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Tugun Bypass NSW AUSTRALIAN CONSTRUCTION ACHIEVEMENT AWARD 2009 FINALIST SUBMISSION PacificLink Alliance - Creating Tugun Bypass Technical Report Michael O’Dwyer Abstract: The following document outlines some of the key issues contended with in the creation of the Tugun Bypass – one of the most long-awaited road infrastructure projects in South East Queensland. FINALIST SUBMISSION- PACIFICLINK ALLIANCE - 1 of 19 CREATING TUGAN BYPASS INTRODUCTION The $543 million Tugun Bypass was delivered by PacificLink Alliance in 27 months, despite five government stakeholder layers across two states, 20 approval authorities, a highly interested media and active community. The bypass’ relatively short route does not adequately express the number and complexity of issues surrounding its design, approval and construction. The alliance solved complex approvals, significant environmental constraints and difficult geology to deliver seven kilometres of high quality dual carriageway motorway linked to two state traffic systems, six bridges and a tunnel under the Gold Coast Airport future runway expansion. The alliance project team has redefined through innovation and professionalism what is possible in an Australian construction context. The team overcame extraordinary challenges and delivered one of Australia’s highest quality roads. ACHIEVEMENTS INCLUDE: Built a tunnel top down in a swamp, under an airport flight path, adjacent to an environmentally sensitive area, on Federal Government land, which connected a road between New South Wales and Queensland; Met ‘impossible’ early deadline – Essential Tunnel Works delivered by 10 November 2006, a period of only 81/2 months, 31/2 of which were consumed in developing and gaining approval of complex, detailed environmental management plans; Project completion six months early, delivering the project in 27 months and 3% under the target outturn cost; Crossed five government jurisdictions – two state, two local and federal – and had 20 approving bodies; Constructed a tunnel 12 metres below the water table and met all leakage criteria; Installed life and fire safety systems which permit Australia’s only 100 kilometre per hour speed environment tunnel, with all but two classes of dangerous goods allowed; Worked adjacent to SEPP14 wetlands, including extensive dewatering without impacting the sensitive environmental area; Took extraordinary steps to address environmental challenges and meet community expectations, including testing and installation of a frog-specific fence; Worked below an operating airport flight path with maximum headroom of only six metres; Excellent health and safety record, including 500,000 hours worked lost time injury free; Proactive and open communication with 120 community groups and the local community, and delivered major legacy project walking trail through Hidden Valley; FINALIST SUBMISSION- PACIFICLINK ALLIANCE - 2 of 19 CREATING TUGAN BYPASS Delivered an outstanding urban design solution through urban and rural landscapes, flat and undulating land, and in two states, within a distance of only seven kilometres; Constructed Hidden Valley bridges using an innovative bridge launching system to minimise the impact on the sensitive environmental valley below; Top down construction of Tugun Hill bridge to maintain access for residents, then excavated 25 metre hill in two weeks; and Minimised traffic disruption while tying into live interchanges carrying 40,000 vehicles per day. The construction of Tugun Bypass is truly testament to what can be achieved when the constructor works with the designer and client to develop and deliver innovative solutions and, ultimately, a remarkable project. PacificLink Alliance was an alliance between Abigroup Contractors (contractor), SMEC Australia (designer) and the Queensland Government Department of Main Roads (client). SCOPE OF WORK Completed in mid-2008, the Tugun Bypass has provided a new, motorway standard link between Queensland and New South Wales (Figure 1), easing congestion and reducing travel times for tourist, heavy vehicle and local traffic. The bypass is four lanes wide, with provision for upgrading to six lanes and a rail line in the corridor. Final approval of the project was received from the Federal Government in February 2006. Construction works for the Tugun Bypass began in June 2006. Design, construction and commissioning of the project was completed in 27 months, six months early, and 3% under the target outturn cost. The project team demonstrated innovation and creativity to skilfully navigate a complex maze of planning, environmental, jurisdictional and cultural heritage issues, any one of which could have derailed the project. PROJECT ELEMENTS The Tugun Bypass project included design and construction of: seven kilometre dual carriageway (provision for upgrade to six lanes); 334 metre tunnel underneath the Gold Coast Airport runway extension; six bridges, including four overbridges and twin bridges across a valley; 800,000 cubic metres of earthworks; 160,000 cubic metres of concrete; and 100,000 tonnes of asphalt. Installation of complex mechanical and electrical systems, including: microwave and wireless connections to two traffic management centres using different traffic control systems in two states; automated tunnel fire control system; FINALIST SUBMISSION- PACIFICLINK ALLIANCE - 3 of 19 CREATING TUGAN BYPASS detection systems including over height vehicles; traffic speed, volume, type and weight; air quality; and water level; and remotely monitored impressed current cathodic protection system. The advanced life and fire safety systems have resulted in the only tunnel in Australia with a 100 kilometre per hour speed environment, and with all but two classes of dangerous goods allowed. The preliminary EIS identified areas of high environmental value, including protected wetlands, significant vegetation, culturally significant areas and areas containing threatened flora species and fauna habitat. The project took extraordinary measures to: protect endangered fauna including Wallum Sedge frogs, planigales, potaroos, and sugar gliders; relocate or revegetate threatened flora; manage acid sulphate soils and sites contaminated with heavy metals; and provide compensatory habitat. The alliance was also responsible for: consultation with 120 active community groups with a vocal minority opposing the project; managing five layers of government stakeholders and a highly interested media; and approvals from more than 20 bodies, including Gold Coast Airport Corporation. ESSENTIAL TUNNEL WORKS The Essential Tunnel Works (ETW) were a critical part of the project delivery. They had to be completed by 10 November to avoid harsh penalties by the Gold Coast Airport Corporation. The ETW scope included: construction of 17,200sqm metres of tunnel diaphragm walls and barrettes using 16,500 cubic metres of concrete and 4,260 tonnes of reinforcement steel; excavation and construction of tunnel roof slab, including 9,000 cubic metres of concrete, 2,960 tonnes of reinforcement steel and an average concrete pour of 630 cubic metres and maximum of 2250 cubic metres per day; installation and commissioning 21 extraction wells and 44 re-injection wells for groundwater management, an average 20 metres deep; installation of 58 deep-well cathodic protection anodes of 30 metres depth; installation of 9,000 square metres of primer and waterproofing membrane and 9,000 square metres of concrete protection slab to roof structure; installation of a groundwater cross drainage system; FINALIST SUBMISSION- PACIFICLINK ALLIANCE - 4 of 19 CREATING TUGAN BYPASS construction of the rail slab, including 18,500 cubic metres of concrete, 1,550 tonnes of reinforcement steel and an average concrete pour of 1,500 cubic metres; and placement and compaction of 12,000 cubic metres of cement treated backfill and sand fill over the completed works. TYPE OF CONTRACT The $543 million Tugun Bypass was delivered by an alliance between Abigroup Contractors (contractor), SMEC Australia (designer) and the Queensland Department of Main Roads (client). The project was jointly funded by the Queensland and Federal Governments, with the federal contribution capped at $120 million. In July 2005, Main Roads sought proposals from consortia interested in entering into an alliance to design, construct and maintain the bypass. Initiating a competitive alliance (dual target outturn cost) selection process in parallel with the final stages of the approvals process helped enable a timely start to construction, once the necessary approvals were obtained. A number of key points made this alliance contract innovative, including using a competitive alliance process, a dependent long term maintenance contract and significant non-owner participant incentivisation. The alliance method of project delivery adopted for Tugun Bypass produced a number of project management ‘firsts’ for Main Roads and has significantly influenced the method of future project delivery, as well as adding to the body of ‘alliance knowledge’ in Australia. DUAL TOC ALLIANCE Due to concerns about the ability to achieve value for money without some time flexibility to negotiate an appropriate target outturn cost (TOC), a competitive or dual TOC process was chosen whereby two parallel interim alliances were appointed to develop a complete design and construct proposal, including a fixed TOC. The interim alliances were very compressed, with a period of fourteen weeks for this work. The process ensured
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