Road Construction

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.

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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.

Bridport Main Road Upgrade

Bridport

Task

• Total reconstruction of the Southern Section of Bridport Main Road, including strengthening and sealing of the road for 8km and upgrading an additional 5 Northern locations spanning over 10km, this required the placement of over 200,000m² of new Pavement
• Cut to fill of over 45,000m³
• Relocation of overhead and underground services to facilitate the works
• Upgrading of 14 Junctions including the provision for passing bays for through vehicles
• Upgrade existing bus stops
• Replacement of Hurst Creek Bridge

Challenges                                                  

• Replacing Hurst Creek Bridge while under traffic and maintaining creek flows.
• Undertaking all works in multiple zones without affecting traffic flows.

Outcome

• Shaw completed the works on time, on budget, without incident.
• Shaw also undertook client requested major variation works without affecting the project completion date; this required the acceleration of all works.

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.