DESIGN, PROCESS & DELIVERY SOLUTIONS

1 Safety, quality, sustainability, innovation and employee training are the cornerstones of Austrak’s SUCCESS

The Company

Since its establishment in 1980, Austrak We have produced more than 18 million As a wholly-owned subsidiary of major has grown to become a world leader in the sleepers for medium and heavy duty rail, international construction company design and manufacture of pre-stressed and 800,000 sleepers for light rail and Laing O’Rourke, Austrak has the concrete sleepers. tramways. Over this time, we’ve created a backing of the largest privately owned broad range of products designed to meet construction firm in the United Kingdom. During more than 30 years of business, the varying needs of the rail industry. Laing O’Rourke provides Austrak with Austrak has cemented its place as the the backing of a global, multi-billion dollar largest concrete sleeper manufacturer Austrak partners with Swedish innovator organisation with operations in Europe, the and supplier in Australia. As a dedicated Abetong Teknik – a close relationship Middle East and Australasia. sleeper technology company our focus that enables the transfer of world-leading remains on achieving the best in sleeper technology and knowledge. Working Creativity, flexibility and an aligned focus design and manufacture. closely together, we ensure any new towards joint goals encapsulate Austrak’s developments in the field are quickly added business approach. Safety, quality, sustainability, to our available designs. innovation and employee training are the cornerstones of Austrak’s capability. As well as providing these pre-existing Working in close partnership with clients lines, we can work in partnership with provides an environment for driving clients to create new products that are innovation and change. tailor-made for their specific requirements. Long before the manufacturing process Austrak is an industry leader in the begins, we work in close partnership design, construction, commissioning with our clients in an open and highly and operation of concrete sleeper consultative way. We take the time manufacturing plants, having built and and strive to get a strong understanding run 12 factories in Australia and overseas. of our clients’ needs across all key areas Some of these factories have been – everything from ballast condition to custom-built for specific projects, and maintenance schedules. Our clients capacities range from 50,000 to more have input into the sleeper design from than 1 million sleepers per year. the very beginning and are encouraged to work alongside our design and engineering team.

2 3 “quality and certainty of schedule are two of the most important things for us. Austrak has delivered on both counts.”

Peter Thomas Project Director Port and Rail Expansion Projects, FMG

Innovative Proven Reliability Sleeper Solutions

Austrak specialises in providing concrete While we specialise in sleeper solutions, In over 30 years of operation, we have Austrak is a dedicated sleeper company sleeper solutions. Our core focus is to our real product is the intellectual property never had an ‘in ’ failure of any with a sole purpose - to provide high service our clients with cost-effective tied up in our factory designs and operating Austrak sleeper product. This is largely due quality engineered sleeper solutions using concrete sleeper solutions. Our emphasis systems. We have proven and robust to our in-house Factory Data Management state of the art manufacturing processes. on researching and developing sleeper systems, processes and equipment. Software, which is at the heart of our Benchmarking and performance design and production technologies Our focus on research and continuous factory management system. monitoring is used extensively to ensure ensures we remain industry leaders. improvement ensures we implement the It is the result of years of development and optimum manufacturing efficiency most innovative and efficient technologies. and performance. We make sure that all of our products captures the essential elements required to meet exacting standards including fit for Our factories operate under Austrak’s ensure that we consistently deliver Reliability, repeatability, and value for purpose structural design, beam strength, own work methods and quality assurance high-quality sleepers. We record and money are the hallmarks of the Austrak materials specification and selection, standards which are third party accredited capture everything from our raw materials system which has been continually concrete durability, manufacture process, to ISO 9001. The systems also comply with test results, to our operator training improved since our inception in 1980. correct stressing, concrete compaction, the requirements of ISO 14001. records, right through to our daily dimensional integrity, aesthetics, visual production and quality results. inspection processes, and performance We also operate an integrated testing processes. management system (IMS) which has various quality control processes built in. These include: • State-of-the-art concrete testing laboratories at all factories • Trained and competent management and operators • Management system that ensures compliance to the applicable standards including AS1085 Railway Track Material Specifications.

4 5 Product Range Design

Austrak’s versatile and comprehensive Austrak is an industry leader in the Austrak’s in-house research and range of products meets the various specialised field of manufacturing development capability ensures we can requirements and needs of our clients. pre-stressed concrete beams for turnouts, design sleepers and turnout beams for crossovers, diamonds and catchpoints. almost any type of railway requirement. We have designed sleepers to These have been developed for varying accommodate axle loads varying from nine Whether designed in-house or in axle loads and gauges as well as tonne for tram sleepers, through to conjunction with Abetong Teknik or divergance ranging from 1:6 through 30 tonne for freight railways, right up to other specialist consultants, Austrak’s to 1:25. 50 tonne axle loads for heavy haul lines. experience and network of specialists Austrak’s capabilities extend to producing ensure we deliver innovative solutions for Our product range includes: sleepers and turnout products using all new requirements. Designs can be made • Broad gauge approved fastening systems. from clients providing bending moments • Standard gauge or from basic load parameters. Our various Following an extensive research, • Narrow gauge design techniques can be used from development and testing process, Austrak • Narrow/standard allowable stresses to limit state design. has developed timber replacement • Standard/broad gauge changeable Austrak has also developed and patented sleepers. The highly-engineered solution • Turnout bearers its own design techniques using specific for replacing ageing timber sleepers was • panels data collected on the operating railroad. based on extensive rail track data and • Monorail analysis to ensure the sleepers are a similar Through innovation, value engineering and • Gauge widened sleepers size and match the specifications of the an unrelenting commitment to quality in • Guard rail sleepers line. The sleepers are longer-lasting, more sleeper design, manufacturing systems • Splay rail sleepers economical and lower maintenance than and processes we are striving to be the • End stop sleepers timber sleepers. world’s premier provider of concrete • Timber replacement sleepers (TRS) sleeper solutions.

6 7 Testing Production Technology

Comprehensive testing is an integral Austrak has proven experience in factory Currently Austrak has factories in: part of Austrak’s design and production construction and operation. • Geelong, Victoria process. We create and refine sleeper We have proven and robust manufacturing • Rockhampton, Queensland designs to ensure they meet train speed systems, processes and equipment and • Port Hedland, Western Australia and load-bearing specifications. continual research ensures we remain a • Wagga Wagga, New South Wales Before mass producing a new design, leader in the field. • Dubai, United Arab Emirates the company carries out computer-based Our factory employees undergo rigorous modelling to prove the theoretical design. training to ensure quality, productivity and In the past we have built and operated Then exhaustive repeated-load tests on safety are of the highest standard. Our factories in: prototype sleepers are evaluated against operational and management staff bring • Mackay, Queensland the theoretical data and the client’s extensive experience to the business and • Wickham, Western Australia performance expectations. a client-focused approach to each project. • Townsville, Queensland During production we perform various • Katherine, Northern Territory Austrak builds and operates factories in tests to ensure the conformity of: • Tennant Creek, Northern Territory close proximity to large-scale projects to • South Hedland, Western Australia provide cost and time efficiencies. For • Materials utilised in the products; • Malaysia example, two factories were built in the • Prestressing; and Northern Territory to manufacture two • Concrete strengths million sleepers for the 1410 kilometre rail

line from Alice Springs to Darwin, Sample sleepers are taken from each bed one of Australia’s largest to ensure the final product meets testing projects. The construction of the factories criteria for first crack and bond as well was fast-tracked and the sleeper as dimensional testing. All sleepers are production rate accelerated allowing the visually checked as part of our quality project to be completed three months assurance program. ahead of schedule.

8 9 Safety Above All Safe and Timely Delivery

Austrak is committed to a ‘no compromise’ Factories safer by design: Austrak is proud to be the only company We have worked with some of the world’s approach to health and safety which is Our factories are designed to incorporate to have exported heavy haul (40TAL+) most demanding and iconic railway enshrined in our ‘mission zero’ approach. valuable safety features to minimise risk sleepers from an overseas manufacturing networks. In servicing the ongoing and on-site. Some design initiatives include: facility into Australia. We have developed growing demands of our clients, we have Mission Zero is our safety program robust manufacturing processes and established 12 factories and delivered designed to eliminate all accidents in the • One way traffic flow on site has procedures that can withstand the more than 18 million sleepers. Our workplace by 2020. mitigated risk of reversing vehicles transport and logistics to deliver sleepers demonstrated local and international A slingable pack design: • Zonal areas separating vehicles, to remote project locations. We have a manufacture and delivery model ensures From a risk assessment, Austrak has moving equipment and pedestrians to proven record of meeting our clients’ our clients are supplied with superior determined that the logistics component prevent collisions expectations to consistently and safely quality sleepers, when they are needed, of the supply chain is the most likely to deliver to schedule, quality and that meet the lifetime requirements of • Designated wet areas away from the cause serious harm. Special precautions cost requirements. the project. main production area developed to need to be taken before a sleeper is reduce risk of slips and trips Austrak continue to invest in our plant and Importantly, Austrak understands the moved to minimise the health, safety and equipment to ensure we deliver quality priority of meeting schedules so as not environmental risks. Austrak have designed • Overhead positioning of services sleepers that can be relied upon to perform to jeopardise delivery of the overall a proven and robust slingable pack and utilities to prevent slips, trips and to the required standards. We have existing project programme. design to enable safer and more efficient electrocution. capability to support and assist our loading and unloading process. This is an facilities with state of the art, remote online alternative to the forkliftable pack. fault diagnosis systems from anywhere in the world. Our ongoing investment improves our sleeper reliability and in turn, our clients’ infrastructure delivery performance. Additionally, our rigorous preventative and predictive maintenance regimes help ensure optimum performance of our sleepers long after the tracks have been laid and are in use.

10 11 We work with our clients to develop CERTAINTY solutions that maximise the benefit to them. Our design flexibility and innovation OF DELIVERY has met the diverse demands of private and government sector organisations by ENSURES OUR working in unison with them, developing and refining specific solutions tailored to CLIENTS COME each situation. We have the ability and expertise to work in remote and regional BACK AGAIN locations and have worked on the biggest rail projects in Australia. Major AND AGAIN projects

Alice Springs BHP Billiton Main North-South Queensland Rio Tinto Pilbara Iron Ore to Darwin Railway Iron Ore Projects Line Project Rail Projects Iron Ore Projects and Infrastructure Project

Client: Australasia Railway Corporation Client: BHP Billiton Iron Ore Client: Australian Rail Track Corporation Client: Queensland Rail + QR National Client: Rio Tinto Ltd, Norths Ltd and Client: Fortescue Metals Group (FMG) (Austrak was a subcontractor to ADrail) (ARTC) Robe River Associates Location: Western Australia Location: Queensland Location: Western Australia Location: Northern Territory Location: Victoria, New South Wales and Location: Western Australia Overview: Austrak’s long-term relationship Overview: Austrak is proud to have a Overview: FMG contracted Austrak Queensland Overview: The Alice Springs to Darwin with BHP commenced in 1986 when the 30 year relationship with Queensland’s Overview: Since 1987 Austrak has had to manufacture and supply materials railway line was one of the largest company was contracted to manufacture Overview: The Australian Rail Track passenger and freight rail services. Until an ongoing relationship with Rio Tinto, necessary to lay 255 kilometres of single infrastructure projects ever undertaken and supply sleepers and turnout bearer Corporation (ARTC), with the support 2009, both areas were managed under one of the world’s leading mining and track railway that connects the company’s in Australia. As part of the overall project, sets for the partial duplication of the line of the Federal Government, initiated the banner of Queensland Rail. With exploration companies. port facilities at Port Hedland with their Austrak was charged with the responsibility to Mt Newman, Yandi, Whaleback and the Melbourne to Brisbane rail corridor the separation of services, we now work iron ore mine site. To meet this challenge, By leveraging its existing factories and of manufacturing approximately two million Jimblebar. upgrade project to improve the closely with both Queensland Rail and Austrak used its existing local factory being able to quickly build new factories concrete sleepers in just 16 months for the performance and competitiveness of the QR National. in Wedgefield, Port Hedland in Western To date, Austrak has manufactured and in remote locations, Austrak is supremely 1410 kilometre single track railway. Melbourne to Brisbane rail network. Australia to ensure all sleeper production supplied about one million sleepers and We are the sole supplier of concrete positioned to deliver Rio Tinto’s specific met the demanding schedule. To meet this daunting challenge, Austrak 200 turnout bearer sets. Austrak was awarded the more than $100 sleepers to both companies. design needs now and in the future. designed, constructed and commissioned million contract to manufacture and supply We are proud to continue our long-term To support BHP’s requirements, two strategically located factories at 1.25 million standard gauge mainline relationship with FMG and have recently Austrak rapidly built and commissioned Tennant Creek and Katherine. sleepers and 22,350 dual standard/broad supplied 445,000 sleepers for their a single bed rail sleeper factory at South gauge pre-stressed sleepers over two Solomon Expansion Project in the Pilbara. By constructing and managing its own Hedland in Western Australia. A new five years. In addition, Vossloh commissioned factories, the project team was in complete bed factory was built and commissioned Austrak to initially manufacture 122 turnout control of the supply chain, manufacturing at Wedgefield in 2000 and this supports bearer sets valued at more than $3 million. processes and quality control, being well BHP’s current production needs. This positioned to deliver the job in the most facility has also been producing turnout To provide cost-effective sleeper delivery cost effective and timely fashion. bearers since 2005. and guaranteed quality control, Austrak designed and built its own dedicated factory in Wagga Wagga, New South Wales to support the contract.

12 13 Management Systems

Austrak’s management systems are • Training continually evaluated to ensure the Training begins with the induction of company is delivering to world standards. new staff and continues through to a competency based system to • health and Safety ensure our staff attain the specialist We recognise the importance of staff skills needed to control the sleeper safety and ensure that in all facilities we manufacturing process. have specialist personnel who control safety and quality assurance systems. • Technology We have specialised in-house Our operating factories have third-party developed production and quality accreditation to AS4801:2001, Health systems to monitor, control and report and Safety Management Systems. on all factory systems. • Quality • Community Since 1996, Austrak’s quality assurance Austrak aims to participate in system has been third-party accredited community activities that develop and to ISO 9001. The system extends from nurture positive relationships built on verification of raw materials used in mutual understanding, respect and concrete blends, to monitoring process trust. Wherever possible, we employ control variables, to operator training local people to further develop the local and auditing. economy. • Sustainability We have a documented Reconciliation Austrak recognises the importance of Action Plan (RAP) in place that outlines environmental issues and our systems our commitment to Indigenous comply to ISO 14001. Factories are Australians. designed with waste minimisation and energy efficiencies in mind. • Innovation Austrak has an active and significant R&D agenda focused on further developing efficient sleepers, production processes and environmentally sustainable solutions. 14 15 austrak.com +61 7 3308 7880

October16 2012