Civil Operations

The project comprises the civil construction works associated with the Offplot and Utilities section of the gas processing plant.

The scope of works includes reinforced concrete foundations (20,000 m3), reinforced concrete pavements (17,000m2), detailed earthworks comprising some 250,000 m3 of engineered backfill, underground electrical cable installation (400 km), pre-cast and insitu trenching, firewater GRE pipework (4km), electrical, instrumentation and communication works, underground services, stormwater surface drainage, roads and fences

BGC Contracting subcontracted to CB&I on this package.

CB&I's initial scope of work includes the engineering, procurement, construction and pre-commissioning of two 120,000 cubic meter full containment LNG storage tanks, three condensate tanks and associated civil, piping, electrical and instrumentation work.

BGC’s scope on the Pluto LNG Tank Project involved site works, concrete shell & roof construction for 5 storage tanks. 2 Number LNG storage tanks and 3 Number condensate storage tanks.

LNG Storage Tanks

2 x 72m diameter / 47m high Reinforced Concrete LNG Storage Tanks, including construction of all concrete to bases, walls and roofs. (23,000m3 of concrete)

Condensate Tanks

Earthwork foundations for 2 x 66m diameter tanks, and 1 x 27.5m diameter tank.  (16,000m3 of earthworks)

The work under this contract consisted of the civil engineering works associated with the construction of the overland conveyor formation at the Clermont coal mine.

The construction components in this project included clearing and grubbing, topsoil removal and re-use, construction of light vehicle roads including bitumen seals, industrial stockpile areas including foundations and drainage structures and sedimentation basins.

Also included within the scope was the construction 95,000m³ of pavement of the Northern Haul Road (3.6km), construction of 450,000m³ of rock earthworks for the In Pit Crushing Conveyor in conjunction with Rio Tinto Coal’s mining fleet, reinforced earth wall for the ROM and engineered backfill behind the structure and paving and trimming the ROM

The Project comprises three contractors completing the embankment construction for the 260km railway line between Port Hedland and Cloud Break Mine, including the associated drilling, blasting and culvert requirements along this length. The Project included working adjacent to and the crossing of operational infrastructure including the Great North Highway, the existing BHPBIO Mt Newman railway line and others of a more minor nature.

The total works include a quantity of 3.5million m³ of rock to be drilled and blasted on the Project, forming part of the total of 7million m³ of fill that is required. As the Project is spread over 260km, and with a tight completion schedule the planning and logistics form a vital part in the completion of the Project.

Re-location of 44 Heritage Artefacts (rock art) to an on-site Preservation Area.   Drilling, blasting and excavation of 638,000m³ of rock. Placement & compaction of 100,000m³ of rock fill.  Haulage and processing of 65,000m³ of rock into road base material. The remaining 473,000m³ of rock fill was stockpiled for future use.  Establishment of a site office complex for the client.  Workforce peaked at 110. including specialist subcontractors.

The Brownfield package was for Woodside Energy Limited's Train V LNG Expansion Project. The works were located within the existing North West Shelf Venture's Onshore Gas Plant located on the Burrup Peninsula. Train V is immediately adjacent Train IV and is practically a "copy".

The scope of works includes concrete foundations (10,100m3), earthworks, underground cable installation, pre-cast and insitu trenching, pipework, electrical, instrumentation and communication works, underground services, stormwater drainage, smoke detection systems, HVAC, building works including structural steel, cladding and architectural finishes.  The scope also includes for relocation of existing facilities and services.

The Greenfield package was for Woodside Energy Limited's Train V LNG Expansion Project. The works were located within the existing North West Shelf Venture's Onshore Gas Plant located on the Burrup Peninsula. Train V is immediately adjacent Train IV and is practically a "copy".

The scope of work for the Greenfield package involved the installation of approximately 22,000 cubic metres of structural concrete and footings, the installation of approximately 400 kilometres of electrical and instrumentation wiring, building works (including HVAC and smoke detection system) and as well as associated civil works for the complete LNG V processing train.

Burrup Fertilisers Pty Ltd is building and will operate a 2,200 MTPD liquid Ammonia Plant at the King Bay - Hearson Cove industrial area on the Burrup Peninsula. The Plant will produce and export Ammonia for the world market.

The package involved the placement of approximately 19,000m3 of concrete, 1,500 tonne of reinforcement with associated earthworks and drainage.

BGC supplied concrete from our own batch plant.

The Project was for the $1.5 Billion LNG Train 4 Expansion for Woodside Energy Limited at the Burrup Peninsula in Karratha Western Australia.

The Train 4 Site Preperation Package was for the construction and testing of consolidated rock plate foundations to support the new LNG Train 4, associated pipe racks/tracks, substation 2, FAR 16, Sulfinol facility and power generation facilities. Work included; bulk excavation to remove unsuitable sub grade material, Crushing of materials to produce backfill material, Backfilling of site to produce to specified requirements. Earthworks, concrete work, electrical works and buildings for the Train 4 facilities. A design and construct project consisting of 1.3 million tonne of earthworks (including crushing of rock).

Material sorted utilizing various plant and transported to crusher. Crushing and screening using a double toggle jaw crusher. Material hauled from crushed stockpile to excavation area using 85T dump trucks. Excavation of site area undertaken with 100T excavator loading into 85T dump trucks. This material was then taken to the crusher for crushing and screening to provide suitable backfill material.

Burrup Fertilisers Pty Ltd is building and will operate a 2200 MTPD liquid Ammonia Plant at the King Bay - Hearson Cove industrial area on the Burrup Peninsula.  The Plant will produce and export Ammonia for the world market.  The work scope included the excavation, construction and backfill of concrete ringbeam foundations for two ammonia storage tanks.

THe package included up to 190,000m3 of rockfill and 50,000m3 of subbase was imported to site to build the 23 Hectare Pad Area to receive the world class Ammonia Plant.  A further 50,000m3 of rock was blasted on site to provide the remaining fill required to complete the pad.

BGC was responsible for installing all electrical, water, drainage, sewage and communication services. BGC used direct labour and plant to complete 3,000 metres of stormwater drainage on the site.  Specialist subcontractors were engaged to complete the other services.

The Project was for the $1.5 Billion LNG Train 4 Expansion for Woodside Energy Limited at the Burrup Peninsula in Karratha Western Australia.

The initial $12 million contract for ‘Trunkline Onshore Terminal (TOT) Site Preparation Works' was signed on 31 May 2002 with an original end date of 31 December 2002. The contract was extended to include a $9 million concrete works variation. Various additional works were added progressively to increase the final value to approximately $23 million.

The Site Preparation Works required 90,000T of rock to be crushed and placed as foundation material. 180 linear metres of reinforced concrete walls to be built, with heights varying from 1m to 5m. Earthworks to be filled with 25,000m3 of cut. Temporary buildings were supplied and erected for future use by subsequent erection contractors. Extensive relocation of services needed within the operational gas plant. The variation works included over 4,000m3 concrete, construction of pipe rack footings, pedestals, manholes and associated service works.

Team 45 is the integrated project management team of Fortescue Metals Group, The Pilbara Infrastructure, FMG Chichester and Worley Parsons.  Team 45 and Worley Parsons act on behalf of and as disclosed agent of the Pilbara Infrastructure and FMG Chichester.   The project involves the supply of railway ballast for the construction of a 260km rail line being built by FMG.  The rail line runs from Port Hedland south to Cloud Break Mine.

The project involves the quarrying, crushing and delivery of approximately 720,000 tonnes of minus 53mm ballast.  

Project Managers for the design and construction of on-site infrastructure requirements for a new coal mine.  The scope of works included in the project were:

• Assisting developing the master plan for the site and managing the design of the on-site infrastructure works;
• 3.6 km rail loop including all earthworks / culverts;
• 2 km raw water supply pipeline;
• Hardstand and offices for mine infrastructure area (MIA);
• Access roads to the MIA and coal processing plant and main road intersection upgrade; and
• Raw water storage dam and Co-disposal dam.

The Material Offloading Facility (MOF) Road Upgrade package was for Woodside Energy Limited's Train V LNG Expansion Project. The works were located within the existing North West Shelf Venture's Onshore Gas Plant located on the Burrup Peninsula. Train V is immediately adjacent Train IV and is practically a "copy".

Whilst called the MOF road package, the works are located on the existing MOF Road on the Burrup Peninsular, this road is used to transport material from the MOF Wharf to the Train 5 project site

The scope of work involves the widening of the existing MOF Road to transport heavy modules from the MOF Wharf to the LNG Train 5 site, works included Drill and Blast, cut to fill, trenching (electrical and power) installation of electrical and power, heritage clearing, road seal and traffic control.

The scope of works undertaken during initial construction phase included:

• Mine access road and internal road to office / industrial area
• Construction of 5.5kms rail loop
• Installation and placement of 2 x barrel 8 metre diameter multi plate culverts at Chum Creek
• West and East Environmental Dam and Clean Water Dam.

The Truckline System Expansion Project (TSEP) was for the $1.5 Billion LNG Train 4 Expansion for Woodside Energy Limited at the Burrup Peninsula in Karratha Western Australia.

Supply of rock to protect and stabilise sections of the North West Shelf Venture's second trunkline. The 130 km trunkline will link the Venture's offshore gas production and onshore gas processing facilities. The contract involves the quarrying, processing, delivery and stockpiling of over 1,000,000 cubic metres of rock armour. The rock is quarried from a lease held by the Dampier Port Authority.

A new quarry facility was established at the Dampier Port Authority which is operated by BGC. The establishment of the quarry required approval from the EPA and Aboriginal heritage clearance. An existing diesel fuel line needed to be relocated. The Telstra Fibre Optic Lines servicing Woodside and Dampier Port Authority facilities at Dampier also needed to be relocated.

Reclamation works for the construction of a new land backed wharf load-out facility were undertaken.

The Kemerton Power Station Project is located approximately 150 kilometres south of Perth in the state of Western Australia.  Siemens have been contracted by Transfield Services to construct a "Peak Load" power station consisting of two turbines with a total capacity of 260 MW fired by natural gas or low sulphur diesel fuel.  Siemens have engaged BGC Contracting to carry out the Main Civil Works Contract. This encompasses earthworks, roadworks, underground piping, concrete works, electrical earthing/lightning protection, steel erection, cladding and building works. The project included:

• 4,500 cu. m of excavation;
• 4,200 cu. m of backfill;
• 5,500 cu. m of concrete; and
• 4,000 sq m of roadworks.

The Kemerton Power Station project also involved the erection of 360T of client supplied structural steel primarily to the turbine buildings. These steel framed buildings were clad (double skin) with 3000 sq m of cladding.

In addition, BGC constructed the Control Room building. This was a concrete - framed blockwork building with all the various building trade activities, together with a suspended concrete slab roof structure covered with membrane.

The project comprised the following works which were carried out at the North West Shelf Venture's Onshore Gas Plant located on the Burrup Peninsula:- the supply and installation of Security fencing and gates around the perimeter of the plant, the upgrade of the Main Gate car park and entry to the Gas Plant, the repair of a section of damaged seawall on the Eastern side of the plant and the reinstatement and upgrade of a disturbed roadway at No Name Creek which is at the Western end of the plant

The scope of works, with a contract sum of approximately AUD $11.0 million involved the following:-

Security Fence Upgrade - This included the demolition and disposal offsite of the existing perimeter security fence and the installation of approximately 6.5 kilometers of new perimeter security fencing and the installation of approximately 12 new gates at various locations around the plant. A specialist contractor was engaged to carry out the fencing component of works.

Car Park Upgrade and security camera service trenches - The front gate and car park area upgrade included the removal of old pavement and installation of new pavement including road base, asphalt and kerbing. This also included the installation of various components of precast concrete and also bases for the new lighting as well as  miscellaneous associated civil works required for the main gate security upgrade.

Repair of Seawall at Eastern end and upgrade of road at No Name Creek - A section of Seawall (approx 150m long by batter dimension = 25m) that was washed out during 2005 - 2006 cyclone season required repair prior to the new security fence being installed. This required the installation of a 20m long 3m high precast concrete retaining wall and the importation and placement of approximately 10,000 tonnes of rock armour. A section or road way was required to be upgraded prior to the installation of the upgraded security fence at No Name Creek. This consisted of approx 2,000m2 of roadway box out and removal offsite, installation of road base and 2 coat chip seal, installation of RCP drainage and end treatments, and the construction of rock lined V drains on the sides of each roadway.

Located 100 kilometres west of Mackay and 35 kilometres north-east of Nebo, the Hail Creek operation produces coal from one of the world's largest coking coal deposits.  The mine was officially opened in November 2003. BGC undertook the clearing and topsoil stripping of this newly established mine site in a Eucalypt forest area.  Works included:

• Clearing, stacking and burning of site timber.
• Stripping and stockpiling of topsoil.

Construction of 12klm haul road for 160 tonne coal haulers from mine to coal preparation plant. Strip and stockpile topsoil and generally prepare the area under the road.  Carry out general earthworks and install reinforced concrete pipe culverts under road. 

Drill, blast and crush hard rock from quarry and place and compact road base material (sub-base 175mm sub- base, 175mm to 280mm at crown base course). Other associated earthworks, erosion control and wet land embankment.

Burrup Fertilisers Pty Ltd is building and will operate a 2,200 MTPD liquid Ammonia Plant at the King Bay - Hearson Cove industrial area on the Burrup Peninsula.  The Plant will produce and export Ammonia for the world market.  This contract involves the procurement, installation and testing of in ground piping for the seawater cooling and fire protection piping systems across the entire site.

The scope included the installation of large diameter glass fibre reinforced piping.  Diameters ranged from 12 inch to 68 inch.  Works included excavation, installation and hydro testing of all piping.  Approximately 4000 linear metres of various size pipes installed.  All piping was manufactured overseas and shipped to Fremantle.  Off site works included prefabrication of pipe spools to reduce the about of on site labour.

Detailed planning required to:

• Finalised detail design
• Procure and import material
• Prefabrication of pipe spools
• Installation amongst other mechanical installation contractors

The Pluto LNG Project, a liquefaction facility with forecasted production of 4.3 million tonnes per annum, is located on the Burrup Peninsula in Western Australia, approximately 20 kilometres (12 miles) northwest of Karratha. The project is expected to be completed in 2010.

BGC Contracting was subcontracted to Van Oord for the Shore Crossing Civil Works Package. The project comprises civil construction works for Van Oord, to create the transition between off shore works and on shore works such that the Pluto gas pipeline can be brought on shore. The scope of works involved the creation of various on shore lay down areas, creation of a temporary groyne to be used as an off shore working platform to undertake drill and blast activities, removal of the groyne and blasted material to create an off shore to on shore pipeline route. This involved shifting approximately 8,000 cubic metres of structural material off shore and stabilising batters to suit the Pilbra marine environment.  On shore drill and blast was also undertaken to create a clear trench for the on shore portion of the gas pipeline.

Construction of access roads and preliminary earthworks for the Ravensthorpe Nickel mine at Ravensthorpe 575km Southwest of Perth.  The package was to devleop the Greenfields site, works included:

• Roadworks and drainage;
• Haul roads;
• Establishment of barrow areas;
• Construction of borefields;
• Plant laydown erea; and
• Camp site infrastructure.

Moura Mine is a coking & thermal coal mine and is located approximately 220kms west of Gladstone. BGC was awarded this second contract (2005) and is carrying out further dragline spoil regrade to fit Anglo Coals design criteria.

The work was executed on this project using the following equipment;

• 1 x 475-3 Komatsu Dozer - fitted with dozer guidance GPS
• 1 x 575-2 Komatsu Super Dozer
• 1 x D11R Caterpillar Dozer

This being the second rehabilitation project (2005) was carried out ahead of schedule and as a variation to 2004 project, BGC were asked to bulk push approximately 1 million m³ to uncover the coal.

The Project was for the $1.5 Billion LNG Train 4 Expansion for Woodside Energy Limited at the Burrup Peninsula in Karratha Western Australia.

The package was for the provision of a Consolidated Rock Plate Foundation for a 200,000m2 Propane storage tank, Liquids Expansion Project. Project involved removal of loose rock outcrop, drill and blast and excavate to sound load bearing foundations, screen shot rock material into required sizes and replace excavation with rockfill layers to underside of tank foundation level.

Strict controls required, especially during drill and blast operations considering proximity of LNG gas storage tanks (50 metres) and an operational gas processing plant.

Construct only contract, design supplied by Woodside Energy Limited.

Road works on the Derby Highway began adjacent to the Derby Airport in the Kimberley Region of Western Australia and extended south for 6.23kms.  The project involved the reconstruction of the existing road to a seal width of 8 metres, and the construction of flood ways and off-road drainage.

A two-way sidetrack was constructed for use by all vehicles with a 60km/h speed limit, for the duration of the road works.  Ripping up the bitumen seal on the existing road.  24,000m³ of bulk earthworks (18,000m³ as spoil and 8,000m³ as fill within the works).  Insitu concrete works for culverts.  Preparation of subgrade.  Load, haul and placement of gravel subbase and basecourse supplied by the Client from a quarry 30kms from the worksite.  Subbase and basecourse stabilisation.  Two coat sealing to floodways and sand sealing elsewhere on the complete pavement.  Construction of surface drains.  Traffic sign and guide post installation.  Linemarking.

Provision of a Consolidated Rock Plate Foundation for a 200,000m2 Propane storage tank, Liquids Expansion Project, North West Shelf, Burrup Peninsula.  Project involved removal of loose rock outcrop, drill and blast and excavate to sound load bearing foundations, screen shot rock material into required sizes and replace excavation with rockfill layers to underside of tank foundation level.

Strict controls required, especially during drill and blast operations considering proximity of LNG gas storage tanks (50 metres) and an operational gas processing plant.

Construct only contract, design was supplied by Woodside Energy Ltd.

The Burrup Peninsula is an area of special environmental significance and as such strict controls were required during the project. 

This project involves pushing approximately 2 million bank cubic metres of dragline spoil and placing of topsoil to facilitate BMA's rehabilitation at Gregory Mine .

The works reuqired BGC Contracting to push material utilising 5 dozers, 4 x D11R's, 1 x Komatsu 575 Super Dozer, The D11R Dozers are equipped with a GPS Dozer Guidance System. For the topsoil placement we utilised 657 Scrapers.

The project comprises the construction of two x 865m concrete roads / drains for the new CHPP load out area. The scope of works includes excavation to level and placement of approximately 2,000m³ reinforced concrete.

Moura Mine is a coking & thermal coal mine and is located approximately 220kms west of Gladstone. BGC carried out dragline spoil regrading, ripping and aerial seeding of approximately 1.2 million m3. This was the first contract of 2, Moura Rehabilitation 2005 followed.

The work was executed on this project using the following equipment;

• § 1 x 475-3 Komatsu Dozer - fitted with dozer guidance GPS
• § 1 x 575-2 Komatsu Super Dozer
• § 1 x D11R Caterpillar Dozer
• § 1 x D8N Caterpillar Seeding Tractor

The successful early completion of this project led to the awarding of a second rehabilitation project (2005).

Sole contractors for the construction of the Cement Australia Rail Siding and Loading Pad facility at Frost Enterprises Taragoola limestone mine.  Project included cut to fill earthworks, installation of RCP pipes and drainage structures. The loading pad had 600mm, 2.5 road base laid and compacted to 95%.