinto by Calibre Global to perform the extraction, processing and loading of ballast to facilitate the Rio Tinto Cape Lambert Port Expansion Project.
Scope
Approximately 300,000 tonnes of ballast materials were mined, crushed, screened and loaded during the 30 months of the project’s life. During that period, NWSG was responsible for:
- Manage Robe River Mining Ballast Quarry
- Quarry, crush and screen and load railway ballast
- Deliver railway ballast
- Maintain haul roads
- Dust control and traffic management, as well as all OHS responsibilities onsite
Project Challenges
As the project was undertaken in an existing ballast quarry, considerable issues arose due to previous disturbances, inaccessible areas, blasting remnants, etc. Traffic management within the quarry and OHS were, as always, top priorities, but they proved challenging initially in such an unorthodox, unplanned and unfamiliar environment.
Due to the nature of a quarry, all sound generated was amplified, and all dust generated was captured. There too proved difficult challenges to overcome.
Working adjacent to Rio Tinto’s rail line, with trains arriving and departing frequently added a new element to the working environment, and with it brought obvious and significant risk.
How We Managed This
NWSG completed the project by implementing comprehensive traffic and safety management plans that were developed to identify risks and the most appropriate mitigation strategies to avoid problems with workers and plant on site, and to avoid any interruption to Rio Tinto Rail Operations.
By utilising dust suppression agents, water trucks, scheduling specific work for when weather patterns were more favourable and ensuring all vehicles had fully sealed cabins with air filtration and air-conditioning systems, the potential environmental risks were controlled.
By fitting all vehicles and machinery with 2-way UHF radios, set to a company channel, by employing spotters to observe traffic patterns, and to control all access to the quarry – all hazards stemming from operating within such a confined space, with a lot of heavy equipment and vehicles were controlled.
NWSG adopted all of Rio Tinto’s and Calibre’s policies on working within Rail Networks. No Red, or colours similar, were permitted on the worksite. The train timetable and schedule was procured and disseminated each day, with onsite spotters providing incremental timely warnings for incoming trains.
Value Adding
NWSG has previously undertaken considerable works in the Cape Lambert area for Rio Tinto or in a subcontractor capacity for over 20 years, bringing considerable knowledge and expertise to the project.
Zero Harm
NWSG has maintained our focus on Zero Harm and managed to deliver this lengthy, involved project in a high risk environment, with minimal effect to all employees and site visitors.
Project Specifics
Man Hours: 55,000
Peak Manning: 12
Oversize Transport – Interstate Delivery
Location
Karratha, WA – Darwin, NT
Commencement
March 2017
Completion
March 2017
Type of Contract
Lump Sum
Contract Value
AUD $40,000
Overview
Norwest Contracting was commissioned on behalf of a private client to transport two 14.4 x 4.2m transportable buildings from Karratha to Darwin – a 5,200km round trip.
Scope
Approximately 28 tonnes of oversize loads was hauled over 2 states in a 5 day period by two operators in two separate trucks with an oversize pilot covering more than 5,200km. During that period, NWC was responsible for:
- Welfare, duty of care of employees and other road users
- Maintaining contact and schedule accuracy
- Vehicle reliability and maintenance
- Permit and Licence application and validity
- Load security
Project Challenges
Any long distance travel is inherently filled with significant risks and challenges. Employee welfare is always the greatest consideration before embarking on any long distance journey – but when that journey includes the operation of heavy haulage of oversize loads through the Pilbara and Kimberley Regions of WA to Northern Territory’s Top End following a record wet season – all those inherent challenges and risks are intensified. Maintaining contact with our operators was of paramount importance, so was adhering to the pre-planned schedule with designated check-in points along the journey ensuring that the trucks were off the road after dark in a safe location. Making allowances for adequate rest and recovery while maintaining an efficient time line was also a significant challenge that came with the project.
Zero Harm
NWC has maintained our focus on Zero Harm and managed to deliver this lengthy, involved project in a high risk environment, with minimal effect to employees.
Project Specifics
Distance Travelled: over 5,200km
Peak Manning: 3
Total Eden – Baynton West Park Material Supply
Location
Karratha, WA
Commencement
October 2016
Completion
April 2017
Type of Contract
Schedule of Rates
Contract Value
$168K
Overview
Norwest was contracted by Landcorp and Total Eden to supply landscaping materials for the construction of the Baynton West Park including the first asphalt pump track constructed in WA.
Scope
The project consisted of the following materials being supplied:
- Specially blended fill material for pump track construction
- Large landscaping feature rocks
- Screened sand for turfed areas
- Cement stabilised Gravel for hardstand and garden areas
Project Challenges
The Project was being undertaken by Landcorp on behalf of the City of Karratha at a site located in the existing suburb of Baynton West in Karratha. The project had been delayed from the initial subdivision construction due to a lack of irrigation water meaning that the area was fully developed when the works took place. Norwest was engaged by Landcorp to supply fill material for the pump track that met the specification within a tight budget. This required the blending of general fill that Landcorp had stockpiled in previous contracts with sand. The blending was undertaken in an area within the subdivision surrounded by existing dwellings making the management of noise and dust extremely important. This material then had to be transported across the subdivision to the pump track site. Total Eden carried out the construction of the parks and engaged Norwest to supply the materials required, including large handpicked landscape rocks, screened sand and cement stabilised gravel. Norwest worked with Total Eden to develop a blend of gravel and cement that was preconditioned, could be delivered in semi tippers, was well graded and easy to install to produce the required finish of the Landscape Architects.
Zero Harm
NWC has maintained our focus on Zero Harm and managed to deliver this project without incident despite the close proximity to residents, existing infrastructure and other contractors.
Shire of Ashburton – Tom Price Landfill Cell Excavation
Location
Tom Price, WA
Commencement
October 2017
Completion
November 2017
Type of Contract
Lump Sum
Contract Value
$495K
Overview
Norwest Contracting was contracted by the Shire of Ashburton to carry out bulk earthworks for the excavation of a new landfill cell at the Tom Price Landfill Facility.
Scope
The project consisted of the following:
- Excavation of 40,600 BCM of material
- Filling of bund wall around cell
- Creation of 54,765m3 Cell for future waste storage
Project Challenges
The site is located at Tom Price, a remote mining town in the heart of the Pilbara. The design of the cell initially did not suit the current tip road design so changes were required upon mobilisation to ensure it did not interfere with the operations. Due to the depth of the cell the material required to be excavated became rock, requiring considerable ripping with a D10 Dozer to allow excavation with conventional excavator. The presence of unexpected historical waste including asbestos required various redesigns to it was not disturbed. The water table was also found to be shallower than first thought requiring further redesign. Due to the number of redesigns the volume of the cell was greatly reduced. This was overcome by the installation of a large bund around the cell and the flattening of the floor grade to increase the volume and ensure the life of the cell could be maximised.
Zero Harm
NWC has maintained our focus on Zero Harm and managed to deliver this project without incident despite the discovery of unexpected waste including asbestos that was managed appropriately in accordance with the Shire of Ashburton’s requirements.
Pilbara Ports Authority – Cape Lambert VTS Tower
Location
Cape Lambert, WA
Commencement
October 2016
Completion
October 2017
Type of Contract
Lump Sum
Contract Value
AUD $420K
Overview
Norwest Contracting was contracted by the Pilbara Port Authority and Australian Maritime Services to carry out earthworks, drainage, fencing, power and communications installation works for the construction of a VTS Tower located at Cape Lambert for the remote monitoring of ship movements.
Scope
The project consisted of the following:
- Clearing 1300m2
- Removal of vegetation and unsuitable material from site
- 600BCM of imported fill
- 600m2 of road pavement construction
- 66m of drainage installation to Watecorp Standards
- 120m of electrical conduit installation to Rio Tinto Standards 540m of telecommunications conduit and fibre optic cabling to Telstra Standards
Project Challenges
The site is located on top of a hill at Cape Lambert making access to the site for material and equipment deliveries difficult. The site geology is very rocky with a number of existing services making excavation difficult. The clearing permit boundaries were very constrained and there is known heritage sites nearby. Despite these difficult site conditions the project team managed to construct the entire project without incident through careful management of plant movements and skilled plant operation. The project was delivered over two contracts, initial earthworks and roadworks and communications installation allowing the site to be commissioned and operational.
Zero Harm
NWC has maintained our focus on Zero Harm and managed to deliver this project in a difficult environment, without incident to Rio Tinto Standards, The Water Corporation, Telstra and The Pilbara Port Authorities High Standards.
