Road Construction

Midlands Highway - Perth to Breadalbane Duplication

Perth & Breadalbane

Perth to Breadalbane duplication was one of the largest projects in the Midland Highway 10 year Action Plan to improve safety and efficiency on Tasmania’s key north-south connection. 

The project was a joint venture with VEC Civil Engineering Pty Ltd (VEC) team and Shaw Contracting (Aust) Pty Ltd (Shaw) to form the VEC Shaw JV. It was a greenfield project that included the construction of a divided dual lane highway (4 lanes) 4.5km from Perth to Breadalbane, a new intersection and the construction of two structures.

Task

The project’s aim was to improve safety and efficiency of the National Transport Corridor. The project entailed the construction of two major bridge structures, enormous quantities of rock and bolder excavation (300,000 bank cubic metres), the construction of a divided dual lane highway (4 lanes) 4.5km from Perth to Breadalbane, and a new intersection.  Planning the works and in particular the staging of how the project was going to be delivered while mitigating traffic disruption was key to the project success. The long timeframe, the large number of people involved, complexities of the environmental controls and close vicinity to live traffic were just a few of the challenges faced by the VEC Shaw JV team.

Challenges

• Traffic Management - 14,000 vehicular movements adjacent to the project per day.
• Communication - being one of the State’s largest road construction projects at the footsteps of a major airport, the Perth to Breadalbane project drew a lot of public and political attention. It was therefore extremely important that traffic was managed effectively, efficiently, and safely throughout the construction period. 
• Careful stage planning to ensure safe efficient access is maintained to properties for Stakeholders during the works. This included major industrial businesses.
• The number of people movements onsite. In excess of 125,000 working hours were spent over the duration of 2 years, to complete the works. Over 500 people were inducted to the worksite. This meant that people management and the safety of everyone onsite as well as the travelling public was paramount. The project was delivered with zero LTI’s.
• Environmental Management - Protection of the masked owl and the green and gold frogs; and managing working in wetlands.
• One of the largest challenges was the significant amount of rock that was blasted and excavated from site. Utilising Shaw’s inhouse plant as well as neighboring stakeholder Digga Excavations, the team moved approximately 300,000 bank cubic metres (bcm) of rock onsite.
• During clearing and grubbing works at the Airport Interchange, an asbestos dumpsite was uncovered.

Outcomes

• The project was delivered with zero LTI’s;
• Demonstrated industry best practice in blasting and removal of a significant amount of rock that was controlled with zero harm incidents.
• Numerous internal and external audits reflected positive results in project delivery and site safety. The results of these audits were used to continuously improve our processes as well as identify areas that were implemented correctly.
• Excess rock formed part of the Southbank Redevelopment and Punchbowl Rivulet Restoration.
• 260,000 BCM of rock was removed using large excavators and dozers.
• Minimised the impact on the native vegetation, aquatic environment, and fauna.
• This project was the first lump sum project the Department of State Growth had adopted milestone payments. This meant the VEC Shaw JV took all the risks with regards to quality.
• The Project met all the expected timelines. Although the scope increased, the project was completed two months ahead of schedule.
• The Project was completed within budget.

Feedback

“Congratulations to your team on the recent completion of the Midland highway Perth to Breadalbane duplication. With so many critical environmental concerns on this major project”  Craig Tarbotton, Department of State Growth

“It is a credit to the VEC Shaw JV and their innovation and willingness to work together with the Department of State Growth were instrumental factors in enabling the works to be delivered within this timeframe without compromising on safety or environmental aspects.”  Shane Gregory, General Manager, State Roads

“It is the credit of the VEC Shaw JV that (the impact of the project) was kept to a minimum, as they managed the traffic and staged the project in a way that kept everyone safe, whilst reducing the effect on the travelling public. Island Block and Paving commends the VEC Shaw JV for the professional and diligent manner in which they conducted the works.” Phil Thurlow, Director Island Block and Paving 

Channel Highway Road Reinstatement

Margate

Tasks

The Channel Highway connects Hobart to Kingston, Margate, Snug and Bruny Island accommodating approximately 11,000 vehicles per day.  Shaw Contracting were engaged by the Department of State Growth on a design and construct basis to stabilize, overlay and reinstate 1.76km of the Channel Highway directly south of Margate that had underlying subgrade issues causing the road to deform and pothole frequently.

Local contractors and suppliers were also engaged, promoting the growth of the local economy.
The scope of work over the length of the 1.76 km section consisted of:

• In-situ cement stabilization of the existing pavement material
• Overlaying the stabilized pavement with Class 2 material
• Two coat sealing 
• Asphalting
• Line marking
• Installation of traffic furniture 

The project was completed on time and on budget with a strong focus on stakeholder management. 

Challenges 

The project had numerous challenges that required innovative solutions and management from the Shaw Contracting team. Notable challenges included:

• Completing the design within the constraints of time, budget and quality set by DSG. 
• High volumes of traffic per day with no detour roads available to bypass the worksite required the project team to shorten work lots thereby reducing delay times to road users. This was verified through several daily drive throughs to confirm timeframes. 
• The project was severely constrained by cold weather impacting the ability to seal. The project team worked efficiently to achieve project progress to beat the sealing window. 
• Management and safe continuation of work during the COVID-19 global pandemic

Outcome

Being a design and construct project, Shaw are very proud of the design provided and subsequent works undertaken. The experience and capability of Shaw’s engineering and project delivery teams provided excellent outcomes for the Department of State Growth and the road users of Tasmania. These outcomes include not only a project delivered on time and on budget, but Shaw’s focused stakeholder engagement strategies ensured the project was delivered with positive stakeholder feedback. 

Prossers Road Upgrade

Prossers Road

Tasks

Prossers Road is the connecting road between Nunamara and Lilydale road. It allows vehicles, primarily freight trucks to bypass Launceston on their way to Bell Bay. The 9.8km of road upgrades spanned over two areas of work. The existing road was partially sealed and partially graveled. Shaw were engaged to undertake major improvements for the safety and usability of all road users, the scope of works consisted of:

• Earthworks / Road Widening
• Drainage Works (Cleaning Table Drains, installing new Culverts 
• and extending existing)
• Pavement Placement
• Two-coat Sealing Works
• Line Marking Installation of Traffic Furniture  

The feedback the project delivery team received from adjoining landowners was that the road became dusty in summer, boggy in winter and overall unpleasant to use.

The work was conducted under the Minor Works Agreement over 2 consecutive 
summer periods.

Challenges 

Prossers Road is located in an area that experiences regular inclement weather resulting in wetter and colder conditions than would be expected from nearby Launceston. There were many trees located along the extent of the road that shaded the work area making gravel dry back problematic during construction, this also resulted in a narrow window for gravel and sealing works. Shaw’s experienced grader operator and pavement team were able to maximise efficiency with high daily gravel volumes being placed to finish the works in the Summer periods to best practice quality standards and with limited impact to all road users.

Due to the high volume of large trucks, in particular, log trucks, Traffic Management was implemented and maintained allowing traffic to flow without impediment with a focus on road user and worker safety.

Outcome

Shaw Contracting completed the works on time, on budget, to the highest quality standard and without incident. Shaw received positive feedback from multiple adjacent residents, one resident went as far as writing to the Premier of Tasmania advising of the ‘’excellent work and the professional nature” that Shaw demonstrated during the works, this meant a great deal to the project delivery team as well as the company as a whole.

Midland Highway, Tundbridge (White Lagoon) to Mona Vale Road

Tundbridge

Task

The White Lagoon (Tunbridge) to Mona Vale Project is located on the Midland Highway from the northern side of Tunbridge Tier Road junction to just north of Mona Vale Road junction. To achieve a minimum 3 Star AusRAP rating, the scope of the Project involves widening the existing Midland Highway to provide alternating lengths of “2+1” lane arrangements separated by a central flexible safety barrier.

The Project also included improvements to the horizontal alignment of the highway, localised improvements to vertical curves, provision of turn facilities, safer access to adjacent land, and upgrades to the Tunbridge Main Road and Mona Vale Road junctions.

The key outcomes of the Project were:

• Improvements to the overall capacity of the highway to cater for future traffic growth and freight movements
• Additional safe overtaking opportunities through provision of a “2+1” lane arrangement
• Head-on collisions will be eliminated through provision of a flexible safety barrier within a central median
• The section of Midland Highway between White Lagoon (Tunbridge) and Mona Vale will be rated a minimum 3-Star under the AusRAP rating system

To achieve the Department of State Growth’s project objectives, Shaw were required to undertake the following works:

• Excavate 180,000 cubic meters of assorted material
• Drill, Blast, Excavate and Place 110,000 cubic meters of Dolorite Rock
• Construct 160,000 cubic meters of embankment
• Supply and place a combined total of 451,000 square meters of pavement material
• Supply and Place 154,000m2 14mm PAFV 52 Seal and 17,000m2 Asphalt Seal
• Supply and install 15,100 meters of Tensioned Wire Rope Safety Fence
• Stock underpass construction and extension to existing
• Multiple drainage structure installations and improvements
• Extensive traffic signage and furniture installations

Shaw Design Innovations:

This project was Construct only, that being said; Shaw were instrumental in providing solutions to design issues throughout the project from major access and drainage redesign; through to the redesign of a 2km section of the project that was not fit for purpose which now meets the requirements of the AusRAP 3 Star Safety Rating, this result was achieved by Shaw collaboratively working with the Principle to achieve the best project outcomes.
 

Challenges

Shaw undertook the complicated construction requirements of this project whilst instigating an innovative construction staging plan that resulted in no delays to road users over and above the standard traffic management requirements. 

During the construction phase Shaw changed the vertical alignment in places up to 9m, the horizontal alignment was changed by up to 50m whilst maintaining two lanes of traffic at all times. To achieve this excellent outcome with minimum delays incurred by road users was a great demonstration of Shaw’s ability to be innovative in our project delivery. Furthermore; Shaw undertook the blasting of over 110,000m3 of solid Dolorite Rock adjacent to the existing Highway and close to historically sensitive structures, by implementing an innovative Blasting process with specially timed detonation and blasts sequences whilst providing best practice blast monitoring. Shaw completed all of the blasting works with zero impact on the surrounding structures and barely a pebble landing on the highway, this was an excellent outcome. 

Outcomes 

Shaw delivered the Midland Highway, Tunbridge (White Lagoon) to Mona Vale Road, Road Improvements and Safety Upgrade Roadworks Project to the highest standard meeting and exceeding the Client’s expectation, without significant hold ups to road users and without incident.

Shaw is very proud to have been a part of this project working collaboratively with the Department of State Growth and all stakeholders to improve the Midland Highway and Tasmania’s infrastructure to meet the requirements of the residents, interstate and overseas visitors alike both now and in to the future.
 

Dilston Bypass

East Tamar Highway

Task

The East Tamar Highway is one of the most heavily travelled highways in Tasmania.  The construction of the Dilston Bypass on the East Tamar Highway has improved the safety, freight efficiency and provided an upgraded transport link with the Bell Bay Port. The project included two kilometres of dual carriageway and seven kilometres of three-lane highway with wire rope safety fencing separating opposing traffic streams, as well as replacement of the existing Barnards Creek Bridge with a new four-lane bridge. Works included excavation of over 700,000m³ including drill and blast.

The Launceston City Council approved a revised development application which incorporated a southbound underpass ramp on the southern junction and fog detection speed reduction signs for the northern seagull junction. The Dilston Bypass was fully funded by the Australian Government.

Challenges

Measures to help reduce road kill were a feature of the project and there was extensive consultation with property owners to minimise the impact on farming operations during the construction period.

The Project provided significant benefits for the local community and transport industry including:

• Reduced travel times
• Greater freight transport efficiency
• Improved amenity for Dilston residents
• Reduced traffic noise for local residents
• Wider sealed shoulders to benefit cyclists
• Improved safety performance
• Elimination of flooding problems at Coulsons Creek.

With more than 80 working on the project, weather conditions were a major challenge.  A late summer start meant completing earthworks and gravelling before winter rains set in was critical.  Also, bridge construction had to contend with the replacement of a major water main before bridge construction commenced.

​Outcome

The project has increased safety of the East Tamar Highway, improved travel times and transport efficiency. Works were completed as per the schedule and to the Client’s satisfaction. The local community was very pleased with the works completed.

Kempton Road Improvements

Midlands Highway

Task

This section of highway improvements was, as the name implies, a 4.3km section of highway that starts at the Melton Mowbray Intersection and heads south towards Kempton. To achieve the requirements of a minimum 3 Star AusRAP rating, the core ethos of the project was to reconstruct this section of the Midland highway to become a “2+1” lane arrangement with a median flexible safety barrier to provide separation between opposing lanes of traffic.

The project also involved some reasonable upgrades for this length, including but not limited to:

• New p-turns (x3) to provide suitable turning points for trucks once the median safety barrier was installed
• Installation of a 1.5km long overtaking lane in either direction
• Renewal of a twin span pre-stressed bridge structure, through installing a new superstructure with increased capacity (bridge presently deficient in handling mass management trucks)
• Parapet wall construction to an existing box culvert structure to allow widening of the road
• Extension of a stock underpass
• Major stormwater culverts upgrade including 1200 culverts 6m deep under the existing highway
• Function change of Lake Highway intersection and installation of designated U-turn bays.
• Alterations to adjacent landowner irrigation schemes, stock routes and accesses onto the highway

The key improvements to this section of highway due to the works are:

• Improvements to the overall capacity of the highway to cater for future traffic growth and freight movements
• Additional safe overtaking opportunities through provision of a “2+1” lane arrangement
• Head-on collisions will be eliminated through provision of a flexible safety barrier within a central median
• Achieve the minimum 3-Star rating under the AusRAP system required of the federal hgihway network as it is upgraded.

Shaw Project Delivery

This project was Construct only, however due to the pressing nature of project delivery to meet tight timeframe requirements, Shaw were instrumental in providing solutions to design issues throughout the project, which was achieved by Shaw collaboratively working with the Principle to achieve the best project outcomes. Some of these keys issues included ongoing subgrade issues, inherent drainage issues that were not scoped within the design, and landowner negotiations.

​

Challenges

Shaw undertook this project with innovation that enhanced environmental considerations of the project, as well as safety, namely:

Local Quarry Operations:

Shaw Contracting worked with local landowners to utilise an existing quarry lease within 5km of the Site. The quarry had not been commercially operated for approximately 5 years. TO reduce the carbon footprint of long cartage for materials, Shaw’s operated the quarry and undertook all testing requirements of DSG to provide suitably compliant sub-base 2 and select fill materials. This material had significant environmental benefits by reducing cartage of materials from Leslie Vale quarry, but also reduced the congestion on the highway as 3x other DSG projects were between the project and the quarry.

Staged Bridge Reconstruction:

Shaw had to replace an existing B2 bridge structure under traffic. The bridge specifically was Quoin Rivulet Bridge, a twin span bridge with a pre-stressed plank superstructure. Due to the limitations of the area, it was not feasible to build a side-track/ diversion. As such, 1 side of the bridge was strengthened before a 3-stage replacement process allowed Shaw to the existing superstructure and reinforce/ widen the substructure, all whilst maintaining the traffic flow of the Midland Highway. This works was further challenging as all of this had to be undertaken over winter to meet programme requirements. Dewatering, temporary earth training walls and pipes were used to manage the water flow through the Site. To deliver this project, Shaw partnered with VEC Civil Engineering, who provided the Bridge Supervisor and carpenters, whilst Shaw fulfilled the Project Management and civil works of the bridge.

Controlled Demolition of existing superstructure:

In order to preserve the existing bridge substructure, Shaw Contracting had to demolish the existing superstructure in a controlled fashion. This was also undertaken to prevent concrete entering the rivulet. Typically, machinery such as a pulveriser or rock breaker could not be used. Instead coring, saw cutting and developing the deck back to plank widths and removal via crane were all undertaken to allow controlled removal without damage to the substructure being reused.

Furthermore; Shaw undertook pavement reconstruction adjacent to historically sensitive structures of Melton Mowbray, and implementing low vibration roller practices. Shaw completed all of the works with zero impact on the surrounding structures.

Outcome

Shaw delivered the Kempton Stage 1 Midland Highway project to a high standard of quality within the Contract time frame, being the first major Midland Highway upgrade of the 2016/2017 financial year to be completed for that construction season. This was delivered effectively with no major safety or environmental incidents.

Shaw are very appreciative to again work with the Department of State Growth and all stakeholders to continue being a major Contractor in delivering the 10-year plan to improve the Midlands Highway and Tasmania’s infrastructure as a whole.

Birralee Main Road

Bass Highway

Task

The project involved the conversion of 3.2km of Bass Highway single carriageway to dual carriageway, and included the installation of flexible safety barriers along this section of the Bass Highway. Conversion to a dual carriageway was required to reduce driver confusion occurring due to changes between single and dual carriageways on a short section of highway.

The objectives of the works were to improve driver safety by:

• The elimination of head on crashes;
• Reducing the severity of loss of control crashes;
• The development of a consistent road environment; and
• Providing a minimum Australian Road Assessment Program (AusRAP) safety standard for this section of the National Highway

Works included:

• Cut to Fill and importation of 60,000 cubic meters of material
• Placement of 112,000m² of Pavement material
• Sealing 3.2km of Highway
• Extension of Stock Underpass
• Installation of assorted Stormwater Drainage Culverts
• Installation of 8000m of Tensioned Wire Rope Safety Fence
• Profile adjustment and resealing of existing Highway

Challenges                                                  

Undertaking the Works in multiple traffic zones without affecting traffic flows or inconveniencing road users.

Outcome

Shaw also undertook additional major works requested by the client without affecting the project completion date; this required the acceleration of all works on site to meet our client’s needs.

Shaw completed the works on time, on budget and most importantly; without incident.

Formby Road Redevlopment

Devonport

Task

Devonport City Council awarded the Formby Road Redevelopment project to Shaw Contracting to reconstruct the main arterial road into Devonport whilst extending the new city cycleway along the tight corridor between Formby Road and the rail line.

Challenges

Construction challenges included the following:

• Management of 20,000 vehicles travelling though the site daily
• Interaction with the rail line operating 24 hours per day bringing cement to the wharf
• Consultation with numerous businesses along the Formby Road development, requiring constant access and on street parking at all times
• Major redesign of integral components of the retaining walls and elevated walkway to achieve desired outcomes
• Full reconstruction of road including up to 4m high retaining wall between rail line and Formby Road whilst ensuring traffic flows through the site

Outcome

The project was successfully completed under budget, and with positive feedback from all businesses and road users including letters of recommendation and public praise through local media outlets.

Shaw Contracting provided alternative design solutions to use Mass Bloc retaining walls between the rail line and Formby Road, saving both time and money for the client.

Traffic movements through the site were smooth and flowing with very little delay, if any, incurred by the travelling public.

Carpark & Access Road

Launceston Airport

Task

Shaw Contracting was engaged by Launceston Airport (APAL) to undertake a major landside upgrade of its carparks, access roads and associated infrastructure including but not limited to:

Design and construct undercover parking, walkways and traffic gantries
Major stormwater upgrades, fire mains, sewer and fibre optic works
Addition of over 400 car spaces including staff carpark
Project delivery with no delays to any flights, passengers or users of the facility with a seamless transition to the new link roads
Major lighting upgrades to modern LED luminaries
Major changes to bus, taxi, and passenger pickup/ drop off operations
Enhanced entry/egress safety on to the main road

Challenges

Being such a multi-faceted job, a comprehensive skill set was required to effectively deliver the works.  With total project expenditure 140% greater than at tender, Shaw was required to encompass a wide variety of additional works requested by APAL, whilst still meeting the original design intent and program. Shaw was able to accommodate all requests and deliver a high quality outcome. Some key challenges under this project included:

Coordinating nominated APAL subcontractors for gating hardware, advertising installations and security systems.  Some of these sources were interstate.
Completing airside works and completing lifting plans to the strict requirements of CASA with limitations around aircraft and safety buffers
Undertaking works in a heritage listed flora avenue, and working in areas with endangered fauna (green and gold frog).
Preservation of the airports communications systems which were within the footprint and required live relocation of some cables.

Outcome

This was the first major project competitively won and delivered under the new ownership of Shaw Contracting Australia. Due to its complex nature and spanning a period of over 12 months, in excess of 70% of Shaw employees spent time on this site making it a real ‘team effort’.  The project successfully achieved all of APAL requirements and delivered a significant key piece of state infrastructure. Shaw was also able to deliver this project incident and injury free.