NRW CAPABILITY · 2 16M Motor Graders Equipment used at Middlemount Coal Mine consists of the...

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NRW CAPABILITY CIVIL & MINING

Transcript of NRW CAPABILITY · 2 16M Motor Graders Equipment used at Middlemount Coal Mine consists of the...

NRW CAPABILITYCIVIL & MINING

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ABOUT NRWNRW is proud to be one of the leading civil and mining contractors in the Australian resources and infrastructure sectors. Our ongoing success is a direct consequence of the commitment we make to our clients, our people, the communities in which we operate and our shareholders.

Our people are the basis of our success and we invest heavily in their growth and development. Keeping them safe at all times is paramount to the foundations on which our business is built.

Our flat management structure allows us to be proactive in managing major projects whilst maintaining the required flexibility to respond quickly to client needs.

NRW has strong ties to the communities and the people in the remote regional areas in which we predominantly operate. Our Indigenous training program, Powerup; our Indigenous joint ventures; and our ongoing sponsorship of local organisations are just some examples of how we maintain these ties.

NRW has an exceptional industrial relations record, with zero lost time due to industrial action across the whole business.

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HEALTH & SAFETY AT NRWKeeping our people safe at all times is paramount to the foundations on which NRW is built. We want every single one of our employees, and our sub-contractors’ employees, to feel safe at work and our commitment to safety is reflected at every level of the organisation. We strongly believe all accidents are preventable and join existing and prospective clients in a shared vision of incident and injury free projects. As a result of these beliefs, NRW boasts an industry leading safety record.

NRW is committed to achieving the highest possible performance in occupational health and safety across all business operations with a target to eliminate all safety incidents and injuries on every project. Implemented in 2012, NRW’s A Safe Day. Every Day. Program is the umbrella for all safety initiatives within the company. Since implementation, NRW has established a positive safety culture and an industry leading safety record.

Safety at NRW is everyone’s responsibility and all employees are actively encouraged to contribute to the occupational health and safety plan through the identification and mitigation of risks. Every employee is also highly trained in the safety procedures relative to their role and the correct operation of plant and equipment.

Our Occupational Health and Safety Management Systems are accredited to AS4801:2001, the applicable Australian Standard and subject to continuous audit. We stringently manage risk through a planned and careful approach focusing around hazard identification, minimisation, monitoring and control procedures, and by reviewing safety performance.

To assist in achieving commendable safety record, our management plans have been based on a safety management systems, principles and guidelines that promote continuous improvement.

SUSTAINABILITY AT NRWNRW is absolutely committed to the principals of sustainable practice with environmental management and social responsibility key drivers in day to day decision making.

Our sustainability objectives are achieved by:

• Strict compliance with environmental obligations

• Minimising adverse environmental impacts through strong integrated management systems

• Efficiency improvements in our use of energy, water and resources

• Promoting innovative thinking and solutions

• Promotion of our employees’ general health and well-being.

• High level of engagement with stakeholders and local communities

• Only doing business with suppliers and subcontractors who uphold the same high levels of sustainability commitment.

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POWERUPPowerup, NRW’s Indigenous pre-employment program, provides opportunities for Indigenous candidates lacking entry level skills to break into the civil and mining industries. Each Powerup Program is tailored to meet specific project requirements and guarantees all candidates employment with NRW on successful graduation.

The Program delivers competency based training using hands-on activities such as driving haul trucks and rollers, including OH&S practices and procedures, which is empowering for the candidates.

Since its inception in 2008, Powerup has progressed steadily, and over 250 graduates have been placed into the NRW workforce to date.

ABORIGINAL ENGAGEMENT NRW appreciates that many of our civil and mining projects have an impact on the local communities and traditional owners of the land on which we operate. Our company encourages Aboriginal businesses, contractors and employees to be a part of our success through employment, training and business development opportunities.

• ABORIGINAL WORKFORCE NRW is committed to the engagement and growth of a highly skilled indigenous workforce.

• ABORIGINAL BUSINESS DEVELOPMENT NRW is committed to strengthening ongoing relationships with local Aboriginal traditional owners.We will continue to recognise opportunities for joint venture partnerships to help support and develop sustainable Aboriginal businesses in the civil and mining industry. Wherever possible, NRW will contract local Indigenous companies for the provision of services and plant.

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PLANTNRW has a dedicated Plant Department providing support, assistance and cost efficient strategies to both our Mining and Civil Divisions.

NRW’s extensive range of plant, owned or leased, is fit for purpose and maintained to the highest standards by experienced maintenance personnel. The Plant Department has the systems and processes in place to effectively mobilise plant to a project wherever it is required nationally or internationally.

NRW’s current fleet includes:

Project Type Size/Model Quantity

Excavators 100T - 500T >20

Excavators <100T >10

Dump Trucks 50T - 220T >110

Dozers D8/D10/D11 >25

Graders Cat 12G, 14G, 16G >15

Loaders Cat 992/988, WA600 >10

*A full detailed fleet listing of current plant, including make, model and year of manufacture is available upon request.

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MININGNRW is a leading provider of contract services to the mining sector. With a proven capacity to safely deliver contracts that meet timeframes and budgets, NRW has become a contractor of choice for many of Australia’s leading mining companies.

With an extensive schedule of plant and equipment, and a fully mobile workforce, NRW has demonstrated experience in developing mines in remote locations throughout Western Australia, the Northern Territory, Queensland, as well as undertaking operations in West Africa.

Significant works have been undertaken in the iron ore, coal, gold, diamond and mineral sand sectors. Services provided include ore mining, overburden removal, surface and mine development, tailing dams, environmental remediation, drill and blast, crusher feeding and related ancillary services.

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Prior to 2007, NRW also undertook contract mining operations at the following mines:

• Western Limb Cutback, Tom Price - Rio Tinto

• Kimberly Diamond Mine - Kimberly Diamond Company

• Kanowna Belle Gold Mine - Delta Gold Limited

• Tiwi Island Mineral Sands - Matilda Minerals

• Darlot Gold Mine - Barrick Gold

• Paddington Gold Mine - Goldfields Limited

• Yandi JSE Prestrip - Rio Tinto

MINING PROJECT HISTORY Project Name Client Value AU

($M) Start – Finish Peak Manning

Nammuldi Incremental Tonnes Rio Tinto $142 Aug 2015 – Oct 2017 140

Middlemount Dry Hire and Maintenance Middlemount Coal JV $830 Feb 2013 – Jun 2020 100

North Star Iron Bridge $75 Jan 2014 – Jun 2015 100

Western Turner Syncline Mining Rio Tinto $237 Dec 2009 – Dec 2013 450

Ranger Tailing Storage Facility ERA $10.5 Sep 2013 – Nov 2013 93

Christmas Creek TSF 1 Fortescue Metals Group $8.2 May 2013 – Jul 2013 119

Middlemount Contract Mining Middlemount Coal JV $300 Jul 2011 – Feb 2013 300

Simandou Mining Pre-Development Works (West Africa) Rio Tinto $175 Jan 2008 – Dec 2012 220

Solomon Pre-Mining Development Works Fortescue Metals Group $93 Jul 2011 – Dec 2012 450

Christmas Creek Mining Fortescue Metals Group $384 Feb 2009 – Dec 2012 430

Hope Downs Mining Services Rio Tinto $75 Oct 2006 – Jul 2012 35

Bootu Creek Mining OM Holdings $120 Nov 2008 – Jul 2012 65

Tom Price Mining Rio Tinto $90 Jun 2004 – Jun 2010 130

Cloudbreak Mining Fortescue Metals Group $40 Mar 2008 – Nov 2008 100

Surface Mining Trials Rio Tinto $28 Jun 2005 – Sep 2008 28

Hope Downs South Mining and Prestrip Rio Tinto $30 Nov 2007 – Apr 2008 100

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CASE STUDY

MIDDLEMOUNT COALContract 1: Client: Middlemount Coal Joint Venture | Contract Mining Services | Value: $300 millionContract 2: Client: Middlemount Coal Joint Venture | Dry Hire | Value: $830 million

The Middlemount Coal Project was the first mining contract awarded to NRW in Queensland and was NRW’s first contract in the coal mining industry.

The original five year mining Contract was awarded in 2011 and included; clear and grubbing, long and short term detailed mine scheduling and planning, drilling and blasting including design, load and haul of 36 million BCM of overburden each year plus approximately two million tonnes of coal.

In February 2013, the new owners and NRW Holdings Limited reached an agreement to restructure the Mining Services Contract with Middlemount Coal JV into a Dry Hire Contract. As both Peabody Energy and Yancoal are coal mine operators it was a logical step for the Middlemount Coal JV to become the operator of the Middlemount Mine.

As part of the new arrangement NRW now provides ongoing maintenance services for the fleet. The original contract was due for completion in June 2016, but has been extended to June 2020.

The Dry Hire Contract value is approximately $830 million.

Quantity Plant

2 550T Excavator

4 350T Excavator

1 190t Excavator

13 220T Rigid Dump Trucks

9 190T Rigid Dump Trucks

6 140T Rigid Dump Trucks

3 Rigid Water Carts

2 16M Motor Graders

Equipment used at Middlemount Coal Mine consists of the following:

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CASE STUDY

WESTERN TURNER SYNCLINEClient: Rio Tinto | Value: $237 million

Equipment used at Western Turner Syncline Mine consisted of the following:

Quantity Plant

1 190T Excavator

1 190T Shovel

1 100T Excavator

8 140T Rigid Dump Trucks

2 D10 Dozers

1 16M Grader

1 14M Grader

2 Water Carts

NRW and Eastern Guruma Pty Ltd, who represent the traditional landowners of the area for mining, established a 50/50 Joint Venture to undertake works at Rio Tinto’s Western Turner Syncline Mine.

The Project commenced in December 2009 and continued until April 2014.

There were approximately 450 people employed at the mine on a 2:1 roster and for the last two years of the Project the indigenous employment was maintained at greater then 26%.

The Project scope included design and setting up of three areas of the mine using contour mining methods to allow the client to have an immediate start at the contract end. Work included; establishment of new haul roads and separated light vehicles roads; construction of ROM pads and backfilling civil infrastructure that is adjacent to the mine.

The Project involved mining of ore which is hauled to the Western Turner ROM pad with a fleet of 785 and 777 dump trucks. The ore was then hauled to the Tom Price mine via a 15 kilometre purpose built road by a fleet of five 350T pit hauler off-highway road trains.

NRW mined approximately 500,000 BCM per month to achieve the nine million tonne per annum target. NRW’s sister company Action Drill & Blast was also engaged on this Project to undertake drill and blasting – as a result interface between the drill and blast and load and haul was significantly more efficient and productive than when with non-related contractors

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CHRISTMAS CREEK Client: Fortescue Metals Group | Value: $384 millionNRW undertook continuous mining operations at Fortescue’s Christmas Creek Mine utilising standard mining methods for overburden and selective mining of ore utilising surface miners within numerous mine pits.

The Project commenced in February 2009 and was completed in December 2012. During this time approximately 11 million BCM of overburden was moved and three million BCM of ore mined. NRW provided all short term planning for the Project load and haul, as well as drill and blast.

At the peak of the Project NRW were mining approximately 1 million BCM per month with a total manning capacity of 430 personnel.

NRW supplied services to operate and maintain all of NRW’s plant and equipment on site. Additionally NRW managed the maintenance of the client’s ultraclass trucks and excavators, highlighting NRW’s reputation for quality maintenance on remote sites. This high level of delivery was underpinned by NRW’s customised maintenance system, called MinePoint, which allows review and analysis of historical data as well as future planning with regards to major component change-outs and scheduled servicing.

Equipment used at Christmas Creek consisted of the following:

Quantity Plant

10 1992 Front End Loaders

23 777 Dump Trucks

14 785 Dump Trucks

8 D10 Dozers

4 16M Graders

3 777 Water Carts

1 EX2500 Excavator

1 EX2600 Excavator

1 EX1900 Excavator

1 EX1200 Excavator

1 PC3000 Excavator

NRW also operated and maintained the following Fortescue equipment fleet:

Quantity Plant

6 MT4400 Dump Trucks

17 MT3700 Dump Trucks

2 9400 Liebherr Excavators

3 994 Front End Loaders

1 24M Grader

CASE STUDY

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CASE STUDY

NORTH STARClient: Ironbridge Joint Venture (JV) (Fortescue, Formosa, Baosteel) | Value: $75 million

NRW and Njamal ICRG JV Pty Ltd established a Joint Venture to undertake works at Ironbridge Operations’ North Star Mine. Njamal are the Traditional Landowners for the area where North Star is situated, and this partnership enables the Njamal community to develop their business skills and capability with NRW’s experience and support, whilst providing employment opportunities to their people.

The Project commenced in November 2013 and continued until December 2015.

Approximately 120 people were employed at the mine on a 2:1 roster, and the JV maintained a 15% Indigenous employment at its peak.

The initial Project scope included mine development works such as mine access, road construction, bulk earthworks for the mine, process plant and infrastructure, road construction of the Great Northern Highway intersection to the Concentrate Handling Facility, Gabion ROM Wall construction, commissioning feed for the process plant and the pre-strip and mining of the main IMA pit.

The Project also involved mining of waste and ore hauled to the North Star ROM with a fleet consisting of a 190 tonne excavator and CAT 777 dump trucks. The JV mined approximately 650,000 tonnes of ore in readiness for commissioning of the process plant.

NRW’s sister company, Action Drill and Blast, were engaged on the project to undertake drill and blast operations resulting in the elimination of interface issues between drill and blast and load and haul operations.

Equipment used at North Star consisted of the following:

Quantity Plant

1 190T Excavator

1 120T Excavator

1 30T Excavator

1 25T Excavator

6 100T Rigid Dump Trucks

3 40T Articulated Dump Trucks

1 D11 Dozer

4 D10 Dozers

2 16 Graders

1 14 Grader

4 Water Trucks

4 Rollers

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CASE STUDY

Quantity Plant

9 D9R Dozers

12 40T Articulate Dump Trucks

4 40T Excavators

4 13T Loaders

4 30T Loaders

2 16H Graders

2 14H Graders

3 18T Rollers

2 11T Rollers

4 30,000L Water Carts

The Simandou Mine is situated in a unique location on the Pic De Fon Mountain in Guinea (West Africa). NRW were contracted for the mining pre-development works in 2006 and were onsite continuously until finalising the Contract in December 2012.

The original scope of works developed into further assistance to Rio Tinto including the construction of the Beyla airstrip, surface mining trials, the National/Regional Roads Program and drill pad and access road construction.

NRW worked with local organisations and communities to provide constant education, training and competency evaluation to the French and local dialect speaking workforce.

The project had approximately 220 in country workforce comprised of expatriates and local personnel.

Equipment used at Simandou consisted of the following:

SIMANDOU PRE-DEVELOPMENT WORKS (WEST AFRICA) Client: Rio Tinto | Value: $175 million

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CIVILThe strong success of NRW’s Civil Division has been built on a foundation of consistently delivering project works to the highest standards. Since beginning as a small civil construction contractor, NRW has demonstrated an outstanding safety record and the capacity to deliver high quality projects on time and on budget.

NRW’s extensive plant list provides cost and scheduling efficiencies on each project undertaken, and ultimately savings for clients. NRW has experience in construction for both private and public infrastructure.

NRW civil projects have included:

• bulk earthworks;• concrete installation;• project rehabilitation;• conveyor line preparation;• construction of roads;• drill pads;• rail formations;• tailings dams and waste water storage;

• run-of-mine pads;• seawalls;• airstrips;• greenfield mine development;• bridges;• tunnels;• accommodation camps; and• ore storage facilities.

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BULK EARTHWORKSNRW’s growth has been built on the reliable execution of high quality, safely delivered bulk earthworks projects for blue chip clients in the resources and infrastructure sectors across Western Australia and Queensland.

Works undertaken include earthworks for ROM walls, stackers and reclaimers, stockyards, causeways, conveyor construction, car dumpers, railtrack and related ancillary works.

NRW’s capability and capacity to successfully deliver both large and small scale bulk earthworks contracts is self-evident with the subsequent award of variations to existing large contracts. Testament to this, were the award of the Nammuldi Haul Road overpass, Silvergrass Access Roads and Nammuldi Roads, all variations to NRW’s existing Nammuldi Below Water Table Contract for Rio Tinto.

PROJECT HISTORY

Project Name Client Value ($M)

Western Turner Brockman Bulk Earthworks Rio Tinto $376

Cape Lambert Port B – Car Dumper 5 and Stockyard Earthworks Rio Tinto $110

Cape Lambert Port B – Car Dumper 6/7 and Stockyard Earthworks Rio Tinto $206

Cape Preston Bulk Earthworks and Breakwater CITIC Pacific Mining $290

Brockman 4 Rail, Road and Infrastructure Bulk Earthworks Rio Tinto $204

Karara Iron Ore Project Bulk Earthworks and Concrete Karara Mining Limited $203

Herb Elliott Port Fortescue Metals Group $203

Nammuldi Below Water Table Rio Tinto $186

Yandi Sustaining Project Bulk Earthworks Rio Tinto $131

Roy Hill Mine Site Earthworks Roy Hill $65

Mesa J TSF5 Earthworks Stage 1 & 2 Rio Tinto $6

CASE STUDY

CAPE LAMBERT PORT B EARTHWORKS Client: Rio Tinto | Value: $316 millionNRW, in joint venture with Indigenous partner, Ngarluma and Yindjibarndi Foundation Limited (NYFL), were on site at Cape Lambert from April 2011. The JV undertook major bulk earthworks in preparation for stockyards; car dumpers 5, 6 and 7; railtrack and ancillary works including pipe jacking and access roads.

The Project comprised of earthworks for the provision of two new stockyards and three car dumpers, delivered as two separate contracts over two and a half years. The first contract for $110 million involved bulk earthworks for car dumper 5, stockyard A and out loading berm which had two million cubic metres of drill and blast work up to 30 metres deep with 2.6 million cubic metres of rock and common cut and fill as well as 0.5 million cubic metres of

unsuitable excavation and disposal and two kilometres of culvert installation.

Following NRW’s performance on the initial project, NRW was awarded a subsequent $206 million contract involving Car Dumpers 6/7, and Stockyard Earthworks. This project involved 1.8 million cubic metres of drill and blast, two million cubic metres of cut and fill, one million cubic metres of unsuitable excavation and disposal and four kilometres of culvert installation with a 2.2 metre diameter double pipejack under the live port railway feeding the shiploaders.

Project challenges included stringent environmental conditions and a high level of interface with other contractors.

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RAILNRW has extensive experience in undertaking and successfully delivering major rail earthworks formations, duplications and sidings for major resource companies such as Samsung C&T, BHP Billiton Iron Ore, Fortescue Metals Group and Rio Tinto. The scope of works on these projects typically include drainage, drill and blast, culvert installation and bridge construction.

NRW has undertaken rail formation works in the remote region of the Pilbara in Western Australia for over a decade. Most recently, NRW undertook the Roy Hill Rail Project which has seen the construction of approximately 330km of heavy haul rail formation between the Roy Hill Mine and Port Hedland. Initially undertaking work on sidings for both BHP Billiton Iron Ore and Rio Tinto, NRW’s first major rail project commenced in May 2007 for Fortescue Metals Group comprising 106 kilometres of rail formation earthworks. To date, NRW has completed over $2 billion worth of rail projects including formation, duplication or rail siding bulk earthworks.

PROJECT HISTORY

Project Name Client Value ($M)

Roy Hill Rail Project Samsung C&T $620

RGP5 Rail South Duplication & Chichester Deviation BHP Billiton Iron Ore $245

Port Hedland Inner Harbour Project BHP Billiton Iron Ore $227

Greenfields Rail & Bridge Works Fortescue Metals Group $213

Brockman 4 Rail, Road and Infrastructure Rio Tinto $204

Midwest Rail Upgrade Brookfield Rail $141

Christmas Creek Rail Extension Fortescue Metals Group $118

Fortescue Mainline Duplication Fortescue Metals Group $93

Yandi JSE Loop and Quail Siding & Bridge Rio Tinto $93

Solomon Spur Rail Fortescue Metals Group $70

Thomas Rail Marshalling Yard Fortescue Metals Group $38

Ore Car Repair Shop BHP Billiton Iron Ore $35

Jimblebar Mine and Rail Earthworks BHP Billiton Iron Ore $26

Coonarie to Spring Siding BHP Billiton Iron Ore $11

Mesa J Rail Formation and Mine Earthworks Hamersley Iron Pty Ltd $6

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CASE STUDY

ROY HILL RAIL Client: Samsung C&T | Value: $620 million

The Roy Hill Rail Project, NRW’s largest civil Project to date, consisted of approximately 330km of heavy haul rail formation and drainage between the Roy Hill Mine site and Port Hedland.

Together with sidings, level crossing and associated works, the overall materials moved was approximately 10.5 million cubic metres, of which over three million cubic metres was rock. The scope also included in excess of 36 kilometres of culverts.

In order to reach maximum efficiencies on the Project, NRW separated the works into five sections – Section 1 commenced in Port Hedland and Section 5 finished at the Roy Hill Mine – with each managed and resourced

independently. Each section, located approximately 70km long, had its own camp and section managers.

Preliminary construction commenced in October 2013 and the Project was completed in April 2015. At its peak, the Project employed a workforce of up to 1,650 personnel and utilised approximately 800 items of plant.

Prior to award of the Roy Hill Rail Project, NRW carried out earthworks on Fortescue’s Rail which runs parallel to the Roy Hill Rail Project. Our experience and understanding of the materials and terrain on that project put us in a position where we were able to add value to our client.

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CASE STUDY

KARARA IRON ORE PROJECT Client: Karara Mining Limited | Value: $203 millionRepresenting the first major concrete works package NRW had undertaken, the Project encompassed all of the preliminary construction work for the iron ore crushing and processing facility.

Works include the construction of major concrete foundations and structures for the plant and associated infrastructure, including ball mills, primary and secondary crushers, load out vault, and conveyor trestle foundations. The pouring of more than 50,000 cubic metres of concrete was a major component of the Project.

As well as site earthworks and concrete foundations, the contract included construction of site drains, 18 kilometres of access roads, a retention pond and the all-weather airstrip. The earthworks and road works for the plant site and associated infrastructure had an approximate total volume of bulk earthworks of 500,000 cubic metres of cut to fill and borrow to fill which took into account approximately 18 kilometres of road works.

This project was significant not only because it was the first major concrete package undertaken by NRW but it also showcased NRW’s ability to deliver a major project combining the two key civil elements of bulk earthworks and concrete structures. This allowed NRW to remove all interface issues that commonly occur between these disciplines, saving significant to construction time for our clients.

CONCRETE NRW has successfully managed and delivered concrete works alongside bulk earthworks since 2002. NRW has established a dedicated team of specialised concrete project personnel including project managers, engineers and supervisors to specifically manage concrete works packages.

NRW’s concrete capability includes foundations and structures for plant and associated infrastructure including ball mills, primary and secondary crushers, load out vaults and conveyor trestle foundations. To date, NRW has undertaken 161,000 cubic metres of concrete works, with the most recent contract being the Roy Hill Concrete Package for Samsung C+T at the Roy Hill Mine for over 53,000 cubic metres.

PROJECT HISTORY

Project Name Client Concrete Volume Value ($M)

Western Turner Brockman Rio Tinto 7,000m3 $305

Roy Hill Concrete Package Samsung C+T 53,000m3 $225

Karara Iron Ore Project Karara Mining Ltd 50,000m3 $210

Brockman 4 Rail, Road & Infrastructure Rio Tinto 2,000m3 $204

Herb Elliott Port Fortescue Metals Group 16,500m3 $203

Western Turner Syncline Civil Concrete Rio Tinto 21,000m3 $90

Port Hedland Inner Harbour Blending Yards BHP Billiton Iron Ore 5,000m3 $36

Hope Downs Village Installation Rio Tinto 1,500m3 $18

Pannawonica Bridge Repair Rio Tinto 5,000m3 $17

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CASE STUDY

ROY HILL CONCRETEClient: Samsung C&T | Value: $225 millionThe award of the Roy Hill Concrete Package, builds on NRW’s existing relationship with both Samsung C&T and Roy Hill, and follows the construction of NRW’s 330 kilometres Roy Hill Rail Project and the Bulk Earthworks Contract undertaken at the Roy Hill Mine Site.

The scope of works included insitu and precast concrete, inground and aboveground services and detailed earthworks for the iron ore processing plant, stockyard, overland conveyors and crushing areas.

To meet the client’s tight deadlines, the project team was required to pour an extraordinary average of 1,500 cubic metres of concrete per week and in order to do so mobilised a peak of 660 personnel to the Project within the space of three months.

Specific works undertaken included:

• 53,000m³ of structural concrete;

• 500,000m³ of earthworks;

• 60 kilometres of underground and aboveground HDPE and carbon steel piping; and

• 5 kilometres of rail works for the stackers and reclaimers.

The project had a construction duration of ten months commencing in April 2014 with peak manning of 660 personnel.

NRW’s Project team met the Client’s deadlines whilst working hard to build a positive safety culture and comradery which resulted in an extraordinary interim safety achievement of 990,000 man hours with a TRIFR of zero. With the manual intensive labour carried out by the team, this was no easy feat and industry leading in terms of performance.

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ROADS NRW has a long history in road construction, from haul and access roads on mine sites in remote Western Australia, Queensland and Guinea, West Africa, to large scale government infrastructure alliance projects in metropolitan areas.

NRW has been responsible for the following components on various road construction projects: clearing existing vegetation; removal, haulage and stockpile of topsoil; foundation compaction; embankment construction; drainage installation; pavement construction; bituminous surfacing; signs and line marking; guardrails, topsoil re-spread; landscaping and rehabilitation. Traffic Management is also undertaken on all road projects conducted by NRW.

PROJECT HISTORY

Project Name Client Value ($M)

Great Eastern Highway Upgrade Alliance Main Roads WA $280

Brockman 4 Rail, Road & Infrastructure Rio Tinto $204

Wheatstone Access Roads Bechtel $103

Simandou (West Africa) - Miscellaneous road works Rio Tinto $35

Hope Downs Access Road Rio Tinto $35

Yandi Access Road Rio Tinto $33

Windarling Haul Road Portman Iron Ore Ltd $29

Nanutarra Road Tunnels Rio Tinto $26

Silvergrass Access Roads Rio Tinto $14

Ernest Henry Monakoff Haul Road & Infrastructure Xstrata Copper $12

West Angelas Access Road Rio Tinto $12

Norwich Park Back Access Roads & Dragline Ramps BMA $10

Ravensthorpe Heavy Haulage Bypass Main Roads WA $10

Cloudbreak to Christmas Creek Haul Road Fortescue Metals Group $8

Saraji Back Access Roads & CSW Pad BMA $8

Middlemount Haul Road Rehabilitation & LV Separation Middlemount Coal $4

Nammuldi Roads Rio Tinto $3

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PORT DEVELOPMENT NRW has experience in a variety of port based earthworks. This includes breakwaters, marine offloading facilities and other port side earthworks in remote areas.

NRW understands the importance of working in close proximity to the coastline and customises the delivery of work to ensure all environmental concerns are taken into account.

PROJECT HISTORY

Project Name Client Value ($M)

Cape Lambert Port B – Car Dumper 5 and Stockyard Earthworks

Rio Tinto $110

Cape Lambert Port B – Car Dumper 6/7 and Stockyard Earthworks

Rio Tinto $206

Cape Preston Bulk Earthworks and Breakwater CITIC Pacific Mining $290

Port Hedland Inner Harbour Project BHP Billiton Iron Ore $220

Herb Elliott Port Fortescue Metals Group $203

CASE STUDY

CAPE PRESTON BULK EARTHWORKSClient: CITIC Pacific Mining | Value: $290 millionThe Cape Preston Breakwater and Bulk Earthworks Contract for CITIC Pacific which included 5.3 million cubic metres of drilling, blasting and excavation undertaken to provide 1.3 million cubic metres of fill for the construction of embankments. In addition, 5.2 million loose cubic metres of rock and processed rock products were placed at the 3.2 kilometre Breakwater.

Constructing a breakwater more than 2.5 kilometres into the sea, presents an enormous challenge, particularly if the waters encompassing the breakwater are in a proposed marine park and island nature reserves are in close proximity. It was clear from project inception that the Cape Preston Breakwater and Bulk Earthworks Package represented a high environmental risk.

CASE STUDY

GREAT EASTERN HIGHWAY UPGRADEClient: Main Roads WA | Value: $280 millionNRW, in alliance with Main Roads, GHD and Leighton Contractors, upgraded Great Eastern Highway between Kooyong Road and Tonkin Highway. The 4.2 kilometre section was improved to provide a six lane dual carriageway with median.

Major intersections were upgraded to reflect dedicated turning movements and u-turn facilities at key locations, as well as bus priority lanes at major intersections. In addition, the pedestrian and cyclist facilities were upgraded.

This major urban infrastructure project included significant traffic management, service relocation and community relations management.

GOVERNMENT INFRASTRUCTURE In 2010 NRW developed a team dedicated to the delivery of government infrastructure projects.

PROJECTS INCLUDE:

Project Name Client Value ($M)

Forrestfield–Airport Link Public Transport Authority $1,176

Great Eastern Highway Upgrade Main Roads WA $280

Ravensthorpe Heavy Haulage Route Main Roads WA $10

CASE STUDY

FORRESTFIELD–AIRPORT LINKClient: Public Transport Authority | Value: $1.176 billionThe Salini Impregilo – NRW Joint Venture has been engaged to deliver an 8.5 km extension of the existing Public Transport Authority urban rail network. The project will connect the Midland Line, just past Bayswater Station, to Forrestfield, running underground in twin bored tunnels underneath the Swan River, Tonkin Highway and Perth Airport.

Included are three new rail stations, namely: Belmont Station (located underground in Belmont); Airport Central Station (located underground at Perth Airport to service both domestic and international flights); and Forrestfield Station.

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DAM CONSTRUCTIONNRW has completed numerous tailings and water storage facilities including new dams and raises to existing facilities. These projects have been undertaken as stand-alone contracts as well as scope inclusions in larger projects.

PROJECT HISTORY

Project Name Client Value ($M)

Dam Projects

Area H Dredge Ponds BHP Billiton Iron Ore $29

Gregory Crinum Mine BF BMA $18.5

Vasse Tailings Storage Facility Stage 1 FMG $8.2

Nammuldi Waste Fines Storage Facility Rio Tinto $11.49

Saraji Mine BF BMA Saraji $7.5

Larger projects which included dam construction

Karara Iron Ore Karara Mining Limited $210

Dugald River Early Works MMG $12

Roy Hill Mine Site Earthworks Roy Hill Pty Ltd $70

Nammuldi Below Water Table Rio Tinto $170

AIRSTRIPSNRW has been constructing and undertaking airstrip upgrades and extensions in remote regions, since 2002.

The scope of works has included; sealed and unsealed runways, taxiways, aprons, carparks and associated ancillary works. NRW is capable of conducting the following components as part of an airstrip project: clearing and grubbing, foundations preparation, bulk earthworks, pavement construction, three coat sealing, line marking, aerodrome navigation, system installation, lighting, signal markers and cones, windsocks, flag poles, footpaths, drains and security fencing.

Project History

Project Name Client Value ($M)

Karara Airstrip (Karara Iron Ore Project) Karara Mining Limited $210

Beyla Airstrip (West Africa) (Simandou Pre-development Works) Rio Tinto $175

West Angelas Airstrip Extension Rio Tinto $46

Boolgeeda Airstrip (Brockman 4 Pioneering) Rio Tinto $44

Boolgeeda Airstrip Upgrade Rio Tinto $25

CASE STUDY

BOOLGEEDA AERODROME PROJECTClient: Rio Tinto | Value: $25 millionNRW, in Joint Venture with Indigenous Contractor Eastern Guruma Pty Ltd, was responsible for the upgrade and expansion of the existing gravel airstrip at Rio Tinto’s Boolgeeda Aerodrome located near their Brockman 4 Mine.

The works included over 300,000 cubic metres of fill to construct a 2.2 kilometre long, 45 metre wide bitumen sealed runway, complete with a new taxiway and apron as well as a new access road and carpark.

The scope also included ground works and in-ground services for new terminal buildings and airport. The upgrade took approximately seven months to complete, and had a peak workforce of approximately 70 personnel.

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REHABILITATIONWhilst most projects undertaken by NRW have rehabilitation included in the scope of works, NRW has also carried out rehabilitation works as standalone contracts.

Project History

Project Name Client Value ($M) Rehabilitation Area (Ha)

Stand alone rehabilitation contracts

Channar 84 East 5 - Waste Landform Rehabilitation Rio Tinto $6 43.9

Rehabilitation of Mesa J Pannowonica Pilbara Iron $1 60

Ranger 1 - Pit 1, Stage 2 Preload Works ERA $9.8 33.5

Rehabilitation of W31 Terraces - Mt Whaleback BHPBIO $1 5

Contracts which included rehabiliation as part of scope

Roy Hill Rail Samsung C&T $620 1,355

Roy Hill Minesite Earthworks Roy Hill $70 280

North Star Early Access and Bulk Earthworks Ironbridge Operations $44 58

Solomon Pre-Mining Development Works Fortescue Metals Group $190 60

Solomon Spur Rail Project Fortescue Metals Group $73 24

Nammuldi Below Water Table Bulk Earthworks Rio Tinto $170 88

Fortescue Main Line Rail Duplication Fortescue Metals Group $93 77

Cape Lambert Port B Car Dumpers 5, 6, 7 and Stockyard Earthworks

Rio Tinto $316 20

Rapid Growth Project 5 South Duplication BHPBIO $125 35

Rapid Growth Project 5 - Chichester Deviation & Homestead Siding

BHPBIO $120 30

Hope Downs Village - Permanent Access Road Rio Tinto $35 5

Earthworks Rail Section 2, Port Hedland to Cloudbreak Fortescue Metals Group $213 600

Brockman Line Extension Rio Tinto $204 81

Finucane Island Junction duplication, Marshalling Yard and Access Road

Calibre Rail $224 67

Ore Car Repair Shop Bulk Earthworks BHP - Calibre $34 36

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CASE STUDY

CHANNAR REHABILITATIONClient: Rio Tinto | Value: $8 millionIn May 2011, NRW completed the rehabilitation of the Channar Waste Dump located within the Paraburdoo Mine, 79 kilometres from Tom Price.

Over two million cubic metres of cut to fill material was moved via load and haul and dozer push. The Contract also included ripping and seeding.

The land has been rehabilitated to stringent environmental standards and sets the standard to which NRW can undertake rehabilitation works.

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January 2017

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