V1 Alliance Board Submission 23... · The project will be managed by the V1 Alliance with Downer EDI Works taking the lead on the day-to-day project management to deliver all stages

V1 Alliance Board Submission Alliance Project Implementation Plan

Regional Rail Link – Work Package F (ARTC Early Works) Submission 2

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Table of Contents TABLE OF CONTENTS .......................................................................................................2

1 EXECUTIVE SUMMARY...............................................................................................3

2 INTRODUCTION ...........................................................................................................5

2.1 BACKGROUND...........................................................................................................5

3 SUMMARY OF WORKS................................................................................................5

3.1 CONSTRUCTION OF NEW FORMATION AND TRACK BETWEEN 38.620KM AND 39.240KM 5 3.2 RELOCATION OF MANOR LOOP..................................................................................6 3.3 CONNECT NEW TRACK INTO MAINLINE AT EACH END ...................................................7

4 PROJECT DELIVERY ...................................................................................................7

4.1 GOVERNANCE STRUCTURE .......................................................................................8 4.2 MANAGEMENT AND DELIVERY....................................................................................8

5 PROGRAM ....................................................................................................................9

6 PROJECT RISK AND OPPORTUNITY.......................................................................10

7 BUDGET, ESTIMATE & FINANCE .............................................................................11

8 CONTINGENCY ..........................................................................................................12

9 QUALIFICATIONS.......................................................................................................12

APPENDIX A – TCE ..........................................................................................................18

APPENDIX B – RISK & OPPORTUNITY...........................................................................19

APPENDIX C – WORK SITE DIAGRAMS .........................................................................20

APPENDIX D – RISK REGISTER......................................................................................21



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1 Executive Summary

The purpose of this PIP is to seek approval for the costs associated with the major works for the

execution of the Department of Transport Regional Rail Link’s Works Package F (ARTC Early

Works) for Alliance Board Approval.

The project has produced an IFC design and the construction is scheduled to start in late August

2010 with a completion date of early 2011. The overall project budget is currently $5 million which

is funded by the Department of Transport.

Approval for the preliminary costs associated with Downer’s management costs and those for site establishment and procurement of long lead materials has been granted in a previous submission.

This PIP details the costs involved to deliver the project in its current configuration are listed below. A breakdown of costs is attached.

The planning/permits, track and civil design and consultancy are being undertaken by KBR on

behalf of the Department of Transport, with Arup Solihull designing the signalling.

The Early Works for Work Package F is being performed for ARTC by Downer EDI Works through

the V1 Alliance. The work is being arranged by ARTC as an Enhanced Role under the Interstate

Infrastructure Lease (IIL). The work undertaken as part of the Enhanced Role is subject to an

Agreement between the Victorian Department of Transport and ARTC and under this Agreement

ARTC will be paid its direct costs plus a 10% margin.

The Target Cost Estimate for the works excluding ARTC margin is:

Table 1 : ARTC Budget

Stage 1 Preliminaries (approved on 20/8/2010) $1,465,842.11

Stage 2 Major Works $4,560,909.70

Project Risk $500,000.00

Stage 2 PIP Total (seeking approval) $5,060,909.70

Total Project Budget $6,526,751.81

Recommendation:

The V1 Alliance Board approves the PIP for the major works associated with the Department of



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Transports Regional Rail Link’s Works Package F (ARTC Early Works), sum of $5,060,909.70 for

Alliance Board Approval.



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2 INTRODUCTION

2.1 Background

The Regional Rail Link Works Package F – ARTC Early Works, have been developed as

enabling works to support Works Package F – West Werribee Junction works. Works

Package F is described in the Regional Rail Link Project Wide Scope document Revision

1.2 of 21 July 2010.

The KBR Arup Joint Venture (KAJV) has been engaged by the Department of Transport

(DOT) to undertake the design for the track & civil and signalling.

An Issued for Construction Revision 0 track and civil design package has been issued for

review to ARTC and the target cost and this PIP for major works have been completed

based on the drawings provided with this package.

An Issued for Construction Revision 0 signalling design package has been issued to

ARTC for review. This has resulted in agreement to alter the existing signalling overlaps to

comply with 300m standard. The target cost and PIP have been developed based on the

drawings provided with this package with an allowance to alter the current configuration to

provide 300m overlaps. Any change in cost will be communicated once a revised detailed

signalling design is obtained.

3 SUMMARY OF WORKS

The main construction works have been separated into 3 work zones / stages in order to

reduce the risk of delaying trains.

3.1 Construction of new formation and track between 38.620km and 39.240km

As the track is going to be slewed a considerable amount from the existing running line

the earthworks for the new track between 38.620km and 39.240km can be completed

safely without impacting trains. The site will be protected by a temporary fence 3m from

ARTC’s nearest running rail between 38.550km and 39.400km. It is estimated that these

earthworks will take 2 months to complete and will occur prior to all possessions in the

area.



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It is proposed that the signalling preparation works will occur at the same time as the

earthworks. These works involve the following:

• Install pit and pipe work to new equipment locations • Install pre-fabricated signal bases • Install foundations for URR and Genset • Install cable

3.2 Relocation of Manor Loop

Manor loop will be relocated approximately 50m to the east; including associated

signalling to provide 300m overlaps. The methodology and program will be developed to

work between trains for the relocation. Application will be made for occupations on

Saturday night in accord with time tables published on ARTC website.

Saturday morning

• Closure of Manor Loop to operations. Remove the plain line track in the loop and complete all earthworks and track construction.

Saturday night

• Take possession of mainline with protection on VLine BG tracks. • Disconnect and remove point machines • Disconnect and relocate existing signals • Disconnect and relocate existing trackside equipment • Disconnect URR equipment rack and power supply • Re-locate URR hut, Genset and enclosure • Install and terminate URR equipment rack and Genset • Cut the mainline and remove associated track panels for new turnout locations. • Disconnecting the turnouts, removing points machine and rodding and securing

switch blades. The cut the switch into panels ready for lifting. • Excavate and install bottom ballast ready for turnouts. • Lift turnouts out of existing location panel by panel and install into new locations

and commence welding. • Unsecure switch blades, install existing points machines and connect to new

signalling cables. • Excavate the remainder of the mainline works and install track panels top stone

and weld out. • Connect the loop into the mainline and tamp new works.

Sunday 2100

• Loop and mainline connected. • Install existing point machines and rodding.



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• Install remaining trackside equipment • Remove redundant equipment • Function test system • Commission system

3.3 Connect new track into mainline at each end

The connection of the tracks into the mainline will require a possession to complete the

works similar to the possession required for the relocation of the loop. Ideally this would

happen the following weekend after the first possession to reduce costs in mobilisation of

plant and resources and minimise disruptions to operations.

This section has no signalling equipment however signalling support will be required to

disconnect the level crossing and test the tracks once back in use. Traffic management on

the level crossing will be required whilst the signalling is affected.

4 PROJECT DELIVERY

The Rail Upgrades at Geelong Port Project works will be delivered within the same time

frame as the Regional Rail Link Works Package F – ARTC Early Works and will utilise the

delivery team for the works to allow for flexibility in programming the works.



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4.1 Governance Structure

The Governance Structure for the RRL WP-F ARTC Early Works will be as

follows:

4.2 Management and Delivery

The project will be managed by the V1 Alliance with Downer EDI Works taking the lead on

the day-to-day project management to deliver all stages of the program.

Downer EDI Works will supply the services, labour, construction plant, equipment,

materials, systems and the management necessary to deliver the Construction Phase of

the project. The “Delivery Team” may agree to amend this scope where better practice is

identified, delivering “best for project” results.

Downer EDI Works are nominated as Principle Contractor for the worksite with respect to

OH&S which will be subject to both internal and external (ARTC or other) audits.

Alliance Management

Team (AMT)

ARTC Representative

Patrick Gray

RRL WP-F

Project Manager

Ewan Watson

DEW to report to AMT

Downer Construction Team

Rail Upgrades

Delivery Team

Sub-Alliance Management Team

Ben Leske - ARTC Infrastructure Manager East West

Martin Lock - Downer - V1 Projects Director



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Downer EDI Works will facilitate the track hand back of infrastructure to operations and

will manage the interim condition of the asset prior to practical completion and handover to

ARTC Asset Management.

Downer EDI Works will assist ARTC in the preparation and submission of Configuration

Management documentation as required in the ARTC procedure, EGP-03-01

Configuration Management.

5 PROGRAM

The program for the works is based on the final detailed signalling design that is being

revised to accommodate ARTC Signalling Standards and the possession dates that are

yet to be announced. An indicative representation of the length of time required for the

major tasks is indicated below;

Item Work Description Days End Date

1.0 Set-up site, install rail fencing 5 days 3rd September

1.1 Complete Earthworks and track between 38.620km

and 39.240km. Including new Culvert. 50 days 5th November

1.2 Install signalling foundations for signal relocations 30 Days 5th November

1.3

Possession 1 – Relocate loop 50m east of existing

Commission signalling

Signalling Support

4 shifts

2 shifts

4 shifts

20th November

1.4

Possession 2 – Cut, remove and excavate track

(approx 340m) and link into new tracks.

Signalling Support

4 shifts

4 shifts

27th November

1.5 Remove the existing tracks and recover materials (If

required) 15 days 20th December



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6 PROJECT RISK AND OPPORTUNITY

A Project Risk and Opportunity Register is being developed for the works; the main risks

associated with the works are:

1. Geotechnical report supplied by designers is only a concept design with minimal

test pits along the length of the works. The area typically has clay over a ballast

rock a varying depth. The works involves a 3m deep cutting for 300m for the tracks

slew and there is therefore a risk of encountering rock. At this stage due to the

nature of the works Downer will supply a unit price for the removal of rock. When

the grubbing is undertaken to expose the surface of the rock, a detailed survey will

allow the calculation of the volume to be removed. Pricing can then be agreed.

2. Excess spoil and contaminated waste. At this stage there is going to be a large

amount of excess spoil that can not be used due to low CBR values (typically 2%).

The DoT has indicated that excess materials will need to remain on the existing

railway corridor. If the need arises to remove such material offsite at additional

cost, DoT approval will be sought.

3. A Victrack Optic Fibre cable is situated along the Northern edge of the construction

boundary. Compliance with the asset owners plans will be adhered to by means of

non destructive digging to prove the location of this asset. Dedicated access points

will be established at several locations to permit construction traffic to pass over

this service.

4. The current location of URR appears to be suitable for the up end extension

subject to some re-working of the Cess drain. Possible $40,000 savings if the room

does not have to move. At this stage DoT have indicated that this room will require

relocation.

5. There will be the requirement for two track occupations to complete the relocation

of Manor Loop and perform the tie in to the new slewed track alignment. There is a

risk of delay to trains should the occupation be handed back late. Detailed

planning of resources required to undertake each section of the staged work will

mitigate some of this risk.



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7 BUDGET, ESTIMATE & FINANCE

The Budget for the Regional Rail Link Works Package F – ARTC Early Works is to be

determined following agreement on the scope to meet ARTC Signalling Overlap

requirements, and will include project management, construction, commissioning and

contingencies. The project has been estimated on preliminary designs and may be subject

to change once the detailed signalling design is obtained. There is also the possibility of

further changes to the design and scope of works for the project that will be managed if

the eventuate.

The work will be carried out under an agreement with the Director of Public Transport for

the Regional Rail Link Project (WP F ARTC Early Works) as an enhanced role under the

Interstate Infrastructure Lease. The works will be delivered under a Cost Plus

arrangement on the basis of the direct works mechanism of the V1 Alliance Contract for

which the Downer EDI Works Margin is 12% and ARTC will be paid its direct costs plus a

margin of 10%.

The Target Cost Estimate is summarised below, which includes the preliminary costs that

have already been approved. Please find further detail attached:

Target Cost Estimate Summary

Preliminaries (approved)

• Site Establishment $259,313.50

• Management Costs $451,844.75

• Materials $597,629.35DEW Preliminary Cost (incl margin) $1,465,842.11

Stage 2 (seeking approval)

• Materials $264,111.05• Site Facilities $101,800.00• Earthworks Subcontract $1,143,122.00• Staged Track Construction $1,741,896.98• Signalling $709,157.00• Management Costs $108,753.78• DEW Margin (stage 2) $488,260.90• Project Risk $500,000.00

Stage 2 Major Works PIP Total $5,057,101.71



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The price quoted for signalling allows for the expected increase in signal overlaps to 300m

required for the relocation of Manor Loop. This will be adjusted once a revised signalling

design is issued.

The price for earthworks is subject to change as the assumed volume of particular

materials will only be confirmed during the construction process.

The designers KAJV have increased the length of the new culvert required from the IFC

design. An allowance has been made for the increased cost for the extension to the new

culvert.

All pricing provided excludes any allowance for ARTC costs. Pricing within this PIP is

strictly DEW costs and margin.

The project forecast costs will be updated monthly and circulated in the project monthly

report. Any additional forecast required by either Downer or ARTC or if a major project

issue occurs that affects the forecast an update will be sent through as required.

8 CONTINGENCY

There has been a provisional sum of $500,000.00 allowed for contingency included in the

estimate. This will be reviewed following the results of the construction risk workshop. The

overall budget has not been set by the Department of Transport and the costs are fully

reimbursable it is assumed that an open book policy would be used with any variation to

the price of the works due to unforeseen circumstances will be processed prior to the

works being completed.

9 QUALIFICATIONS

The following are qualifications for the quote:

The following works are included in the quote:

Program



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Downer has supplied their program for the tender process and has priced a management

team on the time frame to monitor program, attend program meetings and provide ARTC

with progress and forecast reports to the end of December 2010.

Planning and Approvals

Downer will complete the configuration change process for the works but will not be

responsible for an issues arising from comments from the relevant corridor / discipline

managers.

Site Facilities and set-up

Downer will set up a secure site compound and access roads for the duration of the works

as per the program.

Survey and peg out

Downer has allowed for survey to peg out the track alignment however establishment and

maintenance of survey datum points will be the responsibility of the designers.

Earthworks

The earthworks has allowed for indicative quantities of rock to be broken out and loose

rock to be disposed off site. The disposal dockets will be collected, correlated and

submitted to the Department of Transport with the invoice for works to ensure that there

are no disputes.

The earthworks have allowed for the placement and compaction of 1m structural fill only

(based on design and CBR values of 2%) and 150mm of capping. These materials will

meet ARTC Standards.

The earthworks has allowed for the construction of the general fill zone of the

embankment using materials sourced from on site only. If this material is unsuitable,

additional cost will be required to import and or mix a compliant material.

Track Materials

The price includes the use of all new track materials as stipulated in the design, except for

junction rails and a quantity of existing concrete sleepers in the mainline at the relocation

of Manor Loop turnouts.



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An allowance has been made to dismantle the redundant standard gauge track after the

new alignment is operational. Sleepers can be transported within 100km. Rail to remain

onsite stacked in long lengths. Used ballast will be stockpiled onsite.

Rail and Welding

The price includes the unloading of 13.7m lengths of rail and Thermit welded into long

lengths. There may be an option to use the flashbutt welder to perform the welding.

The price allows for the replacement of 14No. glued insulated rail joints.

Turnout re-timbering

Downer will supply and install timbers to ensure the integrity of the turnout when it is

relocated.

Track Possession

The works has been planned and priced for 2 consecutive track possessions working

between trains. Any additional track possessions due to unsuitable track windows will

require a variation.

Signalling – Preparation Works

Install pit and pipe work to new equipment locations for 300m overlap

Install pre-fabricated signal bases

Install foundations for URR and Genset

Install cable

Signalling – Possession

Disconnect and remove point machines

Disconnect and relocate signals

Disconnect and relocate trackside equipment

Disconnect URR equipment rack and power supply

Re-locate URR hut, Genset and enclosure

Install and terminate URR equipment rack and Genset



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Install existing point machines and rodding

Install remaining trackside equipment

Remove redundant equipment

Function test system

Commission system

Tamping and regulating

Downer has priced for tamping of the tracks to standard line and levels with a minimum of

2 passes.

Stressing

Downer has priced for the stressing of rails to the standard.

As-built measurements

Price includes measuring and certifying the track is constructed to the design and to

construction tolerances by a qualified track hand-back.

Follow up Tamp

A price has been included for a follow up tamp after 12 months from commissioning and

within 24 months.

The works not included in the quote:

Planning and Approvals

No allowance for participation in the Design Phase except for providing comments.

No allowance for preparing and/or procuring any relevant approvals and/or permits, other

than Melbourne Water permit to work on culvert construction.

No allowance for stakeholder and/or community consultation.

Site Facilities and set-up

No allowance for site restoration, regeneration and planting of the storage compounds.



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No allowance for protection and preservation of Fauna.

No allowance for the provision of a qualified ecologist.

No allowance for relocation of any Utility Services.

Track works

No allowance for new turnouts or components.

No allowance to replace the existing junction rails.

No allowance to increase the standing room within the current configuration.

Earthworks

No allowance for supply of general fill material. It is assumed that suitable material will be

sourced onsite to be placed below the structural layer.

No allowance to remove soil off site. It is assumed that sufficient suitable area within the

rail corridor will be available.

No allowance for the removal or rehabilitation of unsuitable subgrade.

No allowance for the testing, excavation or disposal of contaminated materials.

No allowance for the specific treatment or management of soil pathogens or other

diseases.

No allowance to increase the standing room within the current configuration.

Signalling

No allowance for relocation of cabling in area of the track slew. Signalling support for this

track work is included.

No allowance for new points back drive detectors.

No allowance for new points motors or rodding. Existing materials are deemed

serviceable.

No allowance to adjust existing level crossing track frequencies.

No allowance to replace equipment within URR, relocate only.

No allowance for new signals. Existing signal masts to be relocated to new position only.



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Completion and handover

No allowance for preparation of ‘as built’ drawings in CAD. All construction drawings will

be marked up by hand, with any relevant information to be updated by designers.



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Appendix A – TCE

Stage 2 TCE Major WorksCost DEW Margin DEW Total

Summary of Funds Approved in Preliminary PIP (excl Margin) 12%Site Establishment 259,313.50$ 31,117.62$ 290,431.12$ Management 451,844.75$ 54,221.37$ 506,066.12$ Materials 597,629.35$ 71,715.52$ 669,344.87$ Totals Preliminary 1,308,787.60$ 157,054.51$ 1,465,842.11$

Summary of Funds Stage 2 PIPEarthworks SubcontractEarthworks 843,122.00$ 101,174.64$ 944,296.64$ Culvert 300,000.00$ 36,000.00$ 336,000.00$ Track MaterialsBallast, FCR, Timbers 264,111.05$ 31,693.33$ 295,804.37$ Construction StagesStage 1 Manor Loop Relocation 770,019.01$ 92,402.28$ 862,421.30$ Stage 2 Re alignment 260,425.45$ 31,251.05$ 291,676.50$ Stage 3 Connect Track Slew to Main Line 436,302.52$ 52,356.30$ 488,658.82$ Remove redundant Track 275,150.00$ 33,018.00$ 308,168.00$ Site Facilities 105,200.00$ 12,624.00$ 117,824.00$ Signalling 709,157.00$ 85,098.84$ 794,255.84$ Management 108,753.78$ 13,050.45$ 121,804.23$ Totals Stage 2 Major Works 4,072,240.80$ 488,668.90$ 4,560,909.70$

Cost Total 5,381,028.41$ DEW Totals 645,723.41$ 6,026,751.81$ less Preliminary PIP Approved Amount 1,465,842.11$ Add Risk 500,000.00$ Stage 2 PIP Approval Required Amount 5,060,909.70$



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Appendix B – Risk & Opportunity



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Appendix C – Work Site Diagrams

Mainine Layout

Works Site 1

Dn BG

Up BG36578 36700 38370 38436 38500

ARTC SGEast end West endRelocation of existing T/O 50m Relocation of existing T/O 50m

36800 Manor Loop

Works Site 2

Dn BG

Up BG38500 39465

ARTC SGfence

38620 Construct tracks 3924038741Culvert

Works Site 3

Dn BG

Up BG38500 Remove the existing track 39465

ARTC SG

38620 39240temporary level crossing

38250



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Appendix D – Risk Register

Documents

V1 Alliance Board Submission 23... · The project will be managed by the V1 Alliance with Downer EDI Works taking the lead on the day-to-day project management to deliver all stages