NEWS FROM ROCLA PIPELINE PRODUCTS · Big box culvert tunnels for cane trains DECEMBER 2003 NEWS...
Transcript of NEWS FROM ROCLA PIPELINE PRODUCTS · Big box culvert tunnels for cane trains DECEMBER 2003 NEWS...
Big box culvert tunnelsfor cane trains
D E C E M B E R 2 0 0 3
N E W S F R O M R O C L A P I P E L I N E P R O D U C T S
Preventing slippage at Hume Dam
Rainwater recyclinggoes underground
Rocla Piper
ISSN 1032-7282
Rocla Pipeline
Products is a
leading supplier
of precast
concrete
solutions for the
civil construction
industry
SRC PIPES
CULVERTS
HEADWALLS
ACCESS
SYSTEMS
PRECAST
BRIDGES
RETAINING
WALLS
CONCRETE
BOARDWALKS
RURAL
PRODUCTS
WATER
QUALITY
SOLUTIONS
Published byRocla Pipeline Products
6 Thomas Street,Chatswood, NSW 2067
A business unit of Rocla Pty LimitedABN 31000 032191
Member of the Amatek Group
As 2003 draws to a close Rocla
can look back on a year of
continued growth, supported by
the release of new products and
a continuing strong performance
by the housing sector.
In the August issue I introduced
our newest precast structural system,
the PermaTrak® boardwalk, which
provides eco-friendly modular concrete
walkways that are durable yet quick
to install.
The first major installation, at the
Epsom Park development in Melbourne,
is featured in this issue. Two new
Rocla® products launched last year -
the ecoRain® rainwater utilisation system
and the MassBloc® earth retention
system - have generated an enthusiastic
response from engineers, builders,
architects, councils and other authorities.
In this issue you can read about the
first major installation of the ecoRain®
system, by Eurobodalla Shire Council
on the NSW South Coast, who installed
23 ecoRain® tanks on a new residential
sub-division.
Our MassBloc® earth retention
system has met the need for a simple
solution for creating massive permeable
retaining walls.
A typical installation, at the Hume
Dam in southern NSW, is featured
in this issue, as well as a story on
the use of the MassBloc® system for
emergency repairs by Orange City
Council. This year also saw the
completion of the largest M-Lock®
Bridge project to date, a 108 metre long
crossing in the Wentworth Shire of
western NSW, which will be featured
in the next issue.
A year of innovation and growth
Stephen T. BakerGeneral Manager,Rocla Pipeline Products
In this issue we highlight the
flexibility and speed of erection of other
M-Lock® Bridge solutions developed
by Rocla and our customers.
We also feature an article on our
versatile Pipeline Precast Products
(PLPC) range, which includes storm-
water pits, sewer access systems,
kerb inlets and other precast solutions
designed for ease and speed of
installation.
Two pipe stories are included
that reflect an increasing demand for
installations that minimise impact on
urban areas, with one solution featuring
large diameter Rocla® Jacking Pipe.
We hope you have enjoyed reading
The Piper this year.
On behalf of Rocla, I would like
to offer the compliments of the season
to all our customers, business partners
and friends.
I wish you all a safe holiday and a
happy and prosperous new year.
Three
Precast crowns provide off-the-shelfsolution for cane tunnels
ProjectRoad upgrade
LocationInnisfail, Qld
AuthorityQueensland Departmentof Main Roads
Box Culvert Crowns, Pipes & HeadwallsRocla Pipeline Products
These giant Rocla® Box Culvert
Crowns were supplied to the
Queensland Department of Main
Roads for an upgrade of
Henderson Drive, a key freight
route between the Atherton
Tablelands and the coastal area
of Far North Queensland near
Innisfail.
This is one of the highest rainfall
regions in the country (more than 4
metres a year) where Tully, Innisfail
and Babinda battle it out for the title
of Wettest Town in Australia.
Although drainage was a major
factor in the upgrade of Henderson
Drive, the culverts shown here were
designed to carry more than rainwater.
Thirty-one 4500 x 4100 culverts
were used to create a rail tunnel under
the built-up road for sugarcane trains,
while eleven 4500 x 4500 culverts were
used to build a road underpass for
cane bin haulers. The upgrade will help
accommodate the increasing number
of heavy vehicles using Henderson
Drive as a freight route between the
Tablelands and Mourilyan port, as well
as reducing conflict between through
traffic and local traffic, particularly
that servicing the local sugar industry.
It is designed to improve safety
and reduce traffic noise for local
residents and improve safety, travel
speed, road width, alignment and
surface condition for all road users.
It will also eliminate several sugar
railway crossings and reduce road user,
general freight and road maintenance
costs. The cane railway line is being
relocated as part of the project.
Rocla also supplied Concrete
Pipes and Precast Headwalls for the
numerous drainage culverts required
to cope with the famous downpours.
In all, some 775 tonnes of Rocla®
Steel Reinforced Concrete products
were used to create box and pipe
culverts under the 3.8km stretch of
upgraded road.
A stormwater outfall featuring the
largest diameter jacking pipe
ever installed in South Australia
won a 2003 Case Earth Award for
Construction Excellence in the
under $2 million category.
The stormwater pipe runs beneath
12 operational railway lines, as well as
underground conduits and services.
The 154-metre tunnel, at a depth
of more than 3 metres, was constructed
by SEM Civil to divert stormwater runoff
from the Mawson Lakes residential
development to existing wetlands.
Mawson Lakes, 12km north of
Adelaide, features an artificial wetlands
area (also constructed by SEM Civil)
Four
to collect runoff from the development. These wetlands, on the eastern
side of the rail corridor, had to be connected to the existing Greenfields
wetlands to the west of the rail l ines. The 1950mm diameter Rocla®
Jacking Pipe is the largest installed in SA and the tunnel is the longest
length for this diameter installed anywhere by Brisbane-based contractor
Tunnel Boring Projects.
Recurrent nuisance flooding and
ponding obliged an Adelaide
council to undertake the
unenviable task of installing new
stormwater drains in the centre of
one of the busiest roads out of
the city.
Payneham Road is a main arterial
route east of Adelaide in an area
undergoing continuous redevelopment
through urban infill and the sub-division
of large residential blocks.
Increasing runoff from side streets
had caused minor flooding in recent
years.
To take the surface flows off the
street and get them underground, the
City of Norwood Payneham & St Peters
needed to install new drainage pipes
along an 800-metre stretch right
down the centre of the busy road, to
avoid conflict with existing underground
services.
This included a new section of
pipeline and the duplication of an
existing line.
A combination of night works and
excellent traffic and project manage-
ment by contractors SEM Civil and
Beltrame Civil minimised disruption
to traffic during installation of the
900mm diameter Rocla® Reinforced
Concrete Pipes and Box Culverts.
1950mm pipe jacked under 12 rail lines
Now the rain in Payneham goesmainly down drain
Five
Simple riverbankrefurbishmentbecomes massiveretaining wall
ProjectEarth retention system
LocationAlbury, NSW
AuthorityNSW State Water
Design ConsultantsNSW Public Works
Construction ManagerSMEC Victoria
Construction ContractorInform Constructions
Engineering DesignCardno MBK
Retaining Wall SystemRocla Pipeline Products
NSW State Water wanted to tidy
up an unattractive embankment
beside the Hume Dam at Albury
that had been used as a dumping
ground for aggregate when the
dam was built in the 1920s. What
started as a simple refurbishment
turned into a massive earth
retention system.
Unexpected additional work
included heavily reinforced concrete
piers and deep-seated stressed
anchors. This work was required to
prevent the risk of damage to a vital
power station cable duct that traverses
the site.
The Rocla MassBloc® earth
retention system was chosen from a
variety of retaining wall options and
slope stabilising measures considered
by the design and construction team.
The MassBloc® system comprises
large, permeable concrete blocks
weighing around 1.8 tonnes that are
interlocked by a precast nib.
The segmental system allows
permanent retaining walls to be
deployed rapidly to counter erosion,
land slippage or wave energy.
Construction is mortarless and
an experienced crew can place up to
70 blocks a day.
Construction Manager Eric
Bradshaw, of SMEC Victoria, said the
potential for ongoing instability justified
the use of a massive retaining wall.
“MassBloc provided a safe, low
maintenance solution, but also offered
collateral benefits,” Eric said.
“The wall is visually appealing,
plus there’s now a turfed area at the
top that can be used as a public
viewing platform.”
The two walls, lower and upper,
each 5 metres high, comprising a
total of 350 MassBloc® units, were
installed by Inform Constructions using
a 25-tonne crane and three workers.
Regional land developer Bourke
Securities is currently installing
infrastructure on its latest
residential development in the
mid-western NSW city of Dubbo.
The development, Holmwood
Estate, covers some 35ha to the
south-east of the town, with 215
lots ranging from 850 to 4000
square metres.
Bourke Securit ies proprietor
George Rice, a former pastoralist
and native of Bourke, personally
builds the roads and installs the
sewer and stormwater systems on
his developments with the help of his
son and a third partner.
“I hired contractors to build
roads and drainage on my first
development,” George said, “but I
couldn’t see the point in hiring
people to do work I could do myself.”
The drainage system at Holmwood
Estate includes Rocla® SRC Pipes
and a range of Rocla Pipeline
Precast Products, including Rocla
CPO® Pits, Rocla One-Piece
Lintels and the Rocla® Sewer
Access System.
Six
Orange City Council, in the NSW Central
West, discovered that keeping a
stockpile of Rocla MassBloc®
components in the yard could be useful
for emergency repairs.
The MassBloc® earth retention system
was being used to build retaining walls on
the sides of a drainage channel, when heavy
rains stopped work.
The rains threatened to undermine a
power pole on the edge of the town.
Had the power pole toppled, it may have blacked out a quarter of Orange.
Council workers used MassBloc® components to stabilise the earth around the pole,
creating a quick, permanent solution.
A similar situation occurred the following week, when the rain threatened to
scour out a sewer access chamber, which could have severely affected the town’s
sewerage system. Again, the Rocla MassBloc® system came to the rescue.
DIY developer does ithis way in Dubbo
MassBloc® tothe rescue
George said the precast components were easy to install and
saved dramatically on construction times.
A loyal customer of Rocla’s Dubbo branch, George said it was
very convenient having a Rocla facility in his own back yard.
Seven
Rocla’s innovative PermaTrak® precast boardwalk system was used
to create safe pedestrian access across an environmentally sensitive
parkland at a residential development in Melbourne.
Epsom Park, once a famous horse racetrack, is now a growing suburb with
425 lots and a projected population of 1500. The fifth stage of development
was recently released.
The State Government developer, VicUrban, undertook a radical redesign
to preserve grasslands of State significance, turning them into a feature of the
development and conserving biodiversity.
The paddock of the former racetrack has been fenced off to create an
island of rare plant species.
With housing now being built on both sides of the paddock, walkways were
required to prevent residents trampling the grasses. Two Rocla PermaTrak®
boardwalks were installed, totalling some 285 metres.
The tracks feature curved paths as well as gentle changes in vertical
alignment to follow the topography of the site.
Landscape architects Tract Consultants specified the Rocla PermaTrak®
system for its durability, low maintenance and design flexibility.
Also, because no footings or heavy equipment were required, impact on
the site during construction was minimised.
The system features all precast concrete planks, bearers and stumps.
Installers Peco Constructions placed the two rows of stumps and risers
individually, then installed the bearers and planks using a small rubber-tread
excavator and lifting harness, working backwards between the rows of stumps.
Peco Constructions said the system was easy to use and could be installed
at the rate of 50 metres per day. The steel-reinforced concrete planks have a
live load limit of 1.5 tonnes, allowing the boardwalks to support a small utility or
maintenance vehicle if required.
Concrete tracks protect sensitiveurban grasslands
ProjectPedestrian walkways
LocationEpsom Park, Melbourne
DeveloperVicUrban
Landscape ArchitectsTract Consultants
ConstructionPeco Constructions
Precast BoardwalksRocla Pipeline Products
bridge to sustain very heavy loads. Thanks to the speed of erection of
the M-Lock® system and its ability to safely carry heavy trucks and
equipment, work on the dam was able to proceed on schedule.
Kerry Rae, of Biggenden Shire Council, said Rocla had recommended
that one day be allowed to install the planks on each span. “However,
it was so easy to construct that our crew installed all the deck planks
in two days and could have done it in one if necessary,” Kerry said.
Rocla supplied all the components for the bridge, including M-Lock®
precast planks and headstocks and Duraspun® concrete bridge piles.
Precast bridge makes light work ofheavy loads
Eight
Rocla M-Lock® precast deck
planks provided a quick and easy
replacement for a burnt-out
timber crossing over Jackie’s
Creek, west of Grafton, NSW.
The single-span timber bridge was
used by local farmers and loggers,
as well as being a strategic asset
for the Rural Fire Service. During the
January 2003 bushfires, firefighters
were forced to waste water wetting
down the bridge before crossing.
On their return, they made further
attempts to protect the bridge, but it
was consumed by the fires. Rocla
supplied three 12-metre M-Lock® deck
planks (two with castellated kerbs)
which were installed by Pristine Waters
Council day labour on council-built
steel piles and abutments. The new
bridge, installed in June 2003, is the
sixth built by the council, with two more
bridges on order.
New bridge providessolid, fireproof access
Biggenden Shire Council in
Queensland found the Rocla M-
Lock® precast bridge system so
easy to construct, it placed all the
concrete deck planks of its three-
span bridge in two days, using a
local crew with no experience in
bridge building.
The new 30-metre, 3-span bridge
across Chowey Creek, 20km northwest
of Biggenden, replaced a timber
bridge that failed to meet a new load
limit. The M-Lock® bridge was
scheduled for construction in 2004
but was brought forward because of
development taking place at nearby
Paradise Dam, which required the
Nine
building setback, to within an existing
high-pressure water main easement.
A key measure of the success of
the initiative is the market acceptance
of the subdivision.
The lots sold within a month of
release on the market in December
2002, one of the slowest sales periods.
The majority of the lots have been
purchased by Masterton Homes, who
strongly supported the connection of
their homes to the Rocla ecoRain®
system and provided advice on siting.
The project was undertaken
entirely by Eurobodalla Shire Council,
with construction carried out by
council’s own construction division,
Euroworks.
ProjectDomestic rainwater utilisation
LocationDalmeny, NSW
DeveloperEurobodalla Shire Council
ConstructionEuroworks
Rainwater UtilisationSystemsRocla Water Quality
Rainwater recyclinggoes underground
A housing estate at Narooma on
the NSW South Coast has set a
new standard for conserving and
utilising rainwater. Rocla®
rainwater utilisation systems with
in-ground tanks were installed on
all lots during construction to
minimise mains water use.
The Dalmeny subdivision is on
land owned by Eurobodalla Shire
Council and was planned during the
harshest drought for 100 years.
Council project manager, Andrew
Parkinson, said the council expected
that potable water consumption would
be halved for a typical dwell ing at
Dalmeny. After a public tender process,
Eurobodalla specified Rocla ecoRain®
units with a 10,000 litre capacity to
ensure maximum stormwater utilisation.
The Rocla ecoRain® system is an
underground concrete tank complete
with filter, pump and automatic controls.
Stormwater is harvested from
the roof, f i l tered and stored in the
underground tank, then pumped back
to the house via an electronically
controlled system.
If the water level in the storage
tank drops below 10 per cent, a small
amount of potable water is used to
ensure continuity of supply.
Back-flow controls and air gaps
prevent contamination of the potable
water supply.
The bulk of the system is installed
as a single unit before the house is
constructed, with the plumbing and
electrical connections made later.
Siting the units on the vacant
blocks required careful design. The
location of all underground services
(water, sewer, stormwater, electricity
and telephone) was carefully
coordinated to maximise the building
envelope of each lot.
The location of the Rocla ecoRain®
units varies from within the front
Ten
Rocla and consulting engineers
Civil Power devised a very
effective and economical oil spill
control system for Victorian
energy supplier TXU. The new
solution combines a Rocla
ecoStop® spill control device with
a Rocla® Triple Interceptor Pit for
oil removal.
The Rocla ecoStop® spill prevention
system provides secure protection
against stormwater contamination in the event of an oil spill. When oil
builds up in the runoff, a float-actuated shutoff valve stops flow from
entering the stormwater drain. There are no electrical or manually operated
components. The Rocla® Triple Interceptor Pit is a 1050mm diameter
stormwater pit with three internal chambers that removes oil from the
flow and stores it for later removal. The combined system has been
installed at TXU sub-stations in Ferntree Gully, Narre Warren and Lilydale.
The transformers at the sub-
stations can have as much as 2000
litres of coolant inside.
Thanks to the Rocla® control
system, any catastrophic spill would
be contained in a bunded area capable
of holding many thousands of litres.
Brisbane contractor ReadiPlumb
Services needed an in-line oil and
sediment separator for an
industrial carpark at Acacia Ridge
but the crowded drainage system
left no room for an upstream pit
and weir.
Rocla devised a solution featuring
a Downstream Defender* oil and
sediment separator with a customised
high-flow bypass pipe.
A larger than standard inlet pipe
of 300mm was connected to the
Downstream Defender, with a 300mm
bypass pipe to divert surcharges.
This reduced installation time and
converted the normal two-pit installation back to a single pit - the
Downstream Defender.
The Downstream Defender is an engineered product that uses
hydrodynamic separation to capture settleable solids, floatables, oils
and grease. This vortex technology keeps the physical size of
Downstream Defender to a minimum while maximising the potential for
stormwater treatment. These characteristics provided the packaged
solution ReadiPlumb was seeking for the limited installation area available.
Cost-effective oil spill control forsub-stations
Compactsolution forstormwatercleansing
Rocla ecoStop® spill prevention system and TripleInterceptor Pit before installation at TXU sub-station.
Nigel Read of Readi Plumb Services (left) and Rocla’s Jason Horswill with the single-pit Downsteam Defender.
*Downstream Defender is manufactured under licence from Hydro International PLC.
Geraldton, on the Mid-West Coast,
is undergoing a major
redevelopment of its coastal
frontage and infrastructure,
including deepening of the harbour,
reclamation of foreshore land
and construction of new rail and
road links to the port area.
Although the city centre is adjacent
to the beach, the central business
district is cut off from the seashore
by a rail corridor.
The relocation of the beachside
rail line on a new route to the Port will
allow the city’s CBD foreshore and
adjacent recreational areas to be
opened up and enhanced, encouraging
tourism and business growth.
As part of the redevelopment, two
existing sea groynes were extended,
with plans to reclaim up to 50 metres
of land along the foreshore area
between the groynes. The City of
Geraldton took advantage of the
Eleven
New outfall pipes point to seachange at Geraldton
opportunity to install two large diameter concrete stormwater outfalls
in the groynes to drain stormwater runoff from the CBD and hinterland
areas into the ocean.
Rocla supplied Class 4 Steel Reinforced Concrete Pipe for the
two 50 to 60 metre stormwater pipelines, respectively 1500mm and
1800mm in diameter. The two new pipelines replace a series of existing
smaller outlets along the town beaches.
A “mirrored” installation of two Rocla CleansAll® gross pollutant traps
solved the tricky problem of attaching an in-line GPT to a twin cell pipeline
at the Sea Crest residential development at Aldinga Beach near Adelaide.
According to Boon Chua, of consulting engineers Connell Wagner, Onkaparinga
Council wanted a proprietary device to lower maintenance costs. “The problem was
to find one that would fit the twin pipe configuration,” Boon said. “The CleansAll
was the only product we could find that was flexible enough in its design; we
were very happy with the way the system fitted neatly to the twin pipes - I believe
this is the first twin GPT in South Australia.”
The reason for the twin pipeline was the need to pass under a low profile road
crossing. The two CleansAll® 900 systems, which were installed by Lorenzin
Constructions, are improving the quality of stormwater runoff that flows first into
on-site wetlands and ultimately into a chain pond wetland system one kilometre away.
Double-barrel GPT useful in a tightcorner
The contents of this publication are copyright and may not be reproduced in any form
without the prior written consent of Rocla Pty Limited. Product applications described in
this publication are to be taken as illustrations only, and are provided without liability on the
part of the company or its employees and agents. ®™ Trademarks of Rocla Pty Limited.
ABN 31 000 032 191. Trading as Rocla Pipeline Products. A member of the Amatek Group.
MassBloc trade mark used under exclusive licence from MassTec Industries Limited
and Fletcher Concrete and Infrastructure Limited. ©Rocla Pty Limited, December 2003.
For further information on products from
Rocla Pipeline Products and Rocla Water Quality
Call Rocla on 131 004
E-mail your inquiry to [email protected]
Visit our website www.pipe.rocla.com.au
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