Summer Edition2016Summer

The WORKS CONTENTS

2 THE WORKS DIRECTOR’S WINGATE DAM UNLOCKS FATHER CHRISTMAS MESSAGE NEW WATER SOURCE FOR SETTLES INTO HIS 05 06 BAROSSA VALLEY 09 NEW HO-HO-HOME CEDUNA AIRPORT NEW FACILITIES HERALD SUPERMARKET GIANT READY FOR TAKE-OFF NEW ERA FOR ROYAL FLYING MOVES INTO NEW 10 12 DOCTOR SERVICE 14 DISTRIBUTION CENTRE 16 FOOD AND BEVERAGE CONSTRUCTION SERVICES 19 FEATURE PROJECT: MCCAIN FOODS AUSTRALIA AUGUSTA POWER EXPRESS DEMOLITION MCMAHON SERVICES STATIONS IN ADELAIDE CBD LAUNCHES STATE OF 20 DECOMMISSIONING 22 23 THE ART WEBSITE

REGIONAL EXPANSION PARNKALLA INTRACT ACHIEVES NORTHERN GROWTH WATERS 26 FEDERAL SAFETY 23 CONTINUES 24 ACCREDITATION

BULEY PRIME MINISTER’S RECEPTION NORTHERN CONNECTOR ROCKHOLE FOR INDIGENOUS INNOVATORS EARLY WORKS 27 28 AND ENTREPRENEURS 29 BATCHELOR INSTITUTE OF PORT BONYTHON VICTOR HARBOR INDIGENOUS TERTIARY FUELS FORESHORE BOARDWALK 29 EDUCATION 30 32 UPGRADE ALL ABOARD FLINDERS COLOSSAL NORTHERN BEACHES ROAD PORTS UPGRADES DECOMMISSIONING IN UPGRADE – DEMOLITION 33 34 THE NORTH WEST 36 PACKAGE

QUEENSLAND ALUMINA NEW ADDITIONS HEAVY LIMITED MAINTENANCE TO FLEET HAULAGE 37 CONTRACT 38 38

TANK DECOMMISSIONING NEW AWARDS IN REMOTE HORN APPOINTMENTS & RECOGNITION 39 ISLAND 40 40

MCMAHON SERVICES 42 EVENTS ‘Our people are central to what we do’ THE WORKS 3 4 THE WORKS Director’s Above: Managing Director, David McMahon and Director, Andrew McMahon MESSAGE

The last 12 months has seen solid The Intract Australia Indigenous Recognition is important to our business, opportunities turn into tremendous contracting business is going providing a sense of achievement and growth and significant achievements through a period of rapid growth as also driving us to continually improve our for our group of companies. Our group the Commonwealth’s Indigenous business practises. It was fantastic to turnover for the 2015 / 2016 financial year Procurement Policy continues to make receive a number of industry awards this was outstanding, exceeding $200 million waves throughout Australia. Intract has year including the SA Master Builders for the second year in a row. successfully delivered a range of projects Award for Excellence in Commercial across South Australia and the Northern Construction / Redevelopment at the Recently we were recognised by InDaily’s Territory increasing their workforce to iconic West End Brewery. South Australian Business Index as a Top over 40 full-time staff, of whom 95% are 100 company, coming in 24th position Indigenous. We were also awarded on the global and runner up in the top fastest-growing stage, winning the World’s Best Industrial companies, ranked in terms of revenue. The Industrial and Resources Demolition Project at the 2016 World Construction division is going from Demolition Summit for the successful Our approach to diversity continues to strength to strength. Projects of note decommissioning of the BHP Billiton Iron be a strength. We recently established include the structural, mechanical and Ore facility in Port Hedland, WA. the McMahon Services Events division, piping package completed at Petro acquiring assets from the premier Diamond’s Fuel Storage facility in Our continued investment in great National events seating company, Elite Port Bonython, SA and the continuing people supported by the best plant Systems. Construction Management contract with and equipment is shaping our business Lion at the West End Brewery. Recently for a long period of success. We thank Providing events scaffolding, platforms the team passed 1,000 days LTI free - a our clients for the many opportunities and seating systems, McMahon Services testament to our safety culture. presented to us and we look forward to Events will have the largest range of another prosperous year ahead. seating system options in Australia. Some Our continued growth has also resulted of the marquee events we are contracted in further geographical expansion David McMahon to deliver include the Australian F1 Grand opening up a new office in Katherine and Managing Director Prix, Adelaide Clipsal 500 Supercars and expansion of our Townsville operations Santos Tour Down Under. to a larger facility. Both of these regional Andrew McMahon offices further complement and support Director the Darwin, Brisbane and Gladstone operations as we continue to grow our presence in Northern Australia.

THE WORKS 5 WINGATE DAM UNLOCKS NEW WATER SOURCE FOR BAROSSA VALLEY

MCMAHON SERVICES The water will be piped to a holding McMahon Services also undertook the SUCCESSFULLY DELIVER dam from where it will be ready for the supply and installation of a complex NEW WATER STORAGE DAM foundation customer’s use for urban network of pipework infrastructure IN ADELAIDE’S NORTHERN irrigation in Hewett and vineyards in the to connect the dam system to the REGION. Western Barossa Region. upstream supply and downstream consumer. This included pumps to the The project involved the construction three pump stations, valve assembly McMahon Services worked closely with of a flow gauging station, three pump and over 1000 lineal metres of pipeline, Bunyip Water and HydroPlan as part stations, a 680 mega litre storage dam, varying in diameter from 32mm to of the Gawler Water Re-use Scheme a 430 mega litre storage basin and all 320mm. The project required the (GWRS), a key step in a program to associated pipe and ancillary works. supply and installation of all high and unlock new sources of water in the low voltage electrical conduits, as Barossa Valley. McMahon Services were responsible well as underground communications for delivering all works including land infrastructure. The GWRS emanated from the creation clearance, site preparation, demolition of a large borrow pit adjacent the of existing infrastructure and bulk Hard landscaping works consisted of Gawler River, excavated to source fill earthworks to form both basin structures. an access road running along the top of material for the construction of the the dam embankment, a heavy vehicle Northern Expressway. The pit provided turning zone and maintenance vehicle a significant opportunity to harvest urban The basin structures were formed carpark. stormwater runoff from the Gawler River using site won clay material, cut and catchment when flows are above the filled to form a 600mm clay layer, and The final works included the installation environmental threshold (616L/s), and incorporated a HDPE lined sump of all stormwater pipework, headwalls, store it in the new and existing dams scour protection in the form of reno swales and drains, as well as all soft in the Barossa region, and the nearby mattresses and rock lining. This was landscaping including spreading of Kangaroo Flat underground aquifer for placed at the inlets of the dam structure topsoil to bank slopes, hydro-mulching subsequent reuse in Summer. to protect the clay liner from erosion. and planting of native vegetation.

6 THE WORKS PROJECT CHALLENGES

Due to the depth of the pipe risers, the valve assembly was fabricated prior to installation within the chamber. McMahon Services designed and fabricated a complex steel frame to ensure verticality upon lifting and placement.

The inlet pit cover design was also changed from original design to allow for a single sheet of fibre-reinforced plastic to be slid on and off the top of the lid and held down with four bolts. This option ended up being much lighter and easier to remove than the original heavier design that called for an aluminium cover raised in 4 x 4 metre sections.

A significant sustainability initiative for the region, the dam will substitute at least 800 mega litres per annum of River Murray water used in the Barossa, with stormwater harvested on the vineyards. HydroPlan irrigation design engineers have enhanced the water security by connecting to treated wastewater from Bolivar, and providing for managed aquifer recharge expansion to include stormwater anticipated from the Roseworthy Township Expansion.

THE WORKS 7 8 THE WORKS FATHER CHRISTMAS SETTLES INTO HIS NEW HO-HO-HOME

MCMAHON SERVICES KEEP “This excellent outcome has been INSTALLATION FESTIVE TRADITION ALIVE achieved through great collaboration, BY INSTALLING ICONIC with all parties coming together to In preparation for the day of installation, FATHER CHRISTMAS AT ensure that this festive favourite and a comprehensive traffic management NEW CENTRAL MARKETS South Australian icon returns” said plan and logistics schedules were Haese. LOCATION developed. The traffic plan indicated layout of traffic redirection equipment, To begin the journey, he was moved positioning of vehicles and pedestrian For as long as most Adelaide residents from long term storage in Gillman signage. can remember, Rundle Mall has been to a temporary storage location in the home of the iconic giant Father Wingfield before being transported to Two traffic controllers were onsite Christmas, appearing on the façade his new temporary home at McMahon during installation and removal to assist of David Jones throughout the festive Services headquarters in Dry Creek. the McMahon Services project team season. with all traffic and pedestrian control. The logistics schedules provided Due to renovations on David Jones’ timing of truck arrivals which was an Rundle Mall façade, the giant three STRUCTURAL integral part of the day’s events, in turn tonne Father Christmas decoration MODIFICATIONS preventing vehicle congestion on the was forced to find a new home. busy Grote Street. Following a high-pressure wash, The Adelaide Central Markets iconic structural modifications were necessary Following the festive season, Father 115 year old heritage listed Market in order for Father Christmas to be Christmas was transported back to the Tower presented the perfect location erected onto the brickwork of the McMahon Services yard, where he will to display one of Adelaide’s beloved Market Tower at the Central Markets. stay until next year. Christmas decorations. The internal structural beams were Adelaide Central Markets welcomed The new CBD placement was the result cut down to suit dimensions of the news crews to capture the installation of collaboration between the Adelaide new Central Market location and an and removal of Father Christmas, City Council, Adelaide Central Market engineering consultant was engaged excited to share his new home with the Authority, David Jones and Rundle to provide a design for new fixing cleats public. Mall Management Authority, whom and plates attached to the façade of were all eager to find the best place to the Market Tower, which ultimately You can view the footage on our display the large-scale decoration for connected and supported the Father YouTube channel: the iconic Father Christmas. Christmas. www.youtube.com/McMahonServices Adelaide Lord Mayor Martin Haese An in-house surveyor was used to was very pleased with the solution, mark up the location of the holes saying he was glad Father Christmas that were to be cored into the tower’s would be back to delight city-goers. façade to anchor the 15m decoration. While onsite, McMahon Services boilermakers carried out alterations to the veranda in order to strengthen it for Father Christmas’ platform to rest on. Exceptional care was taken in order to eliminate potential damage to the heritage listed structure.

THE WORKS 9 CEDUNA AIRPORT READY FOR TAKE-OFF

MCMAHON SERVICES As Head Contractor, McMahon McMahon Services supplied and WERE ENGAGED BY GHD Services scope of works included erected the new hangar structure ON BEHALF OF BP TO the upgrade of an existing taxiway measuring 45 metres long, 20 metres CONSTRUCT A HELICOPTER and air ground lighting, construction wide and 7 metres high. The hangar OPERATING BASE AT of new taxiway and apron, hangar included high bay lighting, industrial workshop and parking, heliport ceiling fans, compressed air, power, THE EXISTING CEDUNA terminal, installation of 12 modular data and epoxy coated floor for safety AIRPORT, AS PART OF BP’S office and workshop buildings, all and ease of maintenance. ‘GREAT AUSTRALIAN BIGHT services infrastructure and installation EXPLORATION’ PROJECT. of security fencing. Significant earthworks were completed on the project utilising a Upgrades to the airport were The modular buildings supplied combined local workforce and local required following BP’s award of by Ausco included the heliport earthmoving contractors. Road base a rotary wing services contract to terminal, toilets, change rooms and material totalling 8,000 tonne was Bristow Helicopters Australia. Bristow disabled amenities, training rooms, transported from Streaky Bay in order engaged to transport rig workers flight planning and operations to construct the building pads for the from Ceduna to the rig some 300kms administration buildings. All modular hangar, offices, heli apron, landing offshore to BP’s permit areas in the buildings were built in Adelaide and pad and taxiway. Great Australian Bight. transported to site and placed into position. Walkways and covered roofs Trenching and installation of over The construction site was a leased were also included as part of the 1km of new services included fire area within the existing Ceduna modular buildings. water, sewer, trade waste, potable Airport. water, stormwater, electrical, data and communications Installation of stormwater swales, underground 10 THE WORKS 60% LOCAL WORKFORCE ENGAGEMENT

pipes and excavation of a basin the rain subsided, the project team Despite best intentions, BP has catchment area was also completed modified the construction program decided not to proceed with the in order to collect all building and land and progressed with other elements of exploration drilling program. water run off to a single location. the project. “We have looked long and hard Included in the scope was the Local engagement was a major part of at our exploration plans for the construction of a night-time landing the successful delivery of this project. Great Australian Bight but, in pad, upgrade of an existing taxiway f More than 100 workers were and installation of new air ground the current external environment, engaged throughout the process, lighting. All works were completed we will only pursue frontier with 50 on site at the peak of utilising McMahon Services in-house construction activity. exploration opportunities if they trades, as well as specialist local are competitive and aligned to our subcontractors. f The project created employment strategic goals. After extensive opportunities for the local area, with The inclement weather provided 25 Ceduna-based workers engaged and careful consideration, this has challenges on the project, specifically during the process across a variety proven not to be the case for our when it came to the placement of of roles. project to explore in the Bight.” the building pads. The building pad f Approximately 20 per cent of the material was required to have a certain local workers involved in the project Claire Fitzpatrick - percentage of moisture, however were Indigenous and engaged Managing Director wet weather during construction in roles from administration to BP Exploration and Production, created a higher amount of moisture, surveying and plumbing services. preventing compaction of the layers Australia Intract Australia, McMahon Services’ for the building pads. Rather than Indigenous sister company were a wait for the material to dry out once key delivery partner in the project. THE WORKS 11 NEW FACILITIES HERALD NEW ERA FOR ROYAL FLYING DOCTOR SERVICE

THE ROYAL FLYING DOCTOR McMahon Services were engaged on McMahon Services had a team of SERVICE (RFDS) IS ONE the project by Sarah Constructions eight full-time construction workers OF THE LARGEST AND – the lead contractor on the project, on this project utilising in-house plant MOST COMPREHENSIVE to undertake all roofing and cladding and equipment such as our 60 and AEROMEDICAL subcontract packages on the new 100 tonne cranes, 51ft elevated work state-of-the-art facilities. platforms and 45ft knuckle boom lifts ORGANISATIONS IN to successfully complete the project. AUSTRALIA, PROVIDING The new facilities, situated at the EXTENSIVE PRIMARY Adelaide Airport – adjacent to the Extensive planning was required to HEALTH CARE AND 24-HOUR main runway, features space for six ensure long lead time items were EMERGENCY SERVICE TO aircraft along with parking for an procured ahead of time to meet PEOPLE, SPECIALISING IN additional nine aircraft on the tarmac. the strict overall project schedule. REMOTE AREAS. It also features an impressive 2,230m2 McMahon Services executed industry corporate office, including a medical leading temporary safety systems to The new $13 million Adelaide base and patient transfer facility. allow the installation of all roof and heralds the start of a new era for wall cladding at height. This included the Royal Flying Doctor Service as The transfer facility incorporates a temporary anchors, static lines and it delivers 24/7 emergency retrieval streamlined system, which hosts handrail systems that were installed services, inter-hospital transfers and patient care bays with resuscitation and re-positioned throughout the primary health care services to all equipment and other necessities project. South Australians. providing a truly modern and safe workplace for staff and health service The zinc cladding of the boardroom The new aeromedical base was made delivery partners. was a standout architectural feature possible by fundraising, bequests, of the project. McMahon Services corporate and public donations to The McMahon Services roofing erected internal scaffolding to allow enable the RFDS to provide the finest and cladding project team installed the installation of interlocking VM zinc care for all South Australians for 4,500m2 of roof sheeting and safety cladding that wrapped around the four decades to come. mesh, 550m2 of stainless steel corners of the boardroom and wide perforated wall cladding, 2,500m2 of glass windows. The boardroom is heavy duty insulation blanket to roof situated on the first floor and overlooks areas, 1,000 lineal metres of insulation the ground floor, providing an eye purlin spacers, 1,250m2 of insulated catching feature when you first enter wall panels and 80m2 of Anthra VM zinc the premises. cladding to the featured board room.

12 THE WORKS KEY FEATURES OF THE RFDS ADELAIDE BASE INCLUDE: f Stretcher bay to manage eight patients comfortably f Stabilisation bay for acute patients f Refreshment facilities for seated patients and escorts f Multiple under cover ambulance parking bays f Private rest quarters / amenities for crews f Hangar to house six Pilatus PC-12 aircraft f Capacity for nine aircraft on the tarmac apron f State-of-the-art engineering maintenance store and workshop SUPERMARKET GIANT MOVES INTO NEW DISTRIBUTION CENTRE

DISCOUNT SUPERMARKET The warehouse building pad required Utilising Revolution Roofing’s mobile GIANT ALDI RECENTLY complex detailed earthworks to allow for mill, the McMahon Services team were EXPANDED INTO ADELAIDE, the formation of set downs for the freezer able to roll the roofing sheets on site CONSTRUCTING A NEW slab and edge thickenings. McMahon at lengths of up to 53 metres long. 30,000M2 DISTRIBUTION Services also constructed all heavy duty This provided significant efficiencies concrete pavements required for the in the construction program and cost CENTRE IN REGENCY PARK. distribution centre, including final trim, savings. Due to the limited workspace, subgrade compaction and installation of coordination between the rolling of the Engaged by Head Contractor, BADGE, heavy duty kerbing. sheets and the crane lifting the sheets McMahon Services completed a number onto the roof structure required extensive of key construction components of the Construction of the carpark and internal pre-planning to minimise any impacts on new Distribution Centre ranging from road included all bulk and detailed the other site works. earthworks to roofing and cladding. earthworks, subgrade compaction and supply and placement of asphalt surface The new purpose-built facilities located to design levels. The final scope for the at the eight hectare site in Regency PROJECT CHALLENGES civil team included carpark line marking, Park included ambient and temperature installation of pram ramps, transformer controlled warehousing space, ancillary The soft subgrade encountered on slab construction and respread of top buildings, associated hardstand and site created a major issue. McMahon soil to landscaped areas. office space. The massive facility will Services worked collaboratively with act as the hub of ALDI’s SA Region BADGE to undertake multiple trial Distribution Centre, and has the ability to areas to determine the best, most cost service up to 50 stores. ROOFING & CLADDING effective, soft spot treatment.

McMahon Services also secured the The overall method adopted meant that roofing and wall cladding packages for approximately 6,000 tonne of 75mm CIVIL CONSTRUCTION the new ALDI Distribution Centre. A team ballast had to be imported, with an of eight specialist roofers completed the additional 14,000 tonne of rubble being As first contractors on site, McMahon installation of the following: placed to bridge the soft spots. Services completed all early earthworks packages including bulk strip-out f 20,000m2 of Kingklip 700 colorbond Our roofing team had the challenging of the 30,000m2 area to create a roof sheets task of executing their works during the level site to enable construction of f 2,500m2 of True Oak Super 5 winter months, which often provided high the building plateau and heavy duty colorbond wall sheets winds and rain events. This presented concrete pavements. Site preparation significant challenges when dealing works consisted of the construction f Safety mesh to the roofing area with the long 53 metre lengths of roof and removal of temporary ramps for f R2.5 100mm medium duty foil faced sheeting. Additional precautions and the piling rig and the placement of permastop insulation blanket to roof safety measures were taken to ensure a 130mm capping layer including area safe execution of the works at all times, the provision of WG80 geofabric. with close collaboration between crane f Medium duty sisalation to walls operators, riggers and roofers. All works

f 32 colorbond half cylinder rain were completed without incident and

heads within the client’s strict timeframe.

f 200 lineal metres of 300mm colorbond half round eave gutters with external brackets and pops

f 32 PVC downpipes and 0.55 colorbond flashings 14 THE WORKS The new purpose-built facilities located at the eight hectare site in Regency Park included ambient and temperature controlled warehousing space, ancillary buildings, associated hardstand and office space

THE WORKS 15 FOOD AND BEVERAGE CONSTRUCTION SERVICES

MCMAHON SERVICES OFFER A STREAMLINED APPROACH TO CONSTRUCTION PROJECTS WITHIN THE FOOD AND BEVERAGE SECTOR ACROSS AUSTRALIA.

With over 25 years’ experience, we have food grade materials and products, We are flexible with our contracting completed a wide range of projects construction sequencing and models and delivery approach. within food and beverage processing construction separation, delineation Through our strong relationships with environments and understand the and work flow planning. specialist consultants and process challenges associated with this type of technology suppliers we can offer work. With over 500 full-time personnel complete end-to-end solutions, or we across Australia and significant in- can simply provide construction only Food and beverage processing and house trades, McMahon Services offer services. manufacturing facilities require special a wide range of building services to consideration to food hygiene and food accommodate the food and beverage safety standards when undertaking sector. From scope rationalisation and construction activities. Our personnel buildability advice, through to design, ‘McMahon Services have a strong understanding of engineering, budget estimates, food grade standards and the planning and on-site construction, we offer a wide range of specific construction and interface can work with our clients to provide a requirements of fully operational complete project solution. building services to facilities to ensure food safety is accommodate the maintained whilst providing compliant Our demonstrated track record and project delivery. long-term relationships with clients food and beverage such as Lion, McCain, Coca-Cola, These food safety requirements flow Weston Milling, Mauri ANZ, Balfours sector’ right through the project lifecycle and Schweppes, is testament to our including design of food safe systems strong project delivery. and associated products, selection of

16 THE WORKS OUR RANGE OF SERVICES INCLUDE: f Structural concrete works including; f Roofing, cladding and sandwich KEY PROJECTS piling, footings, slabs, pavements panel installations and upgrades and retaining walls and flooring f Lion West End Brewery - f Asbestos and hazardous material toppings Hyde Park, SA audits, removal and remediation f Civil / earthworks including; detailed f Lion Dairy & Drink - Wetherill Park, f Building trade works including; excavation and pad prep and NSW carpentry, painting, tiling, ceilings trenching services and linings, glazing of aluminium f Tooheys – Lidcombe, NSW f Demolition works including; framing and flooring f Boags – Launceston, TAS standard demolition and process f Structural steel works including; plant removal and salvaging f Weston Milling - Port Adelaide, SA building extensions, platforms and f Concrete toppings and remediation landings, pipe bridges and access f McCain – Lisarow, NSW including; epoxy coatings and floor stairs and landings coving repairs f Weston Milling - North Melbourne, f Building refurbishment including; VIC f Electrical upgrades or installations office and administration upgrades, DDA compliance upgrades, wet f Schweppes – Thebarton, SA f Hydraulic services upgrades or area and amenities refurbishment installations including; trade waste, f Americold – Arndell, NSW as well as building façade upgrades sewer, water or fire protection f Americold - Prospect, NSW upgrades f Mechanical HVAC and chiller plant installations and upgrades THE WORKS 17 18 THE WORKS Feature Project: Mccain Foods australia

McMahon ServiceS have food preparation environment below, ‘Done it again’ aS they presenting significant programming SliceD through the and sequencing challenges to ensure highly coMplex roof continuous food processing. The third rectification project key challenge was the unpredicted, high rainfall of the NSW Central Coast for Mccain fooDS region. auStralia at their liSarow facility in nSw. Despite all significant challenges faced, McMahon Services successfully The McCain facility at Lisarow was completed the rectification works with designed and built by Austin Anderson minimal interruption to operational (US Firm) in the early 1970’s as the food processing to the delight of the first Sara Lee Factory in Australia. client. This was achieved by: McCain recently acquired the Sara Lee facility, which has grown to exceed an f Project planning workshops with all 18,000m2 footprint during a number key stakeholders of small expansions. A third-party f Outstanding collaboration and engineering assessment of the facility close communication throughout revealed the need for significant project roofing rectification and McMahon Services was engaged to self-perform f Work zone delineation between the complex contract over a 12 month construction and food preparation period. zones f Stringent food grade PPE worn by Following an intensive tendering construction staff at all times process, McMahon Services was awarded the complex contract to f Flexibility with our work crew roster undertake remedial works of the to accommodate weekend work, ceiling and external roof structures. every week The detailed scope of works involved f Design of structures that required 2 removal and replacement of 18,000m minimal site works to minimise of roof structure, structural steel construction times fabrication and erection, removal and replacement of 4,500m2 of insulated f Weekly food safety risk panel ceilings, installation of new fire assessments and site walks to services upgrade within the factory maintain compliance and mechanical extraction upgrades. f Weekly progress / reporting meetings

This project was particularly testing for This project followed on from the the team as it presented a combination successful completion of other food of significant challenges. Firstly, the grade projects for clients such as Lion, works were required to be undertaken Weston Milling, San Remo, Coca Cola in a fully operational food processing and Schweppes. McMahon Services facility and required food grade look forward to working with other standards to be upheld throughout clients into the future as we continue the 12-month program. Secondly, the to grow our experience and capacity in rectification works occurred in the the food and beverage sector. ceiling and roof spaces above the

THE WORKS 19 AUGUSTA POWER STATIONS DECOMMISSIONING

MCMAHON SERVICES AND At 9.40am Monday, 9 May 2016, the in accordance with our core values FLINDERS POWER ARE Port Augusta Power Station officially of Safety, Teamwork, Leadership and WORKING IN ALLIANCE stopped generating power. McMahon Integrity. TO SET A NEW STANDARD Services, in Alliance with Flinders FOR THE CLOSURE OF Power are currently undertaking the McMahon Services were engaged demolition of the Augusta Power in September 2015 to conduct an ELECTRICITY GENERATION Stations, including Northern Power extensive early works phase. The early OPERATIONS. THIS Station, Playford A and Playford B works agreement enabled McMahon SUPPORTS OUR AIM TO SET Power Stations. The decommissioning Services in partnership with Flinders A BENCHMARK FOR SAFETY includes the removal of friable and Power to meticulously investigate and AND BEST PRACTICE FOR non-friable asbestos and demolition plan the works required for the safe FUTURE COAL FIRED POWER via mechanical and charge felling and effective decommissioning of the STATION AND ASSOCIATED means. Augusta Power Stations. MINE CLOSURES IN AUSTRALIA. Flinders Power Partnership and The early works agreement was McMahon Services have formed an completed over a six month period The Augusta Power Stations have a long alliance to create a single, unified team with key management staff on site and valued history providing reliable to jointly manage the planning, asset working with Flinders Power during generation to the South Australian salvage and decommissioning works operations and shutdown period. and National Electricity Market. The of the project. The successful delivery Detailed programs and cost plans were 90MW Playford A Power Station was of this project relies on the combined developed during this period which commissioned on reclaimed land efforts of both Flinders Power and complemented a full suite of project at the northern tip of Spencer Gulf McMahon Services. This is a dynamic plans endorsed by client, regulator in 1954. The site was subsequently partnership where both Flinders Power and independent consultants. expanded to accommodate the 240MW and McMahon Services create a single Playford B Power Station, which was team, working collaboratively and The site has a long and proud history commissioned in 1963. Generation cooperatively to make best-for-project and is prominent in the region. The was secured through the utilisation of decisions to achieve the project closure program has a high degree of the Leigh Creek Coalfields, and the outcomes. community interest and The Alliance construction of a 250km dedicated commits to engaging in an open and rail line connection. In the early This is a unique delivery model for collaborative fashion. 1980’s an adjacent site was prepared McMahon Services, with an Alliance at Port Augusta, culminating in the Leadership Team formed with construction of the 520MW Northern Flinders Power who share our strong Power Station in 1985. commitment to delivering the project

20 THE WORKS CHARGE FELLING MECHANICAL DEMOLITION COMMUNITY ENGAGEMENT

McMahon Services and Flinders Power McMahon Services utilises in-house McMahon Services (the principal have worked closely with specialist plant and equipment, consisting of decommissioning contractor) has demolition contractor Precision large demolition machinery, including directly employed local labour whose Demolition to undertake some of the a Komatsu PC 1250 excavator skills meet the project requirements. largest and most complex charge specifically designed for demolition Local businesses have been regularly felling works in Australia. In September works with a custom designed engaged to support the project 2016 the significantly deteriorated demolition attachment allowing for a and strong working relationships 60 year old Playford A Stack was reach of up to 44 metres. In support established during sensitive closures. successfully and safely felled, reaching of this, McMahon Services provide a the first major milestone in the two range of excavators including Komatsu The Alliance provide regular project year decommissioning program of the PC 850, PC 450, PC 300, PC 220 and updates to workforce and local Power Stations. smaller. community in the form of newsletters, regular face-to-face meetings with Appropriate exclusion zones (land We have a wide range of cranes, local government authorities and and sea) were strictly enforced by working at heights equipment and emergency services, as well as SA Police and security contractors, heavy haulage plant. Further to this frequent project status reports to ensuring personnel and public safety. fleet, McMahon Services, in partnership stakeholders and regulatory bodies. with Komatsu have commissioned the A detailed Stakeholder Management Flinders Power Managing Director, largest excavator shear attachment in Plan has allowed for the open and Michael Riches said “felling of the the world; specially designed to fit our effective communication between the stack early in the two year program new 400 tonne demolition excavator. Alliance and all project stakeholders. allows for more efficient demolition of McMahon Services have provided other areas of the site and enhances dedicated on-site mechanics and safety for personnel working in and boilermakers on the project to ensure around the ‘Active Demolition Zone’ at machines operate with minimum Playford.” said Michael. stand-down time and at maximum safety standard. Plans are currently in place to fell the remaining two exhaust stacks, being 200 metres and 79.25 metres in height. Detailed engineering and design works are underway for the separation and felling of two off 80 metres high hanging boilers with structural steel columns up to 2 metres in section and 70mm thick. The project will see the use of approved on-site magazines along with international shipments and licenced import of explosive charges.

THE WORKS 21 EXPRESS DEMOLITION IN ADELAIDE CBD

DEMOLITION OF A THREE- safe work site with heavy duty hoarding By adopting a collaborative approach, STOREY BUILDING LOCATED providing a delineation between the the works were successfully delivered AT 62-68 HINDLEY STREET, public and work activities. by the McMahon Services project team. AND DEMOLITION OF Potential issues associated with the AN ADJACENT TWO- Demolition of the buildings began with the surrounding stakeholders and stability removal the underside of the slabs and of adjoining structures were successfully STOREY BUILDING AND footings, and all nominated pavement managed throughout the works. The SINGLE-STOREY BUILDING surfaces including bitumen, kerbs and risks associated these works were UNDERTAKEN IN BLYTH gutters. The specialist demolition crew successfully managed without incident STREET, IN ADELAIDE’S CBD. then removed the redundant retaining or damage to property, personnel or the walls and all demolition waste from the environment. The iconic site, situated over 1,785 site. square metres is being transformed into a new 245 room ‘Holiday Inn Express’ Excavation to the underside of the ‘Demolition is a hotel focusing on limited services at new basement / ground slab level was reasonable prices for business travellers completed making allowances for high risk activity, and short-term stays. compaction of surfaces where required. Backfill of the existing northern basement which is heightened Demolition is a high risk activity, which was required also with approved fill is heightened when working in restricted material and compaction in accordance when working in CBD locations, with limited access and with geotechnical requirements. restricted CBD continual interaction with the public. Site establishment was critical to ensuring a locations’

22 THE WORKS MCMAHON SERVICES LAUNCHES STATE OF THE ART WEBSITE REGIONAL

Technology is constantly changing and at McMahon Services, we like to stay ahead of the pack. So we have invested EXPANSION in a brand new website that allows us to effectively communicate with our current and potential customers through a state NORTHERN GROWTH of the art digital platform

The new website, which was six months in the making, is exceptionally user and CONTINUES mobile friendly and showcases our diverse projects and capabilities that can be viewed on all devices. AS PART OF OUR ORGANIC GROWTH STRATEGY, MCMAHON The new website comprises of our latest SERVICES HAS RECENTLY OPENED UP REGIONAL OFFICES IN projects, up to date news, employment TOWNSVILLE, QLD AND KATHERINE, NT. opportunities, as well as the ability to read bio’s on our management team from KATHERINE - NT TOWNSVILLE - QLD across the country. The new Katherine office is situated Following the establishment of a Visit the site now at in the main industrial precinct, on the satellite project office in Townsville www.mcmservices.com.au Eastern side of Katherine, close to during 2015, the decision was made RAAF Base Tindal. Our new 4,000m2 to find a more permanent home. A facility comprises office compound, new larger facility was found in a laydown area storage building. conveniently located Industrial Estate in Mount St John earlier this year. Heading up the Katherine office is Bernie Pollard who brings 20 years of The Townsville office is proving to be a construction experience after working key location for the McMahon Services‘ many years in Western Australia, New Queensland business complementing South Wales and Queensland. Bernie the Brisbane and Gladstone teams commenced with McMahon Services and growing our presence in the North in July this year and has relocated to of Australia. Katherine from Brisbane. Michael Brennan leads the team in Our move to establish an office in Townsville, a qualified carpenter with Katherine was a strategic initiative over 30 years’ experience working on aimed at increasing services to our domestic, commercial and industrial existing clients, whilst providing further building projects. depth and capability to cater for increased enquiry levels in the region. With a strong focus on facilities and building maintenance, the Townsville The Katherine office will enable team has grown quickly ranging from recruitment of local workers through Project Management, Administration the creation of local job opportunities, and key trades including Electrician, building capacity in the town and Plumber, Carpenter, Painter and a also focusing on the training and Refrigeration and Diesel Mechanic. employment of local Indigenous people.

THE WORKS 23 PARNKALLA 90% OF OUR WORK FORCE WERE EMPLOYED FROM WATERS THE LOCAL COMMUNITY

MCMAHON SERVICES This unique project incorporated The specific geographical location of WERE ENGAGED BY all forms of site preparation works. the project posed some significant SARIN PROPERTY GROUP Over 150,000m3 of bulk earthworks challenges for our team. This included TO UNDERTAKE THIS was required to construct the man working in and around ground water EXTENSIVE RESIDENTIAL made beach which also included and tidal flows from the neighbouring the construction of 900 lineal metres marina. This was particularly evident SUBDIVISION PROJECT of 1m high architecturally designed with the installation of deep services AS PART OF THE LINCOLN retaining wall and placement for the sewerage infrastructure. COVE MARINA EXPANSION of 8,000 tonne of beach sand. IN PORT LINCOLN, SOUTH To overcome this, two six inch pumps AUSTRALIA. In excess of 6,000 tonne of 300mm were utilised operating 24 hours a day rock revetment was placed, and for over four months. Additionally, The project was split into two stages, 34 residential building plots were a series of wells were excavated to a lakeside residential area named prepared. enable water to be pumped away “Parnkalla Waters” and a larger from the work zones. This method was residential area named “South Lakes” The project team also constructed extremely effective, and meant we did situated on deep-water canals with all sewer, water and common not need to drive heavy earthmoving frontage for private pontoons. services infrastructure required for equipment into the marina to undertake the subdivision, which included two the installation of the infrastructure. McMahon Services self-delivered transformers, lighting poles and NBN Stage One – Parnkalla Waters to pits. Additionally, over 380 lineal Innovative techniques when pouring transform the low lying swamp into a 34 metres of stormwater pipe ranging the triple cell culvert were utilised. The waterfront allotment marina subdivision from 375mm to 1200mm and a 22 team were able to specially design complete with essential infrastructure, metres long triple cell culvert was also the head walls in precast concrete so asphalt roads, concrete footpaths, installed as part of the detailed civil they could be lifted directly into place, limestone block retaining walls with works. instead of pouring the head walls in- steps down to the new constructed situ. Each head wall weighed over 10 sand beach and water reserve. Roadworks for the project included tonne and was installed in two hours sub-base course and asphalt as opposed to in excess of one week placement, over 1.25km of kerbing and each for form and pour if we were to the installation of nearly 200 metres of have used the conventional method. guard rail. CHALLENGES

24 THE WORKS During the construction of the project a number of significant sewer changes were required, which included the addition of a pump station in St Andrews Drive. This also included the decommissioning and conversion of an existing pump station, along with a connection into the existing pumping main. In order to assist our client with the total delivery of the project, McMahon Services offered to undertake all of the electrical service and NBN works including all coordination and liaison with SA Power Networks for connections.

Strong communication with residents and the collaborative approach between the client and McMahon Services was imperative to the successful delivery of the project.

In addition, 90% of our work force were employed from the local community, and multiple small businesses in the region were engaged to deliver services for the project.

THE WORKS 25 INTRACT ACHIEVES FEDERAL SAFETY ACCREDITATION

INTRACT AUSTRALIA HAS WHAT IS INDIRECTLY TAKEN ANOTHER HUGE FUNDED BUILDING WORK? STEP TOWARDS BECOMING f Projects are considered indirectly AUSTRALIA’S LEADING funded where an Australian INDIGENOUS ENTERPRISE. Government agency contributes On Friday 4th March 2016, Intract funding to a third party recipient, Australia Pty Ltd was awarded Joint such as a state government, Accreditation with McMahon Services through mechanisms such as under the Australian Government funding agreements, grants and Building and Construction WHS other programs, for example road Accreditation Scheme (the scheme). construction projects funded by the Australian Government or a new Subject to certain financial thresholds, school built by a state government only builders who are accredited under using funding provided by the the Scheme can enter into head contracts Australian Government. for building work that is funded directly or indirectly by the Australian Government. f The Scheme applies to projects that are indirectly funded by the WHAT IS DIRECTLY FUNDED Australian Government where: BUILDING WORK? f The value of the Australian Projects are considered to be directly Government contribution to the funded where an Australian Government project is at least $6 million and agency has responsibility for the project represents at least 50 per cent of the funding and development, for example a total construction project value; or Defence facility, Medicare or Centrelink Office or a fit-out or refurbishment of f The Australian Government existing Australian Government office contribution to a project is $10 accommodation. million or more, irrespective of the proportion of Australian Government The Scheme applies to projects that funding; and are directly funded by the Australian Government with a value of $4 million or f The head contracts for building more. work are greater than $4 million (GST inclusive). f This is a significant achievement for Intract as we continue to strive for excellence in the training and employment of Indigenous Australians.

26 THE WORKS BULEY ROCKHOLE INTRACT AUSTRALIA Former Parks and Wildlife Minister Bess “This will also enable visitors to easily SUCCESSFULLY DELIVERED Price said $1.3 million in upgrades had and comfortably disperse across the site A SIGNIFICANT PACKAGE been completed to cater for increasing to enjoy the site’s facilities,” she said. visitor numbers and protect the park’s OF WORKS ON THE $1.3 “The new and improved sealed carpark significant natural and cultural values. MILLION BULEY ROCKHOLE will service the new day-use area and UPGRADE, INCLUDING THE “Buley Rockhole is a key drawcard for rockholes, while minimising congestion. tourism to Litchfield National Park and is RELOCATION AND SEALING “I’m really excited that the public can also favoured by Darwin locals,” Minister OF THE CARPARK, AND NEW now start to enjoy these upgrades.” Price said. SHADED SHELTERS AND Parks and Wildlife Commission of the FOOTPATH. “With Buley Rockhole’s rising popularity, NT Chief Executive Andrew Bridges said The project forms part of the $10.43 overcrowding was a major issue so the “The upgrades will enhance the visitor million investment by the Territory redesign of this popular site was essential experience” to meet the increased demand.” Government to improve facilities at “Litchfield National Park is one of the various locations in the iconic Litchfield Minister Price said visitors are now Territory’s most popular tourist attractions National Park. able to picnic away from the rockholes and it plays a key role in supporting, themselves and enjoy the new day- building and enhancing the Territory’s use area which include five new tourism industry and the Territory’s shaded shelters, picnic tables and reputation as a must see destination,” a new easily-accessible footpath. he said. THE WORKS 27 PRIME

Intract Australia Director, Michael Rotumah was one of 21 young MINISTER’S Indigenous entrepreneurs and innovators featured at the Prime Minister’s reception for young Indigenous businesses and entrepreneurs earlier this year. The reception celebrated the achievements of Indigenous businesses and their contribution to RECEPTION FOR economic development and the innovation agenda. The event showcased young Indigenous entrepreneurs and connected them with influential business leaders and also encouraged corporate INDIGENOUS leaders to continue their efforts to increase Indigenous employment and supplier use.

Indigenous innovators and entrepreneurs, Indigenous Advisory INNOVATORS AND Council members and senior Indigenous leaders were all brought together at the event, which also included representatives from the peak industry bodies and major corporations who have played a leading role in supporting Indigenous economic participation.

ENTREPRENEURS Prime Minister of Australia, the Hon Malcolm Turnbull MP and Minister for Indigenous Affairs, Senator Nigel Scullion were both present.

28 THE WORKS BATCHELOR INSTITUTE OF INDIGENOUS TERTIARY EDUCATION

NORTHERN Following the commencement of early discussions between the Batchelor Institute of Indigenous Tertiary Education (BIITE) and Intract Australia, a mutually beneficial relationship CONNECTOR was born. Intract were contracted to undertake various building works at the BIITE campus located at the doorstep of the Litchfield National Park in the EARLY WORKS Northern Territory. The initial works included painting, carpeting, asbestos Intract Australia recently completed Each embankment was constructed removal, wall demolition, structural early works as part of the new in three stages at pegged locations steel erection, café renovation and Northern Connector project in specified by the client initially filling entrance signage. South Australia - a new non-stop to approximately three metres in motorway connecting the already height. With Intract supplying majority completed Northern Expressway Indigenous labour, these packages and South Road Superway, The first stage consisted of the of work were a great success story providing an unimpeded trip from initial fill and then the areas were providing significant local Indigenous Gawler to Regency Park, totalling allowed to settle for a period of employment outcomes. 43 kilometres. four weeks before a further one metre high layer was placed with a Following the success of the initial The proposed road alignment final one metre layer added after a building works, BIITE awarded Intract intersects the Ridley Salt Pans, further four weeks. another contract to refurbish 18 providing complicated geotechnical Student Accommodation Units at the conditions. As part of the early Approximately 40,000 tonnes of Batchelor Campus. These works were works to facilitate appropriate brine mud was used from on-site completed with a leading team of road design, Intract Australia stockpiles with between 500 and Indigenous Employees, most of whom were contracted directly by the 700 tonnes of material placed each were sourced through Karen Sheldon Department of Planning, Transport day. Training as job-ready trainees. 85% of and Infrastructure to construct the trainees have since been engaged three trial embankments along the by Intract Australia on full time basis proposed road alignments through and actively working in the business on the salt pans. other projects.

THE WORKS 29 PORT BONYTHON

FUELS

MCMAHON SERVICES McMahon Services were awarded DELIVER EXTENSIVE the Structural, Mechanical and Piping STRUCTURAL, MECHANICAL scope of works on the project. This AND PIPING WORKS AS included the supply of all materials PART OF THE NEW PORT where required, all skilled labour, management and supervision of key BONYTHON DIESEL FUEL subcontractors, set out and survey, STORAGE TERMINAL. provision of plant and equipment, tools, plant consumables, transport, crane Port Bonython Fuels Ltd have services, temporary works, testing and developed a new diesel storage commissioning to complete the works. terminal that receives diesel via a shipping pipeline from tanker ships McMahon Services made a strong berthed at the existing Santos Fuel commitment to the client to utilise as Berth in Port Bonython, South Australia. much local labour and sub-contractors as possible to deliver the contract. To The state-of-the-art fuel terminal our advantage, we were able to engage located approximately 25 kilometres with our local branch office in Whyalla north of Whyalla and 80 kilometres and several of the key management South of Port Augusta is the largest resources were very experienced diesel fuel storage facility in South working in this specific region. Australia. The $80 million project was commissioned in May 2016 and employed over 130 people at peak construction time. PROJECT CHALLENGES

The terminal features three 27ML The site is very exposed to the sea and diesel storage tanks, two bay gantry, is notorious for strong winds. McMahon each bay with three arms (2,400 LPM Services tailored our execution per arm), vehicle access for up to triple strategy to ensure the works could road trains, access to deep water port be progressed in accordance with via existing uncongested jetty, modern the schedule. This included the use driver and administration facilities. of smaller articulated mobile cranes rather than hydraulic slew cranes due The new modern fuel storage facility to the ability to safely operate at higher incorporates high environmental wind conditions. controls with full operational and support infrastructure. The This region is also well known for construction of the new plant also extremely hot weather during summer includes significant provisions for and exceptionally cold climates during future growth and expansion across winter. Once again we demonstrated multiple fuels. our ability to effectively manage and plan works in these conditions, including the execution of appropriate fatigue management systems, excellent site facilities and work environments, extensive use of mobile shade structures and wind breaks.

30 THE WORKS THE WORKS 31 VICTOR HARBOR FORESHORE BOARDWALK UPGRADE

MCMAHON SERVICES DEMONSTRATED OUR DIVERSE BUILDING CAPABILITIES BY CONSTRUCTING THE NEW SCOPE OF WORKS BOARDWALK AS PART OF A MAJOR PRECINCT UPGRADE. f Site clearing The Main Street Precinct Upgrade will see the heart of Victor Harbor’s Town f Demolition of existing retaining wall Centre transformed into a vibrant public space that celebrates the town’s and remedial works character, encourages more activity and improves the links with other areas of the Town Centre. f Boardwalk construction: f Impact driven piles In addition to the Precinct Upgrade McMahon Services were engaged directly by the City of Victor Harbor to undertake Stage Three of the Foreshore Promenade f Form concrete abutment bikeway development. structures

The construction of the boardwalk connects the Foreshore Car Park via the f Composite square-hollow-section coastal dunes to the Causeway Plaza, a distance of approximately 75 metres. framework construction f Boardwalk supply and installation The site was in close proximity to many public facilities including the historic and family favourite horse drawn tram, mini golf course, public carpark and f Handrail supply and installation a local café. This required strong community and stakeholder engagement f Pavement adjustment and remedial throughout the project to ensure minimal disruption to the day-to-day operations works of surrounding businesses and patrons. f Safety railing installation.

32 THE WORKS All AboArd Flinders Ports UPgrAdes

McMahon ServiceS haS of deterioration. Works needed to occur The heavy loads imposed have caused undertaken a nuMber within a short window of opportunity the subgrade zone between four and 15 of individual upgrade between shipments. metres below finished level to undergo secondary settlement. The subsidence projectS for flinderS The project scope included the removal has created issues with stormwater portS over the laSt 12 of existing crane rail, hydro-excavation, runoff, container stacking and vertical MonthS at the flinderS setting up new base plates and alignments. adelaide container installation of fixings, final levelling and terMinal, outer harbor. placement of new 12 metres rail sections. Our specialist civil team undertook Once the new rail was laid, an infill of fast profiling of the top layers of asphalt Flinders Ports are South Australia’s setting epoxy grout was installed in order and engineered to fill to nominal depths leading privately-owned port operator, to infill all voids around the underside of between 200mm to 250mm across the operating seven ports throughout the the crane rail. Once the epoxy had cured, site. We then placed and compacted State located at Port Adelaide, Port placement and compaction of bitumen clean engineered fill, two layers of Lincoln, Port Pirie, Thevenard, Port Giles, was finally undertaken. asphalt, applied a spray primer and Wallaroo and Klein Point. undertook final line marking. McMahon Services have successfully berth 29 hardStand repairS Due to the fully operational Maritime completed a range of projects for Security Zone, McMahon Services Flinders Ports including crane rail repairs McMahon Services were contracted to required a collaborative approach in and Berth 29 hardstand repairs at the undertake remedial hardstand repairs terms of shipping schedules, internal Flinders Adelaide Container Terminal, to approximately 20,000m2 of 90 tonne road users and rail operations, all Outer Harbor. axle load rated hardstand, affected by needing to remain priority throughout the subsidence at Berth 29. works. crane rail repairS The existing 25,000m2 hardstand construction was completed in This project involved the removal and September 2013 and has been subjected replacement of 96 metres of existing to the stacking and movement of crane rail which was showing symptoms containers continuously since that time.

THE WORKS 33 COLOSSAL DECOMMISSIONING IN THE NORTH WEST

MCMAHON SERVICES As the project was in a Category 3 modified at our Adelaide workshop WERE CONTRACTED TO Cyclone passage, the ability to prepare into high reach machines (20 metres DECOMMISSION VARIOUS and make safe for Cyclonic conditions and 22 metres respectively) and were REDUNDANT ASSETS within 72 hours was put to the test with pivotal in the success of the project, WITHIN THE NORTH YARD the arrival of Cyclone Owyn. providing the required reach and capacity for the elevated structures AT BHP BILLITON’S (BHPB) Another key challenge was the sheer and heavy duty steelwork. NELSON POINT IRON ORE volume of steel structures to be PRODUCTION FACILITY, IN demolished. Almost seven and half The Conveyor systems were typically PORT HEDLAND, WESTERN thousand tonnes of steel needed to be demolished first, to isolate the AUSTRALIA. processed from the redundant assets remaining structures. Substantial within the client’s timeframe. The lengths of conveyor were removed, The massive decommissioning project majority of these structures required ranging from low level work carried out primarily consisted of the demolition detailed structural engineering and with a 45t or 75t excavator, to high level of specialised iron ore bulk handling risk assessments plans prior to any work (up to 20 metres high), requiring equipment, including; 4km of conveyor demolition to ensure safe operations. lift studies and complex crane work. system, seven Transfer Stations, a Dust Collector, two Surge Bins, a Sample Due to the nature of the site, a In total there were seven Transfer Station, two Shiploaders, a Stacker traditional method of demolition was Stations to be demolished, ranging and a Bucket Wheel Reclaimer. eliminated, and mechanical shearing in height from 5 metres to 18 metres. was adopted as the preferred method These necessitated some crane lifts A number of unique factors combined of demolition. This method was to remove heavy equipment such as to make this project particularly favoured to reduce the need to access motors, gearboxes and heavy chutes. challenging. Located in the far North the plant and equipment and removed Through the use of the specialist high West of Western Australia meant personnel from the ‘line of fire’. reach excavators, the structures were extreme weather conditions were able to be removed by mechanical encountered with temperatures often Two new specialist excavators were shearing. in excess of 45 degrees. purchased specifically for this project; a Komatsu PC850 and a Komatsu PC1250. These machines were

34 THE WORKS In a few instances, the stability of the INNOVATION equipment was such that close access during demolition was considered McMahon Services are continually reviewing our work practices to improve unsafe, including with an excavator, safety and efficiency, and reduce impacts on the environment. On this and as a result explosive felling was particular project, several of the structures within the scope were coated proposed. This was the case for the with Gilsomastic paint, which contains fibres of white asbestos. Stacker and the Reclaimer, which were rail operated balance machines. Prior The scope of work provided by the client required this steel to be disposed of to the demolition, the machines were to landfill. McMahon Services proposed an alternative which was to recycle decommissioned and relocated to an the scrap steel at an overseas steel processing plant. This required approval area suitable for the explosive felling. from the Commonwealth Government under the Basel Convention, leading to a high level of management and chain of custody procedures. Shearing of the steelwork, following the felling, was carried out with the PC850 An extensive sampling program was undertaken on the Gilsomastic paint and PC1250 excavators. This method system using scanning electron microscopy (SEM) coupled with energy minimised interaction with adjacent dispersive spectroscopy (EDS) to enable a quantitative assessment of the operational activities, significantly asbestos, and in turn provide a robust procedure that allowed the scrap improved safety and minimised labour steel to be exported to an overseas steel processing plant as scrap steel, as time. For all explosive felling, 3D opposed to asbestos waste. simulation models were developed, approval was gained from the Mines The steel was reduced in size to 800mm x 600mm pieces for direct feed Department and trial explosive cuts into the furnace without further processing, with all of the steel packed and were carried out. sealed into 300 sea containers for transportation.

In addition to all above-ground This recycling process saved the project approximately $3 million and rated demolition, we backfilled over 1,500m3 very highly on the waste management hierarchy by diverting in excess of of sumps, and rehabilitated the site 5,000 tonnes of material from landfill, whilst meeting required human health, with 9,311 tonnes of river rock as a environmental and regulatory standards. This was the first time this approach cover material, including the addition to Gilsomastic painted scrap steel had occurred in Australia. of dust suppression additives where required. THE WORKS 35 NORTHERN BEACHES ROAD UPGRADE – DEMOLITION PACKAGE

MCMAHON SERVICES Street houses and nursing home, nine Additional asbestos containing materials COMPLETED SIGNIFICANT buildings within the former Bantry Bay (ACM) were also encountered during DEMOLITION OF Road Shopping Precinct and four demolition of buildings. This required PROPERTIES AS PART OF buildings at the Fitzpatrick site. an additional hazmat report to include THE NORTHERN BEACHES all ACM products within the properties McMahon Services were awarded before further demolition activities could HOSPITAL CONNECTIVITY additional scope throughout the commence. AND NETWORK execution of the works including the ENHANCEMENT PROJECT. remediation of a 7-11 service station. When buildings had been cleared, it was noted that ACM products not The NSW Government is investing $500 The former 7-11 service station on found in the buildings themselves were million to upgrade the roads around the Warringah Road had been operating becoming apparent in surrounding new Northern Beaches Hospital with since the early 1970’s. During this time soils of properties. Additional testing / work proposed to be completed in time it had many remedial upgrades due to sampling and reporting was carried out for the hospital opening in 2018. The hydrocarbons leaking into the ground and the conclusion was that three of the upgrades will provide customers with and surrounding areas. four sites were all built on imported fill a better travel experience, increased containing ACM. capacity on the road network and McMahon Services were challenged improved access through the area, with removing the old fibreglass tanks Careful management was required due including for pedestrians and cyclists. without disturbing or placing at risk, the to the high-risk nature of working with existing road infrastructure on Warringah asbestos and the potential for public Ferrovial York Joint Venture (FYJV) were Road and Hilmer Street. After thorough concern. As industry leaders in the engaged by Roads and Maritime to investigation, an engineered solution was management of asbestos, McMahon carry out the project. FYJV contracted adopted based on existing soil reports Services were able to effectively McMahon Services to undertake the and boreholes. This enabled us to dig manage the ACM utilising in-house demolition of a number of residential nearly 7m down to remove and validate trained personnel within our demolition and commercial buildings including the remaining soils, whilst maintaining a team. Our personnel were able to removal of asbestos. 2 metre buffer zone from the footpath quickly implement all required asbestos that remained operational for pedestrian systems and procedures to ensure the The demolition of properties within the access throughout the process. contaminated material was removed and Frenchs Forrest area included Hilmer disposed of safely.

36 THE WORKS QUEENSLAND ALUMINA LIMITED MAINTENANCE CONTRACT

QUEENSLAND ALUMINA In addition to asbestos removal, the These ‘neg-air’ units maintain a minimum LIMITED (QAL) IS ONE OF team comprises of carpenters to build of six air changes per hour and fitted with THE LARGEST ALUMINA asbestos removal enclosures, scaffolders High Efficiency Particulate Air (HEPA) REFINERIES BY ALUMINA to provide safe access to plant, insulation filters and internal pre filters. PRODUCTION CAPACITY IN installers (laggers) and sheet metal workers to re-clad the working plant. Plant Another measure to eliminate heat THE WORLD, LOCATED IN conditions are hot and relatively hostile stress involves crews wearing specially GLADSTONE, QUEENSLAND. requiring the utmost care, preparation designed under-garments. This and planning employing world’s best garment is worn close to the body and Operating since 1967, the refinery has a practice techniques to execute a program contains tubes continually circulating capacity to produce 3.95 million tonnes that progresses in tandem within a fully with cool water, helping maintain body of the world’s best smelter grade alumina operational plant. temperature. Over that garment they per year. wear a disposable ‘Tyvex’ suit and then When QAL was constructed in the an ‘aluminised furnace’ suit on top of the The refinery covers 80 hectares of a 3,050 early 1960’s, pipe work was lined with other two. Crews also breathe chilled air hectare site on the south-east outskirts asbestos. At the time, it was the best form that is fed via an airline respirator. of the city of Gladstone. Adjacent to the of insulation for pipe work running at high plant is a wharf and storage facility on temperatures and pressures. Now pipes In addition to this, air-conditioning is South Trees Island, which is connected are lagged with pre-moulded ‘Rook Wool’ specially ducted into the structure, and to the mainland by a causeway bridge. insulation. workers can only spend a limited amount The refinery hosts boilers, cooling towers, of time within the work enclosure to electrical substations, vessels and pipe A large part of the overall contract eliminate heat stress. racks, all requiring insulation and in some involves McMahon Services stripping cases, asbestos removal. asbestos and re-lagging sections of pipe To safely remove the asbestos, it is work. Some pipes running at pressure dampened and carefully bagged, moved McMahon Services entered a three year of 5000KPa and 390 degrees and the into another section of the enclosure Maintenance Contract in January 2012 others pipe running, slightly cooler, at 190 where the external surface of the bag to manage and systematically remove degrees and 500KPa. is wet wiped, then double bagged and friable asbestos lagging from over 20km placed in a secure area for safe disposal. of pipes and boilers on-site. A permanent Working with asbestos as well as hot base was established within the plant pipes requires extra precaution to be QAL have their own Hygiene Department and a team of 25 asbestos technicians taken. Asbestos work enclosures have on site, which oversees all of the asbestos was recruited locally. The contract has to be fully sealed and operate under removal. Due to their growing confidence recently been extended for a further two negative pressure. Negative air units in McMahon Services, the Hygiene years, and will now finish in December draw air flow at a minimum of 12Pa Department now allow us to incorporate 2017. (pascal), ensuring that the temperature larger encapsulations into our removal within the enclosure is reduced. processes. Allowing us to construct larger removal areas, it has dramatically cut down the asbestos removal time, resulting in valuable efficiencies gained for the client.

THE WORKS 37 NEW ADDITIONS HEAVY TO FLEET HAULAGE McMahon Services are always focused on having the right tools for the job. We invest heavily to ensure state of the art, innovative plant and equipment is available to deliver projects across McMahon Services has added further capability to our transport division Australia. McMahon Services have recently added with the arrival of a Western Star Prime Mover and Drake Platform Low a number of new items to our fleet including access Loader. This combination provides McMahon Services with strong heavy equipment, light vehicles, trucks, earthmoving haulage capability to transport indivisible, over dimensional and excess equipment and specialised equipment. mass loads up to 92 tonnes.

Light Vehicles Over dimensional items may include heavy machinery, tanks and vessels, drill rigs, modular buildings and other oversize items. Our highly Hilux Utes 40 experienced driver has been transporting over size items for over 20 Volkswagen Transport Pilot Vehicle 1 years and has the ability to load and unload heavy machinery.

Trucks Isuzu Flat Top 2

Earthmoving Equipment 11T Dynapac Smooth Drum Roller 2 KEY FEATURES INCLUDE: PC220 Excavator 4 f 8 row of 8 platform float with or without dolly PC130 Excavator 1 S 590 Bobcat Skidsteer 1 f 11 row of 8 platform float with or without dolly Caterpillar 12m Grader 1 f Loads up to 92 tonnes (150 tonnes gross combined mass) JNR Engineering Land Plane 1 PC 450 Excavator 3 f Variable platform length from 17.5 metres to 23 metres PC 850 Excavator 2 f Deck widening from 3.5 metres to 4.88 metres PC 300 Excavator 2 f Western Star Prime Mover rated at 260 tonnes WA 200 Wheel Loader 1 E 32 Bobcat Excavator 3 f Pilot supplied by McMahon Services E 55 Bobcat Excavator 2 f Transport permits and escort services available

Generators Kubota 20 kva 6

Access Equipment Genie 3369 Rough Terrain Scissor Lift 1

38 THE WORKS TANK DECOMMISSIONING IN REMOTE HORN ISLAND

MCMAHON SERVICES In order to undertake the project safely, In addition to the AST’s McMahon WAS COMMISSIONED the primary activity on site was the Services completed the decommissioning BY ERM TO UNDERTAKE identification and removal of bonded and demolition of site services THE SAFE REMOVAL OF asbestos fragments located on site in infrastructure including septic tanks and ABOVEGROUND STORAGE a centralised hot spot. All Asbestos stormwater system. All waste generated removal works were undertaken by from the project was segregated in TANKS (AST’S) AND RELATED appropriately qualified personnel under appropriate waste streams with steel FUEL INFRASTRUCTURE AT the strict supervision of a fully certified waste being sent for recycling to THE HORN ISLAND AIRPORT. Asbestos Removal Supervisor. Exclusion minimise the volume sent to landfill. zones and signage were put in place to The Horn Island Airport is owned and ensure delineation of Asbestos Removal McMahon Services deployed a full time operated by the Torres Shire Council. It is Works and all personnel were required to team of four personnel to complete considered as the gateway to the Torres wear appropriate PPE at all times. the project. The remote location of the Strait and the Northern Peninsula Area. project presented the biggest challenge The airport is located on Horn Island, Prior to removal the AST’s, hydrant for the team. Due to the location of the Queensland, which is approximately fuels lines were degassed, rinsed with site on Horn Island, mobilising plant and 8km from Thursday Island. a bio solve detergent and cleaned equipment was difficult, this required by high pressure water blasting. All extensive sourcing and liaison with McMahon Services were selected cleaning works were undertaken within ferry and road transporters to ensure for this project based on extensive appropriate bunding, collection and resources were available, and that no experience in undertaking hazardous containment facilities. delays would be incurred. By maintaining area works, particularly in remote clear lines of communications and safety locations whilst maintaining industry The AST’s were then demolished using core expectations throughout, McMahon best practice safety standards. a 22 tonne excavator equipped with services delivered a successful outcome ripper shears. Upon completion of the for the client. demolition of the tanks, the three fuel hydrant lines were filled with foam and capped prior to backfilling.

THE WORKS 39 NEW APPOINTMENTS

Mike Adler PROJECT MANAGER AWARDS Building Services Mike joined McMahon Services as a & RECOGNITION Project Manager within the Building Services division earlier this year. Working in the construction industry for over 20 years, Mike brings a wealth of CHEERS TO MCMAHON To be considered a finalist in this experience to the team. SERVICES category amongst many other fantastic projects performed by quality Mike began his career in the construction On Friday 12th August 2016, McMahon builders was an amazing achievement. industry with the Master Builders Services were thrilled to accept the Going on to win the award was a true Association Training Scheme as a award for “Excellence in a Commercial testament to the team who worked Carpenter and Joiner, quickly becoming Refurbishment / Redevelopment over tirelessly on this historic South familiar with a broad range of experience $5 million” at the SA Master Builders Australian project. through residential and commercial Association Awards, for the iconic Lion construction. West End Redevelopment Works. Project Director Chris Plumb was delighted with the result and praised Mike furthered his education completing The closure of Lion’s Swan Brewery the team for a job well done – “This an Associate Diploma in Building, which in Western Australia signalled that an was a very challenging project with gave him the foundation to launch into extensive redevelopment was required many stakeholders involved. The Commercial Site Management taking at South Australia’s West End Brewery, one-team approach and spirit shown him to projects across Australia. in Thebarton. McMahon Services was by all went a long way to the overall engaged by Lion to undertake the role success.” His trade background, further education of Construction Manager and execute and broad range of knowledge and the roll out of significant upgrade The award on the night was proudly experience in the construction industry works throughout the brewery. accepted by Project Manager, Nigel makes him a valued member of our Sutton on behalf of the McMahon team. Since joining McMahon Services, Over 250 individual projects were Services and Lion Team. Mike has delivered a diverse range of completed by McMahon Services as projects for the Department of Defence part of the redevelopment works at at RAAF Edinburgh and multiple projects the brewery under the Construction for SA Power Networks. Management contracting model. 40 THE WORKS WOMEN IN CIVIL AWARD

McMahon Services are proud supporters of the employment of women in Civil Construction.

‘Women in Civil’ is an initiative of the Civil Contractors Federation SA (CCF) aimed at providing support, information as well as mentoring and networking opportunities for women working in the Civil Construction industry.

Each year at South Australia’s CCF Awards an exceptional female is recognised for their significant commitment to the wider civil sector in their career, demonstrated initiatives and encouragement and empowerment of women in the industry.

In July 2016, McMahon Services’ very own Jayne Bettison was presented with the prestigious award. Congratulations Jayne.

WORLD DEMOLITION AWARD The 2016 World Demolition Awards David McMahon, McMahon Services WINNERS saw 11 companies sharing the Managing Director, said “There has been honours. McMahon Services overcame strong demand throughout Australia McMahon Services, recently took out fierce competition from around the for the Company’s expertise in these the ‘World’s Best Industrial Demolition globe including specialist demolition sectors in recent times.” Project Award’ at the 2016 World contractors from the United Kingdom, Demolition Summit held in the USA. Netherlands, Italy and Canada to win “We have seen the growth of large The winners were announced in Miami their category. industrial demolition projects with the on 14 October during the eighth World rationalisation of the manufacturing Demolition Summit. As one of Australia’s leading and mining industries, and companies construction services providers, this today have policies of rehabilitating sites McMahon Services were awarded for global recognition further strengthens that are no longer economically viable. their successful decommissioning of McMahon Services’ ability to deliver high- We offer a unique turn-key solution, major redundant assets within BHP performance projects for clients such as asset value realisation, demolition, Billiton Iron Ore, Nelson Point Load BHP Billiton that operate under some remediation, and site rehabilitation which out Facility, in Port Hedland, Western of the most stringent safety, quality and has fuelled our growth in this sector” Australia. environmental standards in the world. David said.

LEND LEASE SAFETY AWARD

Congratulations to Matt Kairns from the Civil team for winning the inaugural ‘Lend Lease Safety Award’ at the Air7000 project at RAAF Edinburgh in July this year.

Matt’s award recognises his continual excellence in safety. Whilst Matt was happy to receive the individual accolade, he was quick to praise the entire McMahon Services’ team for their commitment to safety on the project.

THE WORKS 41 MCMAHON SERVICES HAVE who have been involved in the events our clients with the greatest flexibility to RECENTLY ESTABLISHED industry for a combined period of cater for the most demanding events. A NEW BUSINESS UNIT over 100 years both in Australia and This currently includes over 35,000 2 PROVIDING TEMPORARY Internationally. This makes us the most seats, 2,000m of modular roof cover 2 EVENTS INFRASTRUCTURE experienced operator in the Australian and 5,000m of corporate platforms. events sector. ACROSS AUSTRALIA. All grandstands offer ergonomic We offer a complete streamlined bucket or tip-up seats with a larger McMahon Services have acquired solution to temporary grandstand than standard 500mm seat center and assets from the premier National infrastructure including in-house 800mm platform. This provides us with events seating company, Elite design, engineering, supply, transport the perfect foundation to build the right Systems. This business has had a long and on-site installation. seating solution for each client. history (around 30 years) of events scaffolding, platforms and seating With over 25 years’ experience in The Events business has hit the systems throughout Australia. the construction industry, we offer ground running delivering major our client’s a complete project contracts that include Adelaide Clipsal The acquisition included over 35,000 management solution underpinned by 500 Supercars, Melbourne Australian grandstand seating positions along best practice management systems, F1 Grand Prix, Sydney APIA Tennis, with over 1,000 tonne of system quality and safety standards. Canberra ANZAC Day Parade, Credit scaffolding. Union Christmas Pageant, Santos Tour McMahon Services Events will have Down Under and Baseball SA. McMahon Services has also taken on the largest range of seating system a number of key management people options in Australia, which provides

42 THE WORKS OUR CORE SERVICES f Temporary Grandstands f Corporate Platforms f Elevated Media Platforms f Access Solutions f Modular Roof Solutions

THE WORKS 43 CONTACT US E T PO Box155,CapalabaQLD4157 Chandler QLD4155 14/1440 NewClevelandRoad, Brisbane E T PO Box4545,AliceSpringsNT0870 Unit 1/30EldersStreet,AliceSpringsNT0870 Alice Springs E T Building 3,1CawleyRoad,BrooklynVIC3012 Melbourne E T NT0821 PO Box36546,Winnellie 41 BishopStreet,Woolner NT0800 Darwin E T PO Box54,WhyallaSA5600 350 BroadbentTerrace, WhyallaSA5600 Whyalla E T PO Box143Port PirieSA5540 30 EllenStreet,Port PirieSA5540 Port Pirie E T PO Box542,EnfieldPlazaSA5085 26 DuncanRoad,DryCreekSA5094 Adelaide www.mcmservices.com.au 0417820221 (03)93161500 (08)89302500|F (08)86444400|F (08)86335400|F (08)82033100|F [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] (07) 36344300|F (08)89422782 (08)86451762 (08)86334441 (08)82605210 (07)32451685

E T 33 CrawfordStreet,KatherineEast Katherine E T PO Box7145,GarbuttB.CQLD4817 Townsville QLD 68 CrocodileCrescent,MountSaintJohn, Townsville E T 86 BourkeRoad,AlexandriaNSW2015 Sydney E T PO Box903,KarrathaWA 6714 Gap RidgeKarrathaWA 6714 Lot 104ExplorationDrive, Karratha E T PO Box80,Welshpool WA 6986 Unit 11/524AbernethyRoad,Kewdale WA 6105 Perth E T PO Box8179,SouthGladstoneQLD4680 4/40 MartenStreet,SouthGladstoneQLD4680 Gladstone 0439853944 0458070554 (08)91839500|F (08)63507000|F [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] (08) 89302500 (07) 49777700

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