Boral

Boral Asphalt QLD News April 2020

Hi Everyone,

I hope you and your families are all well and managing with all the changes going on in our lives at the moment.

We have all been very fortunate that our business, in the construction industry, has been able to continue with the work we do.

Thank you to everyone across our asphalt business for taking on all the required changes in terms of hygiene, social distancing and ensuring you let us know if you have health concerns.

Our safety outcomes have been really good this year so far with no significant incidents or injuries as I know many of you are concerned, frustrated and are dealing with issues as a result of this Covid-19 virus.

Whilst we are still working, it's important we keep up our focus on managing the hazards and risks in our depots and job sites - so please look out for each other, agree on putting relevant controls in place and talk to your supervisor or manager if you have concerns or need help. We must always ensure exclusion zones are in place at all times, toolbox talks are undertaken before the start of every shift and we continue to 'Look Before you Move' so we reduce the risks we deal with every day.

We have many actions put in place as a result of the sprayer incident late last year. Many of you have been consulted on these and once agreed, we will continue to put in place these improvements as to how we manage our fleet, upskill our drivers and change the way we carry out project works in regional areas. We expect everyone to help implement the required improvements.

We have several successful projects underway across the Qld and a special thank you to all those travelling away and going interstate to help out the other Boral businesses.

Norfolk Island has seen the last ship unloaded with all materials now on island. The team now moves into the full scale asphalt works on the runway and all the associated activities with the project. (Paul Davidson, Chris Jeffery and teams are doing a great job managing this complex project)

Emerald Airport - all works are now completed and we will be de-mobilising the mobile asphalt plant over the next month (Dave Daniel, Dean Catterall and team have successfully delivered the first SMA asphalt runway in ). A special thanks to Mark Taylor, Peter Carbone and Carl Topp for their excellent contract and technical management. There is now a video on the Boral website.

M1 Upgrade (Mudgerraba to Varsity Lakes) - the project has 4-5 weeks to finish with all the main surfacing works now underway. Recent feedback from our client has been very positive (Eddie Mills, James Devoy and team have been managing this project for nearly 2 years!). We have also secured the next package of work on the M1 as a result of the great work done by the Gold Coast team.

We also have the team at the East Sale RAAF Base completing the asphalt works which is due to be completed at the end of May. Following this the T300 mobile plant will be packed up and returned to Brisbane.

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The major project in Cairns (Kate to Aumuller Street upgrade) is underway for Georgiou Group and we have several large scale spray seal projects under way for Isaac Shire, Central Highlands Council and Mackay Regional Council and TMR. Major work was also recently completed for South Burnett Shire. There are several major projects released into the market for tendering by the Federal and State Governments - so we will be actively working with our customers to secure these.

As always it's great to see the level of good housekeeping in all of our depots and the well looked after equipment on our job sites - thank you to all Area managers and supervisors for the focus on this.

I look forward to catching up with you on my next deport or site visit.

Rob McGuire General Manager – Asphalt QLD

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M1 / M3 / Gateway Merge Project by Sheree Cook

With the project coming to a close we are pleased to announce that every milestone within the project has been met on time. This achievement would not have been possible without the dedication and commitment from our entire team. Since our last newsletter we have achieved the following results:

• Completion of the final project milestone (OG surfacing between CH-385 to 1585) • Opening the southern section of the Pacific motorway to five lanes of traffic • Placing a total of 8,327 tonnes of OG under traffic control

To date the project team has completed 65,179 tonnes of asphalt, with 33,479 tonnes of that being completed at night. The feedback received from various stakeholders has been nothing but outstanding, with all parties commenting on the quality of workmanship and timely progression. The outcomes of the M1/M3 project further demonstrates that through a collaborative relationship with our client (LLE), we have been able to increase our productivity and therefore deliver the project prior to their completion date.

Finally we are pleased to say that even through these difficult times, the project team has been committed to completing the works with everyone’s safety in mind. With new social distancing restrictions in place, the team has been acknowledged and commended on their continuous efforts in maintaining these restrictions. It is through this behaviour and attitude that we will continue to deliver excellent projects like the M1/M3 project.

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Toowoomba – Bolivia Hill Upgrade by Alex Taylor

Boral Asphalt Toowoomba has recently been involved in New South Wales for the Bolivia Hill Upgrade between Tenterfield and Glen Innes working for Georgiou and SRG JV. Boral had performed some minor preliminary works previously, however, large delays due to many factors including, heavy rainfalls and bushfires meant that, Boral has only been down for Establishment 1 on the main works in late March and early April this year. We mobilised and began works on Stage 1 for Georgiou, which included part permanent works and part temporary works on the 8% grade hill, to allow a traffic switch on the 'Stop-Go' one lane Bolivia Range. Boral utilised a multi-disciplined crew (Gibson Bethel & Brian Cooke) to juggle primes, seals and asphalt all in a single visit - safely and successfully delivering over 1000T across 3 sections of the Hill in difficult site conditions - given the site access limitations we dealt with over 5 shifts. Credit to the team for their efforts after coming off a recent long haul tour to Roma (5hrs) and then a week away long haul to Bolivia Hill (3.5hrs) from Toowoomba's new Charlton Asphalt Plant. Fantastic effort to all the team involved!

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Gold Coast Lab Upgrade by Eddie Mills

The West Burleigh depot recently completed an upgrade of their lab facilities. The works included fully enclosing the awning and extending the office area. It was undertaken to improve working conditions, primarily reducing dust and noise from the plant and surrounding quarry, and substantially improving the work space for staff in both the testing and office spaces. More improvements are planned for next financial year with installation of kitchenette and finalising plans for their main office. Thanks to Ben and all lab staff for their patience, maintaining work flow while under construction.

Lab Upgrade - Office Lab Upgrade - External

Lab Upgrade - Workshop

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Bundaberg – N2P Controls Upgrade by Bradley Bull

The Bundaberg Asphalt plant control system has been upgraded continuity by N2P Controls. The previous system was no longer supported and a risk to the business continuity. Using site management, fitters, operators and the local electrician, the install was successfully completed without any incidents.

The new system is very streamlined and easy for the operators to control (even the Manufacturing Supervisor can operate it but we all know how good he is!!!). This has been completed in conjunction with other capital works over the past year including weighbridge replacement, Apex and traffic management improvements around the depot.

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Rockhampton – Bowen Basin Reseal Program by David Daniel & Warren Harvey

The Rockhampton seal crew has been completing reseals for Central Highlands Regional Council under the agreement with the Bowen Basin and Gladstone Regional Roads and Transport Groups. Due to the great work of the team with these reseals last year (18/19), the works have been awarded to Boral as a sole invitee arrangement with the contract allowing for a second year at the sole discretion of the principal. The scope of works was for approximately 360,000 litres of bitumen (split between S0.3B Bitumen and Crumbed Rubber Bitumen) and spreading of 2000 m3 of 10mm aggregate. The work was a mix of both urban town streets and rural roads. These works are progressing well, and on target, to complete in the programmed timeframe. The crew has been doing a very good job quality and safety wise. The challenge of social distancing and extra hygiene initiatives have been embraced by the crew and has been well received by the client. Central Highlands Regional Council have advised that they will be giving Boral a variation to complete more resealing works up to approximately half the value of the original contract. Well done to Project Manager - Warren Harvey, Seal Supervisor - Steve Stanton, Acting Foreman - Richard Martin & the Seal Team! Our professionalism in the delivery of the project and customer focus will build long lasting relationships with the program managers, CHRC & George Bourne Associates, well into the future.

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Mackay - Asphalt Patching and Sealing Works for Mackay TMR By Chris Sanders

Since our last newsletter over the past few months the Mackay seal crew have been busy working on their asphalt skills with the assistance of the Cairns crew. Throughout December 2019 – February 2020 the crews together successfully delivered over 4000T of patch repairs along the Bruce Highway from Koumala to Granite Creek. On completion of this, the crew moved north to complete over 1000T asphalt patch repairs between Mackay and Proserpine in preparation for the TMR Reseal Package A (A big thank you to the Cairns personal for their time spent away from family). The Crew is now working towards completing the reseal Package A for TMR prior to the cold weather catching us. So far 500,000L of Olexobit Max Bitumen has been sprayed and we are expecting to spray another 700,000L by the end of May. Boral Asphalt Mackay and TMR Mackay have further entrenched a great relationship over the past 6 months due to the quality of works being provided. Mackay have also been awarded the Bowen Basin 19/20 reseals with Isaac Regional Council which will commence in May. This work consists of a futher 650,000 lt . The Mackay Team are looking forward to the end of Financial year rush.

Above is Ellis’s brand new Cat 2m Profiler and some interesting pavement.

Above is just another day out for the Mackay crew

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Townsville Plant Main Electrical Switchboard and Cabinet (Upgraded Variable Speed Drive System) By Danica Authurs

As you can see in the photo, we received an all new VSD making it easier, when electricians come onsite to program them and also for repairs. The cabling now runs neatly under the plant along the cable trays. The first photo is of Jim Rafferty inspecting it when it first arrived on site. With this upgrade we now have a set of electrical drawings available and a compliant, safe electrical system.

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New electrical cabinet

New cables and trays on the plant

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Cairns – Georgiou Kate to Aumuller St Project by Dean Catterall

Boral Asphalt Cairns has begun delivering on the Kate to Aumuller project for longstanding customer Georgiou Group, the project consists of,

• 211,500 litres of S25E Sami Seal. • 60,000 litters of AMC00. • 23,000 tonne of AC20 & AC14 Mix’s. • 10,500 tonne of SMA 14. So far the Cairns team has completed close to 4,000 tonne of AC mix with only a few minor non- conformances but, for the most part the field, quality has been to a high standard.

Safety onsite has been to a very high standard with positive communication and toolbox talks. Currently, there has been zero safety incidents with the crew working night shifts and weekend intersection shutdowns in trying weather conditions; the team is also working hard on social distancing and maintaining hygiene standards amidst the COVID-19 pandemic.

The project has had some challenging issues, with large areas of multiple lift corrector courses on the current alignment with the need for both longitudinal and transverse key-ins.

A big thank you to all the team in Cairns for all the efforts and hard work so far to achieve the expectations of our customer. Keep up the good work!

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Norfolk Island Airport Contract - Update 3 By Chris Jeffery

November of last year was the last update and there has been a lot of progress associated with Contract. A significant portion of the works up until this point have involved logistics processes with runway construction works now underway.

The three scheduled equipment barges have been received and successfully unloaded with all of the equipment required for the project. Additionally, the second and final bulk ship, the AC Sesoda, has recently been discharged, finally delivering the last of the 42,000 tonnes of concrete and asphalt aggregates on the 22nd of April 2020. Thanks to Shane McGurk and the Boral transport team of drivers for their persistence in completion of this aspect of the project. The photo below shows all 3 ships, the Tao Ace on departure, the AC Sesoda and the GCR tug and barge all anchored at Cascade Bay.

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The logistics work on this project has been extended by poor local weather and environmental restrictions. A final unloading efficiency of 30% was achieved. Significant local weather events - cyclone Louis and Greta restricted discharge by 13 and 16 days respectively (nearly a whole month). Associated with these poor weather events and a requirement to continue unloading through these events, Boral rebuilt the groyne a total of 3 times with 9 partial repairs undertaken on the maintenance of the structure. The photo below shows the peak of the cyclone with 4m waves coming into Ball Bay.

The previous photo shows the final rebuild of the groyne which was the most significant work, with all but 10m of the 75m rock groyne destroyed by Cyclone Gretal. In the subsequent clear conditions after the cyclone the rock groyne was rebuilt by BC Excavations in a total of 11 days which was an impressive feat of construction in these conditions.

In early March, Boral commenced excavation of the existing asphalt apron in preparation for the new concrete aprons. The excavation of the existing surface down to a maximum depth of 650mm was a concern as the underlying subgrade was of a suspect quality and consistency, however, upon excavation, DCP testing, proof rolling and subsequent inspection by Boral’s Design verifier and the PMCA, Kraftur commenced the installation of the timber lean mix concrete formwork.

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After 2 days of preparation the first layer of concrete was approved for commencement. Overseen by Boral’s Project Engineer Luke Smith and experienced concrete Project Manager Marius Illuk and his team, Boral concrete manufactured and transported the leanmix concrete from the mobile concrete batcher and 3 twin steer agitators established from the Queensland business for these works. The lean mix cured for 2 weeks, conforming results were submitted and approved by the PMCA ready for the next 400mm top layer of concrete.

Airport Ground Lighting works continue by Avionics at a steady pace despite some of the setbacks. The installation of the majority of the new pit and ducting and SIT’s for the new lighting system is now completed for the Airport in preparation for the commencement of the main runway 11/29 overlay and subsequent RAP pavement and flanking construction. Additionally the resolution of the wind indicators and the final AGL design have now been achieved, following ongoing changes and revisions of the project scope and subsequent design by the PMCA.

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As part of expediting the apron works temporary parking locations and transportation for the aircraft and passengers have been incorporated into the Boral operational plan. This enables the entire concrete apron areas to be excavated and concrete works poured in a single period rather than waiting for the separate areas to cure and be completed. This was expected to save approximately 4-6 weeks from the original program however no one expected COVID-19 and all the changes as a result of this.

Soon after the completion and disestablishment of the concrete crew and Cyclone Greta, Emergency Management Norfolk Island (EMNI) instilled travel restrictions associated with the COVID-19 virus pandemic from the 18th of March 2020. These new restrictions seriously impacted the ability of Boral to operate under the previously agreed project roster with limited travel of non-essential personnel between mainland Australia and Norfolk Island. There is an enforced 14 day isolation period for all arrivals - with no exceptions. These restrictions still remain in place.

Prior to the commencement of the runway works Boral was required to secure the required 1,400m3 of topsoil for the flanking pavement. This topsoil was able to be sourced just outside the airport grounds and was the culmination of multiple investigations by Boral on various locations throughout the Island.

Engaging a local contractor and using the Boral transport vehicles along with the newly purchased mobile screening plant Boral was able to excavate, transport and screen the required volume of conforming materials

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As part of the commissioning of the screen plant Boral has committed to the NIRC time and resources for the training of the local employees in the safe operation of the screen and other equipment purchased by NIRC as part of the contract. This is important for the longevity of the new equipment and the future abilities of the NIRC.

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After the asphalt crew left self-isolation, asphalt works commenced as promptly as possible with the successful production and placement trial in the Airport carpark in April 2020 with asphalt lead by Project Engineer Tyler Bakes and Boral asphalt’s Supervisor’s Troy Kennington and Ian Kriby. The use of the new CAT rollers has been impressive to date.

Runway 11/29 profiling and asphalt works commenced on the 16th of April 2020 a bit later than expected, but it was good to finally start the process and to achieve good conforming results.

The use of the NIRC truck and new portable emulsion sprayer purchased by NIRC appears to be working well with the tack coat K2P and the residual application rate of between 0.2-0.3L/m2 with it breaking in about 20-40 minutes depending on the humidity. Thanks to Troy Barker for his persistence in the refinement of this process.

The progress of the asphalt works continues to move forward on the primary runway 11/29 despite some mechanical and weather setbacks.

A total of 22 shifts are programmed for the primary runway followed by 04/22 and the taxiway and apron asphalt works.

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With the delay in the commencement for the asphalt by a few weeks the weather and cooler than anticipated ambient temperatures and increased potential of showers, we will require measured reviews and analysis of the weather forecasts available for the region. The limited accurate information available makes this a significant challenge. Just another one to the list. Persistence and teamwork has brought us to this point and it will need to remain a strong focus for the remaining project works.

20 Year Service Award – Lance Volker

Lance was pleased to receive his 20 year service award.

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New Starters

Meet Dave Adams (Asphalt NQ Supervisor) and Josh Blyth (recently appointed Apprentice Fitter, NQ)

Dave Adams joined the NQ business as Josh recently applied and was successful in Asphalt Supervisor in November 2019. the vacant Apprentice Fitter role in the Dave has worked in the Asphalt industry for Townsville Workshop. He opted to finish a 32 years and brings a unique flavour to the diesel fitting apprenticeship he had partially NQ crew. Dave has worked in all areas of completed before commencing at Boral in the asphalt business from production and 2009. Josh brings to the role a wealth of plant lab through to running crews and experience and knowledge, having worked in management. His leadership and the Asphalt Crew for over 10 years. We wish innovative thinking has been welcomed by Josh every success in his future endeavours. the team. Dave seems to be enjoying the regional life after years spent in Sydney and Perth.

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BAQ Training – May 2020 by Robert Crawford

Verification of Competency (VOC)

Since the introduction of the ‘online’ VOC Portal in September 2019, there has been a great take-up with 298 fully completed VOC assessments across 18 different units of competency. The online portal allows any worker to receive the ‘VOC theory’ component online to ensure employee training requirements to be current and to date. The practical component is then completed by an onsite Subject Matter expert. As more demand is evident, further training modules will be added to this training platform. For further information regarding this tool, please contact Wendy Morse or Rob Crawford.

Heavy Vehicle Driver Training

Grant Stack (Logistics) has been delivering the Heavy Vehicle Driver Induction Package to our drivers, which involves both theoretical and in-cab assessments. To date 25 drivers from Whinstanes have attended the Full day Theory component. Further plans are to roll out the theory and in-cab assessments across the state once state travel restrictions have lessened. The training team is currently developing a new “Online Heavy Vehicle VOC Theory Assessment”, to provide a more thorough and Boral business specific tool to assist in monitoring currency of competency across our heavy vehicle drives.

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RTO Enrolments

Since the RTO has be online in January 2020, we have had 46 students enrolled in a total of 137 training units with a 37 units completed.

Boral RTO recently undertook an ASQA audit and received 98% compliance to all national requirements. The RTO is currently in the process of redesigning all relevant Asphalt and Spray Seal units of competency to the newly released 2019 Certificate III Bituminous Surfacing performance criteria requirements making the Boral RTO one of the first RTO’s in QLD to be able to offer this updated qualification.

Awards

The Boral Asphalt Queensland business is proud to acknowledge the hard efforts of two (2) of our operational staff members who are up for State Training Awards for the successful completion of ‘Civil Construction’, ‘Bituminous Surfacing’ and ‘Driver Operations’ competencies . These members are Troy Thehu from the Brisbane Metro Business and Jason Bishop from the Wide Bay business. Furthering, Troy has also been nominated for the ‘Bob Marshman Trainee of the Year’ and the ’Aboriginal and Torres Strait Islander Student of the year’ Award. Congratulations to both Jason and Troy.

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