INFRASTRUCTURE PRODUCTS FUTURE GENERATIONS CAN RELY ON SECOND QUARTER 2012

Same magic view, more durable walkway

+ Transcity Legacy leads to more work+ Maintaining a strong track (record)

www.rocla.com.auCall 131 004

After installation of the Rocla® box culverts.

1

Transcity Legacy Leads to More Work

Legacy Way by the numbers:w Legacy Way will be built using two

tunnel boring machines, each more than 90 metres long, with a 12.4 metre circular rotating cutter head.

w More than two million tonnes of soil and rock will be removed during tunnel construction.

w The deepest point of the tunnel is 40m below the surface.

w More than 185,000m2 of asphalt will be laid across the whole project (inside the tunnels and on surface roads).

w The tunnel ventilation system includes more than 100 jet fans.

Brisbane City’s major toll road project – Legacy Way (formerly Northern Link) – is a 4.6 kilometre underground link between the Western Freeway at Toowong and the Inner City Bypass. A strong track record with head contractor, Transcity, as well as quick turn-around times on product orders and the ability to offer flexible, tailored delivery options were key factors in the decision to appoint Rocla as a supplier of reinforced concrete products for the project.

To date, Rocla has supplied a range of reinforced concrete products to the project, including precast reinforced

concrete pipes, box culverts, base slabs, link slabs and stormwater pits.

In some cases these were produced to project specific design requirements, in accordance with the relevant Australian Standards for precast products.

Legacy Way is the third in a series of major road tunnel projects in Brisbane, all of which Rocla has played a role in supplying. Once complete, the link will include two parallel tunnels – each 4.6 kilometres long and more than 12 metres wide – that, by 2016, will deliver travel-time savings of up to 66% during rush hour.

Rocla’s client, Transcity, is a joint venture team comprising of BMD Constructions, Italian tunnelling experts Ghella and Spanish company Acciona, who are global leaders in infrastructure, renewable energy and water resource management.

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End-to-End Wall Solution at Daunia Mine

Atlantic Civil Products has played a central role in the delivery of a 2,500 square metre, concrete-faced, mechanically stabilised earth wall and two 700 square metre abutments at Daunia Mine in the Bowen Basin. Manufacture of the panels was undertaken at Rocla’s Mackay factory. As well as supplying the walling products, Atlantic Civil Products’ specialist engineering team provided critical design advice and conducted initial site training to ensure a successful installation.

Erection of the wall and abutments was undertaken by Golding Contractors, beginning in early 2012, and completed in May.

In addition to supplying the expertise and products for the wall, Atlantic Civil Products has also supplied the Mine’s stockpile tunnel, which has yet to be installed.

Daunia Mine, which is operated by BMA (BHP Billiton Mitsubishi Alliance), is an open cut coal mine that, once fully operational, will produce up to 4.5 million tonnes a year.

To find out more about Atlantic Civil Products’ Wall Systems, visit www.atlanticcivil.com.au

www.rocla.com.auCall 131 0043

Infrastructure in the Pipeline

With construction of Sydney Ports’ new Intermodal Logistics Centre (ILC) at Enfield well underway, late 2011 saw Rocla begin the process of supplying lead contractor, Leighton Contractors, with a range of reinforced concrete products associated with the project’s stormwater drainage infrastructure.Apart from standard class 2, 3 and 4 pipe, project specific design required supply of class 6 pipe for drainage lines located under high load areas.

The ILC at Enfield will be part of a network of existing and planned intermodal terminal facilities in Sydney. It will service around a quarter of the total intermodal demand, moving more goods by rail. In doing so, it will mitigate the growth in freight truck numbers on our roads.

On completion the ILC will include an intermodal terminal, empty container storage facilities, warehousing, a light industrial and commercial area, a new bridge over the existing RailCorp Marshalling Yard, rail connections and an area incorporating ecological and heritage enhancements.

With the project scheduled for completion in 2013, Rocla expects to continue supplying product until late 2012.

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Hydro-Brake® is Best SolutionThe only product of its kind on the market, Rocla’s Hydro-Brake® was chosen by MWH as a flood attenuation mechanism on the Jindalee Park’n’Ride project for Department of Main Roads in Queensland.The Hydro-Brake® is an innovative Rocla product that gives improved hydraulic performance over conventional water flow regulators by harnessing the energy inherent in the flow field. It has no moving parts, no external energy requirements and includes patented maintenance-reducing features.

The unique operating characteristics of the Rocla Hydro-Brake® provide for high efficiencies at lower flows, with less volume stored after a storm event, meaning more storage is available to manage the peak flows, minimising the risk of downstream flooding.

Ultimately, capacity wasn’t the only standout factor in this solution. The workmanship within the product, and its quick delivery, impressed both client and contractor. Brian Kesby, Project Manager from Queensland Bridge and Civil commented:

“The product was delivered in two parts; first the precast component, complete with precast base, hydobrake fitted, benching of extremely high quality and pipe stubs at the inlet and outlet. Secondly, the precast roof slab with covers and surrounds. This made the installation process one of simply placing the components on to a prepared base and connecting the upstream and downstream pipes.”

The Hydro-Brake® trademark is used under licence from Hydro International PLC.

Same Magic View, More Durable Walkway

Rocla has provided a modular concrete replacement for the existing wooden boardwalk at Iluka Bay in Clarence Valley, New South Wales.The upgrade of the 50 metre-long boardwalk is part of the Clarence Valley Council’s plan to stabilise the foreshore and manage erosion at Iluka Bay. The area is a popular walking track for locals and tourists alike.

Rocla PermaTrak® precast concrete components were used to construct the new boardwalk – these products are particularly well-suited to high traffic areas as they will not rot, twist, warp or burn and are designed to provide a long-life, maintenance-free.

To find out more about Rocla PermaTrak®, visit www.rocla.com.au

www.rocla.com.auCall 131 0045

Integration of Australian Construction Products

More Constructive GrowthEver eager to offer greater value to its clients, Rocla has added another highly regarded infrastructure products manufacturer to its ranks.Australian Construction Products (ACP) was integrated with Rocla in March, after a strategic review of the ACP business indicated that its growth potential could be maximised by giving it access to Rocla’s systems and support structures in Australia.

Specialists in road barriers and end treatments, ACP has been part of the Fletcher Building stable since late 2010, when it was acquired from Southern Steel Group. ACP shares a common product range and market segment with its New Zealand-based counterpart CSP Pacific.

The business also includes Rei-Lux AUS, offering a unique service of Non-destructive Testing of pole and column structures, which currently operates in QLD and NSW and is looking to expand nationally. Realising the benefits of their service in asset management, QTMR has in place a contract with Rei-Lux AUS for programmed testing of major road street lighting.

Jamie Flintoff, Rei-Lux AUS, Business Development Manager points out, “The benefits of proactive testing of these structures, provides asset owners with managed risk and reduced maintenance costs.”

Stephen Baker, General Manager – Rocla Pipeline Products, says the integration of the Australian ACP business with Rocla will offer both organisations new growth opportunities, while providing customers with a complementary range of products. He looks forward to working with Zalman Paris, General Manager of ACP, and his team to explore these opportunities.

“ACP works in the same infrastructure markets that we do and has many of the same customers. Naturally this means there will be synergies in the

solutions we offer and, by joining forces, each business will be able to increase the value it is able to add for its customers,”

says Stephen T. Baker, General Manager – Rocla Pipeline Products

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ACP Products:W-Beam Guardrails w Semi-rigid ‘W-shape’ section galvanised steel highway barriers –

the most popular roadside crash barrier in use in Australia.

Thrie-Beam Guardrails w A roll formed product that has an added corrugation to allow easy transition from roads to bridges and in high volume, high speed areas.

Terminal Ends – a variety of energy absorbing and non-proprietary systems, including: w X-Tension 350 Terminal Ends w FleatTM 350 Flared Terminal Ends w MELT Approach Terminals

Wire Rope Barriers w Sentryline II wire rope safety barriers for use in either ‘edge of

road’ or median strip applications to effectively stop, contain or redirect vehicles.

Temporary Barriers w Includes the ArmorZone™ TL–2 Plastic Barrier – the world’s first

100% polyethylene water filled barrier (no steel reinforcement) to have been judged to have satisfied the evaluation criteria of NCHRP 350 Test Level 2 (TL- 2).

Crash Cushions w The TAU-II™ full-redirective crash cushion for use in difficult and

demanding locations, such as toll booths, utility poles and at the end of rigid barriers.

w The fully recyclable, highly compact Raptor™ – a world first design that reduces severity of vehicle impacts with utility poles and trees.

Carpark/Industrial w Pre-fabricated and custom fabricated solutions for posts, bollards

and protection fences.

Bridge Transitions w Products offered include typical W-Beam to Thrie-Beam to Type F

transitions, as well as W-Beam to Concrete Barrier transitions.

Motorcycle Barriers w ACP holds the exclusive distribution rights to the SPM-IS4

Motorcyclist Protection System – a continuous protection device installed on a steel road safety barrier that prevents direct impact of motorcyclists against post barriers and breaching space between posts.

For more information about Australian Construction Products, visit www.acprod.com.au

ACP at a Glance:w One of Australasia’s leading manufacturers and distributors

of steel and civil roading barriers.w Manufacturing based in Sydney with nationwide sales and

distribution.w Offices in New South Wales, Queensland, Victoria and

Western Australia.w Manufactures W-Beam and Thrie-Beam guardrail

to Australian Standard AS/NZS 3845:1999, and to the requirements of all State Road Authorities throughout Australia.

w Exclusive supplier of the X-350 – the world’s first fully re-directive guardrail terminal end.

www.rocla.com.auCall 131 0047

Maintaining a Strong Track (Record)

NATA Accreditation for Rocla Sites

Rocla is taking its commitment to Quality Assurance a step further, with the testing and compliance facilities at a number of its sites undertaking an accreditation process with Australia’s National Association of Testing Authorities (NATA).

“The process of becoming NATA accredited is recognition of the standard of Rocla’s existing Quality Management System and the strict processes we have in place for concrete testing,” says Rocla’s Technical Services Manager, Graham Underwood.

“Our systems have been third party certified by SAI Global as compliant with the requirements of ISO 9001 for 20 years – this means our clients can have confidence that our products meet specification.”

Rocla’s Quality Management System for materials testing has been developed in accordance with ISO/IEC 17025, and covers 29 tests, including:

w Sampling of fresh concrete w Slump tests w Making and curing compression test specimens

w Compressive strength testsRocla’s Gailes site achieved accreditation in April, and its Mackay, Cairns, Wodonga and Emu Plains branches are in the final stages of the process. Rocla’s Materials Laboratory at Guildford has held NATA Accreditation since 1974.

A recent seven cell, 2400 diameter x 24mt long installation. Other installations involved large box culverts including sizes 2700x1800, 3000x2400, 3600x2100 and 4200x1500.

A collaborative partnership between Rocla and Transfield Services has ensured the highly successful delivery of a series of demanding rail bridge replacements for Australian Rail Track Corporation (ARTC).

Rocla has worked closely with Transfield Services for the last five years, supplying a range of products for around twenty installations as part of an ongoing bridge replacement project.

Typically, products supplied have included large diameter concrete pipe, MassBloc® retaining wall systems and large span box culverts that are made to 300LA live rail load specifications.

With the affected railway lines spanning three states – between Kalgoorlie Western Australia, Adelaide South Australia and Parkes New South Wales – and accommodating more than twenty train movements daily, timely completion of scheduled upgrade work is critical.

Works are confirmed well in advance, so having the required products on site, on time is a key risk factor for Transfield Services. For Rocla this means ensuring delivery of product is on schedule, even when the upgrade site is 1000 kilometres ‘off the beaten track’.

“The strictly scheduled nature of this work means that there is no option to defer delivery – Transfield relies on us to get the product to them on time, every time. Add to that temperatures reaching 49 deg. C in the shade, and it can be a challenging job!” says Rob De Nys, Sales Representative for Rocla.

Stuart Glynn, Projects Program Manager for Transfield Services says Transfield relies on an effective team approach to successfully deliver upgrades in an efficient manner, especially when projects are in difficult environments.

“A strong relationship and effective communication is a critical factor for success. The teams’ relationship ensures results under strict conditions for quality, on time delivery and value for money.” says Stuart.

Product at a Glance:w Capable of removing in excess of 98%

of gross pollutants (>2mm) and oils, and 70% of sediment (75µm – 2.36mm) at design flows.

w Developed in conjunction with the University of South Australia and accredited to ISO 9001:2000.

w Components are made of high strength, steel-reinforced concrete to guarantee lifetime performance.

w Baskets manufactured from stainless steel, with no moving parts to reduce maintenance.

w Baskets are removable and can either be lifted out to clean, or cleaned in place.

w Range of sizes available to cater for various pipe diameters and flow rates.

w Customisable to treat flow through box culverts, open channels and high flow situations.

www.rocla.com.auCall 131 004 8

Gross Success in Malaysia

With its long service life and low maintenance requirement, Rocla’s high strength, steel-reinforced concrete CleansAll® Gross Pollutant Trap (GPT) continues to be popular with clients of Malaysian water and environmental engineering specialists, WET, a decade after they were granted the exclusive rights to manufacture the product in Malaysia.

Over the last 10 years WET has installed close to 300 CleansAll® GPTs – many in the Putrajaya Precinct, a relatively newly developed territory that lies 25 kilometres south of Kuala Lumpur. The units supplied at Putrajaya have been used for a range of applications within residential and commercial areas including the protection of monsoon drains, retention ponds and lakes.

The product is also being considered for the ‘River of Life’ project which forms part of the Malaysia Economic Transformation

Programme introduced in 2010. This project aims to revitalise the Klang River as a heritage and commercial centre. WET is involved in the effort to stop gross pollutants entering the waterway, thereby allowing the river to be a feature for future development.

WET is also exploring the possibility of applying the CleansAll® GPT in a water treatment capacity to lower overhead and maintenance costs by replacing band screens at raw water intakes.

Putrajaya District, where the product has proved popular over the last 10 years.

During installation at Putrajaya.

How it works1. Inlet: Stormwater enters the inlet chamber

and is diverted by a bypass weir into a treatment chamber.

2. Treatment: Oils and floating pollutants are trapped in the treatment chamber. All remaining gross pollutants are retained in the baskets.

3. Sediment sump: Cleansed stormwater passes into the bottom compartment of the diversion chamber, where sediments settle because of the reduced flow velocity and vertical momentum of the water column.

4. Outlet: The cleansed stormwater then leaves the device by passing up and through the bypass channel aperture and into the stormwater system.

5. Overflow: During large storm events, flow is allowed to overtop the weir in the inlet channel without disturbing previously captured materials.

Product awaiting shipment at the Malaysian casting yard.

www.rocla.com.auCall 131 0049

Rocla’s Poles team is seeing specification of its new Rocla® strong poles product continue to rise, following the highly successful installation of 49 of the poles by contractor John Holland Group on Powerlink sites at Bluff, Wycarbah and Duaringa.Suitable for transmission lines from 110 to 330 kV, Rocla® strong poles are a unique solution for this critical infrastructure, being longer and stronger than traditional poles. They are supplied in a range of strengths between 80kN and 220kN and, though the most common lengths supplied are 40 metres or less, the Rocla design team has the capability to design to project specific lengths. On this project the client specified poles of an impressive 54 metres total height with a projection of 46.75 metres above ground level.

The product’s modular nature – along with its engineered tip sizes to suit crossarms and other steelwork components, and various foundation options – ensures construction economics result from ease and speed of installation.

“This project – despite being the first time Rocla® strong pole were used in such a major way – typifies the product range capability. The durability, project specific designs and ease-of-installation this product offers has translated to rising demand from specifiers for transmission and sub-transmission applications,” says Samuel George, Rocla’s Sales Territory Manager for Queensland.

To find out more about Rocla® poles products, visit www.rocla.com.au

Poles Popularity Reaches New Heights

Righting a Rocky Road

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When a major slip closed the Snowy Mountains Highway at Brown Mountain in early March, New South Wales’ Roads & Maritime Services team turned to Rocla to provide MassBloc® products to shore up the highway and make it safe to re-open.The slip had taken out most of the width of the road over a 30 metre length, and carried debris several hundred metres down the mountain side. Reconstructing the road was a difficult task, without considering the added pressure of needing to re-open it as quickly as possible.

Following a geotechnical inspection the day after the slip, design options for the repair were developed over the weekend. Further review and refinement of the design allowed the repair to be optimised to allow earliest possible opening, with Rocla MassBloc® chosen as the preferred earth stabilisation product to prevent future collapse and provide the necessary speed of construction.

A week later, when the slope had dried out enough to allow construction work, repairs began.

The completed work included lower layers of mass rock, over which layers of smaller rock wrapped in a reinforcing mesh were placed. A concrete footing was then poured for a three metre high concrete Rocla MassBloc® retaining wall. This retaining structure as a whole supports the road formation and road pavement layers.

Thanks to the quick response of the Rocla team, who turned product around in record time, the road was re-opened on the 5th of April, just a month after its initial closure.

Rocla Manufacturing and Distribution Centres • Sydney • Mittagong • Blayney • Dubbo • Glen Innes • Grafton • Canberra • Wodonga • Melbourne • Brisbane

• Toowoomba • Rockhampton • Mackay • Townsville • Cairns • Adelaide • Perth

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. A member of the Fletcher Building Group. MassBloc trade mark used under exclusive licence from MassTec Industries Limited and Fletcher Concrete and Infrastructure Limited. TAU-II™ used under licence from RMS Solutions. ©Rocla Pty Limited, July 2012.

Head Office: Tower B, Level 11, 821 Pacific Highway, Chatswood, NSW 2067P: +61 2 8986 0900W: rocla.com.au

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Simplifying Segmental Shafts

Microtunnelling, jacking pipe, drilling and infrastructure contractors across Australia now have local access to a quick, cost effective, easy-to-install alternative system for building segmental vertical shafts.

With sizes ranging from 4.5m to 30m, it is suited to a broad range of applications, including jacking and tunnelling shafts, off line storage, access shafts and large pump stations.

The advantage of the Rocla® segmental shafts, which are licensed from Macrete in Ireland, is the unique Universal Connection, which comes standard for segmental shaft sizes of seven metres in diameter or greater, and allows for both caisson and underpinning installation techniques to be used simultaneously or alternatively with the one segment design.This allows for faster and safer installation no matter what ground conditions are encountered.

The Rocla® Segmental Shafts can be used for either temporary or permanent applications.

The standard design of the product – which is manufactured in line with Rocla® ISO accredited Quality Management Systems – allows for use in depths of up to 30 metres, with segments available for additional depths on request.