ROADS AND STRUCTURES - MCCONNELL DOWELL
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Roads and Structures Gold Coast Light Rail Queensland
At McConnell Dowell
our purpose is providing
a better life.
Breakwater Bridge
Victoria
Adelaide Desalination Plant
South Australia McConnell Dowell – Major Projects
Our culture is founded on We provide outstanding road and
expertise, creativity and progressive structures infrastructure solutions
thinking. We constantly challenge for our clients across diverse
ourselves and our partners to find environments, no matter how
the best solution for every project. challenging or sensitive. That is the
This attitude, along with our McConnell Dowell difference.
safe, high-quality, systematic and
structured approach, has earned us We actively target projects across
the trust and loyalty of our clients. a range of values and market sectors
in order to maintain a diverse order
McConnell Dowell creates road book. Current contracts underway
and structures infrastructure that set include the $65m Jane Street and
the standard – from designing and Mulgoa Road project in New South
constructing major complex freeway Wales, the $140m Public Transport
interchanges to remote critical Projects Alliance in South Australia,
access for resources projects. the $89m HMAS Coonawarra New
Wharf Structure in Darwin, and
Our depth of expertise across the $417m Mordialloc Freeway and
roads, structures, marine, pipelines, $862m Western Program Alliance
mechanical, civil and tunnelling projects in Victoria.
to deliver integrated design and
construct solutions, combined with Current major prospects include
more than 50 years of experience and the ~$200m Hay Point Ship Loader
a commitment to our clients and local and Berth Replacement Project
communities, is what sets McConnell for BHP near Mackay in Queensland
Dowell apart. which is currently in a sole source
ECI phase and projects as a delivery
partner under SA Water Frameworks
in a joint venture with Diona.
Annual Turnover
FY18/19 $1,180M
FY19/20 $945M
FY20/21 $1,030M
(Forecast Feb 20)
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OUR PROJECTS Client: Major Road Projects Victoria
Location: Melbourne, VIC
Contract: Design & Construct
Role: Principal Contractor
Mordialloc Freeway Dates: Oct 2019 – Dec 2021 Value: $417M
Artists Impression
Project Description Design
The McConnell Dowell Decmil Joint Venture has A new shared walking and cycling path will also be In response to community feedback, changes were Teaming up with the social enterprise is a win-win.
been awarded the contract to design and construct constructed along the entire length of the Mordialloc made to the design to include: Ability Works can continue the great work in creating
the 9km Mordialloc Freeway in Melbourne’s south east Freeway, providing safe and reliable journeys for • Bridges over Governor Road, Lower Dandenong Road employment opportunities for people facing barriers
which will link the Mornington Peninsula Freeway at members of the public enjoying more active forms and Centre Dandenong Road instead of traffic lights to employment, helping them to build their skills using
Springvale Road in Aspendale Gardens to the Dingley of transport. • A bridge over Old Dandenong Road to keep machines, equipment and computers and the project
Bypass in Dingley Village, creating a continuous it open for Dingley Village residents team get the tools needed to build the job, knowing
Motorists using the Mordialloc Freeway can
freeway from Frankston to Clayton. they are helping to make a difference.
expect quicker and safer and journeys, with north • A twin bridge over the sensitive wetlands
As part of the project, bridges will be built over and southbound traffic separated and road safety to ensure rainfall and natural light reaches the
Aboriginal Partnership
Springvale, Governor, Lower Dandenong and Centre barriers installed along the inside and outside vegetation below
The project team partnered with Geared Up Culcha to
Dandenong Roads, along with new freeway entry of each carriageway. • Longer and taller fences next to Braeside Park supply Personal Protective Equipment (PPE) to workers,
and exit ramps. to protect local wildlife
Construction of the Mordialloc Freeway will create including custom work boots on the Mordialloc Freeway
A bridge will also be built over Old Dandenong Road 400 jobs, which will include 10% of total labour hours • A wider pedestrian underpass at Braeside Park to project. The Zeke boot is manufactured by KingGee and
to keep it open for Dingley Village residents, and a twin allocated to training apprentices, trainees and cadets, improve connectivity is exclusively distributed by Geared Up Culcha.
bridge will be built over sensitive wetlands to ensure building much needed skills within the industry. • A new intersection at Lower Dandenong The boots have a unique pattern on the soles, insoles
rainfall and natural light reaches vegetation below. Road so Woodlands Drive can remain open.
In addition, the joint venture is committed to sourcing and laces, which reflects the sacred Pilbara landscape
at least 96% of material and employment locally, in the north of Western Australia.
Social Procurement
benefiting the local community and broader economy.
The project teamed up with Ability Works, a social By partnering with this Aboriginal owned
enterprise in Melbourne’s inner east, to design and and controlled business, the project is supporting
manufacture some of the tools needed to build the Geared Up Culcha to donate funds to both the
Mordialloc Freeway. Indigenous Literacy Foundation and the Yaru
Foundation, which provides clean drinking water
Ability Works, who provide employment opportunities
to remote Aboriginal communities in Australia.
for 130 people facing barriers to employment including
people living with disabilities, has supplied 350
settlement plates to help monitor soil levels during
construction of the foundations of the Mordialloc
Freeway.
6 7
OUR PROJECTS Client: Transport for New South Wales & Major Road Projects Victoria Client: Port of Melbourne Corporation (POM)
Location: Echuca, VIC & Moama, NSW Location: Melbourne, VIC
Contract: Design & Construct Contract: Design & Construct
Echuca Moama Bridge Role: Principal Contractor
Webb Dock Role: Principal Contractor
Stage 3 Dates: Oct 2019 – Feb 2022 Value: $178M
MaritimeWorks Dates: Jan 2014 – Dec 2016 Value: $400M
Artists Impression
Project Description Project Description Innovations
Echuca in Victoria and Moama in New South Wales the Project acknowledged their deep and spiritual The Port Capacity Project was a $1 .6 billion upgrade The PCP Maritime Works Package demonstrates
are connected by a single Murray River Bridge that was connection to the land and waterways such as the that included the redevelopment of Webb Dock to McConnell’s ability to design, resource, and deliver
first opened in 1878. Murray River. create a third international container handling facility complex marine infrastructure in a live operational port
alongside the development of a dedicated facility environment. We worked closely with the POM, its
The Echuca Moama bridge project is jointly A small group gathered on the Sandhill, a culturally servicing Victoria’s automotive import-export trade. tenants and four adjacent PCP contractors to plan and
funded by the Australian, Victorian and New South important Yorta Yorta site elevated above the execute our works with no unplanned disruption
Wales governments to build a new bridge to connect surrounding floodplain, within the project’s footprint. McConnell Dowell was the Principal Contractor
to operations. Our Project Director regularly presented
the Murray Valley Highway and Warren Street at delivering the Maritime Works Package of the Port
The Yorta Yorta are the Aboriginal traditional owners at a Project Liaison Group (PLG) forum, alongside
Capacity Project. The Package comprised the design
Echuca with the Cobb Highway at Perricoota Road our dedicated Stakeholder Manager, providing
of a region across north-central VIC and southern NSW, and construction of improved waterside infrastructure,
in Moama. construction updates and look ahead details to key
including Echuca and Moama. The group included some including upgraded navigation aids and berth facilities.
of the MCD and MRPV Project team plus members project stakeholders, the local community and
The scope of works includes:
The project demonstrated McConnell Dowell’s the POM operations teams.
• a new road north of the new Warren Street of the Yorta Yorta community working on the Project.
capabilities to resource and deliver a complex design
roundabout in Echuca with one lane in each direction McConnell Dowell introduced the use of robotic hydro-
and construct project, which was demonstrated
• new bridges over the Campaspe and demolition for breaking back pre-cast piles in confined
by the following project facts:
Murray rivers spaces. This provided safety benefits by eliminating
• 900 tubular steel piles up to 1500mm diameter
the need for workers to enter confined spaces.
• two new flood relief bridges and 45m long driven as single length piles
• 40,000m³ of structural concrete McConnell Dowell designed and purpose built multiple
• a new separated walking and cycling path, providing
access platforms for safe working over water. These
a safe and scenic link between Echuca and Moama • 10,000 tonnes of reinforcing steel
frames were also designed as multi use and were also
via Warren Street. • 40,000m of sheet pile installation used to install multiple heavy pre-cast beams along the
Innovations • 210,000 tonnes of imported quarry product berth alignment. McConnell Dowell’s Engineering Team
The project team mobilised to site just prior to Covid-19 • 15,000m³ of rehabilitated concrete deck developed cantilevering platforms that sat on the wharf
restrictions coming into force. A number of distancing edge and moved along the wharf without the need for
• The removal of 2.3 million m³ of dredge material.
measures have taken place. cranes or other plant. They are a cost-effective solution
The project was delivered within an operational for repetitive work that minimises working at heights
Social distancing measures include toolbox talks and port environment concurrently with four adjacent risks and provides safe access to the works.
briefings. Due to current restrictions, our ‘Welcome to major construction contracts associated with the
Country’ plans were pared back today, however with Port Capacity Project. 2017 Australian Construction Achievement
representatives from traditional owners, *Yorta Yorta, Award winner.
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OUR PROJECTS Client: Department of Planning, Transport and Infrastructure, SA Client: Port of Melbourne Corporation (POM)
Location: Adelaide, SA
Western Program Location: VIC
Contract: Alliance
Alliance (VIC), Contract: Alliance
Regency Road Role: Non-owner participant and Principal Contractor
Level Crossing Removal Role: Non-owner participant and Principal Contractor
to Pym Street Dates: Jul 2019 – Jan 2022 Value: $189.8M
Projects Dates: May 2017 – 2023 Value: $862M
Artists Impression
Project Summary • Pre-assembly of the 65m main span (in two halves) Project Summary Innovations and Value Add
The project comprises an at-grade motorway from in an assembly yard approximately 500m from McConnell Dowell is the principal constructor for the Visual Management Centres (VMC): McConnell
the existing motorway infrastructure to the north (South Regency Road including installation of the steel box Western Program Alliance (WPA), established to remove Dowell implemented a VMC process across three
Road Superway); an overpass of the motorway over girders, pre-cast concrete deck units, cast in-situ level crossings and other rail-related works predominantly levels throughout the Alliance, this process replaces
Regency Road; and an at-grade motorway from Regency concrete deck and edge barriers in Melbourne’s west. Established in 2017, to date they have traditional inefficient and less effective reporting
Road to Pym Street, transitioning to the lowered motorway • During a closure of Regency Road and partial closure successfully completed the removal of the: and escalation processes with the aim to eliminate the
infrastructure (Torrens Road to River Torrens Project). of South Road, the bridge will be moved position using • Kororoit Creek Road, Williamstown North level waste of poor communication.
The concept design includes: SPMTs with each bridge half will weight nominally crossing and duplicated a section of the Altona Loop
Connected Sites Pilot Program: The Connect Site
• A 1 .8 kilometre section of non-stop roadway, providing 1,300t followed by completion works • Abbotts Road level crossing in Dandenong South Project (CSP) is a collaboration between McConnell
three lanes in each direction (at-grade).
• Minimised disruption to traffic and a much • Aviation Road, Laverton level crossing removal project. Dowell, WPA, LXRP and global technology company
• Two lanes in each direction on the South Road surface safer environment for construction of the bridge Orange. Initially being trailed on the Aviation Road site
The team also constructed the new Wyndham Vale
road, providing access to the surrounding community involves placing sensors on machines and around
c) Traffic Management: Stabling Yard for V/Line.
and local businesses. the site to capture data to ensure more richer information
• The North South Corridor is the primary transport
• An overpass over Regency Road (three lanes in In 2020 four additional packages of works were awarded: can be captured live, on-the-ground, to help the project
route through Adelaide and diverting traffic off
each direction). Two lanes in each direction (at-grade) • 3 Level crossing removals on the Werribee Line at make informed decisions and report on progress as
the road would cause significant disruption to traffic
on the surface roads underneath. Old Geelong Road in Hoppers Crossing, Cherry Street well as capturing gained efficiencies. This live, real-time
on other routes and likely cause grid-lock locally
in Werribee and Werribee Street in Werribee data allows the Alliance to improve efficiencies
• Left in and left out only access at Pym Street. to the project
• Cranbourne Line Upgrade works including track and realise cost and time savings.
• Full access to and from the non-stop motorway • The R2P Alliance adopted an approach to
duplication between Dandenong and Lynbrook,
at Regency Road. “encourage” traffic to continue to use corridor whilst Contaminated material management and reuse:
Greens Road level crossing removal, and new rail
• Intersection upgrade at Regency Road. construction works proceeded At Kororoit Creek Road it was identified early that the
bridges over Eumemmerring Creek and Abbotts
• Non-critical turning movements were banned, which soil and groundwater on site was contaminated with low
• Improved cycling and pedestrian facilities. Road. Designs were developed in conjunction
created additional green time for through movements concentrations of Polyfluoroalkyl Substances (PFAS).
• A grade separated pedestrian and cycle overpass with community input and approved for construction
The team at WPA engaged early with the regulator
over South Road in the vicinity of Pym Street. • Key Performance Indicators were agreed with the in January 2020.
and successfully gained approval for the reuse of
Road Authority which allowed the Alliance to measure Building on the previous State Government commitment
• Landscaping and noise barriers. PFAS impacted material onsite, which was a Victorian
performance to initially remove 50 dangerous and congested first. McConnell Dowell has taken these lessons learnt
Innovations • Daily review of traffic and weekly dashboards level crossings across Melbourne, this was increased and delivered discussion papers to the broader LXRP
a) Use of a web-based Comment Integration Tool are issued to review traffic volumes and ensure that to 75 after the State Election in late 2018. This new program alliances to assist the industry in managing
b) Assembly of the Regency Road Bridge main span in all possibly opportunity is provided to keep traffic milestone will see the entire program complete by 2025. PFAS-impacted material. This continual feedback loop
an off-line assembly location and moving the bridge into moving through the project and minimise diversion of lessons learnt being provided to follow on projects
position using Self Propelled Modular Trailer (SPMT): of traffic to other routes. is a key outcome that will be adopted these works.
10 11
OUR PROJECTS Client: Jemena Client: Rio Tinto (Bechtel EPC)
Location: Tennant Creek NT to QLD (481 km) Location: Cape York Peninsula, Far North Queensland
Contract: ECI & Construct only Contract: Alliance
Role: Principal Contractor Role: Principal Contractor
Northern Gas Pipeline Dates: 2015 – Sep 2018 Value: $157M
Amrun Export Facility Dates: May 2016 – Feb 2018 Value: $170M
Project Description Project Description Innovations
The construction of Northern Gas Pipeline project set
McConnell Dowell was engaged by Jemena The Export Facility is known as Chith, the Wik-Waya The Amrun Export Faculty was a collaborative,
new benchmarks in pipeline safety performance with:
under an exclusive ECI agreement to partner in the language name for the red and white eagle (Brahminy construct only contract working closely with the client
• More than 550,000 manhours and more than
NT Government’s competitive process to select Kite) that visits and inhabits the area surrounding the Rio Tinto, EPC contractor Bechtel and the engineering
280 days of physical construction activity with
a proponent to build and operate the North-East Export Facility. consultant Jacobs. There was a six month dual
a Total Recordable Frequency Rate of zero
Gas Interconnector Pipeline. The scope involves the EC I phase prior to award which enabled all parties to
and no Medical Treatment or Lost Time Injuries Constructed in just 12 months the bauxite export facility
construction of approximately 481 km of 1 2-inch drive value adds and clarify the contract requirements.
• The site is spread across 481 km and the project team includes a 650m access jetty and a 350m wharf both
diameter high pressure gas transmission pipeline and Innovations developed in this phase were market
completed more than 5,600,000 kilometres driven fully provisioned with services, conveyors, roadways
associated pipeline facilities including two mainline leading with significant project benefits realised.
on the project (excluding third party transport) with and access walkways.
valves and a midline scraper station. The pipeline
no significant vehicle incidents, collisions of any The second phase involved design completion,
transports gas from existing offshore and onshore gas The scope also included the onshore construction of
kind or adverse involvement with vehicles driven by procurement and preparation for site works.
reserves in the Northern Territory and supplies this 350 metres of ground conveyors and transfer stations
others (general public) McConnell Dowell engaged with a selection of
gas to Incitec Pivot’s Phosphate Hill plant located south works linking into the reclaim conveyor. McConnell
our Chinese partners to prefabricate all the major
of Mt Isa and other users. • More than 53,000 pipe joint movements with Dowell self-performed much of the construction.
components in Shanghai. The China fabrication
no dropped pipe.
The Northern Gas Pipeline Project was constructed was championed by a combined team of project,
in very remote arid lands roughly stretching between Innovations & Technology McConnell Dowell China and fabricator personnel.
Tennant Creek and east to the Queensland border lands. • Food dehydrators in construction camp to process
waste, reducing transport and eliminating waste The final phase was site construction works. The
construction was integrated into the overall project
Innovations • Computerised radiography for welds with a wide
development with key elements supplied by the client.
Some of the challenges faced on the project include: range of cost, quality and time benefits
Cooperative working relationships, pre-planning
• A scarcity of water available for construction activities • Localised remote location cell phone coverage and a commitment to a best for project philosophy
• Very high dust levels due to low subsoil moisture • CAT Vision Tracking system for equipment was the cornerstone of the success of the project.
conditions and water scarcity including physical location, idle hours, operating
The project won the 2019 Australian Constructors
• Extremely high daytime temperatures for some hours and fuel burn
Achievement Award, 2018 Civil Contractors
months of the scheduled construction activities • HELIX In Vehicle Monitoring System used Federation (CCF) winner National Earth Award
• A variety of land owners including large industrial to monitor driver behaviour. for projects valued over $75 million, 2018 “Best
pastoral companies, private pastoralists, Crown Contractor” in Rio Tinto’s Chief Executive Safety
lands and indigenous landowner groups Awards, 2018 QMCA Innovation Award and the
• Summer wet season – necessitating a break 2019 Institution of Civil Engineers Brunel Medal.
in construction activity.
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OUR PROJECTS Client: New Zealand Transport Agency
Location: Auckland, New Zealand
Contract: Design, Build, Operate and Maintain
Role: Alliance - Fletcher, Obayashi, Beca, Parsons
Brinckerhoff and Tonkin & Taylor, McConnell Dowell
Waterview Connection Dates: Aug 201 1 – Jul 2017 Value: $1.54B
Project Description
The Waterview Connection was the largest project in • A pedestrian and cycle bridge over SH20
Auckland’s Western Wing Route, one of New Zealand’s in Hendon Park
Roads of National Significance and involved the design • Four 2-lane motorway-to-motorway connection
and construction of 4.8 km new motorway from the viaduct structures
end of the SH20 motorway at Maioro Street through
to a motorway to motorway interchange with SH16 Innovations
at Waterview. 2.4km of the new motorway incorporated During the design phase the Alliance established a
two 3-lane tunnels, 13 .1 m internal diameter, which value-for-money (VfM) team comprising experienced
were constructed by a purpose built earth pressure design, construction, and client personnel (including
balanced tunnel boring machine. Aurecon staff).
Key components of the Waterview Connection This resulted in some the use of key innovations such as:
project included: • Using the pits required for the tunnel-boring
• A full diamond interchange at Maioro Street machine (TBM) launch and turn-around as the
• A 4.5km motorway connection from Maioro Street permanent drainage sump at the tunnel portals -
Interchange to SH16 at Great North Road Interchange providing saving of $1 .6m
• Twin 3-lane tunnels 2.4km long from Alan Wood • Optimising the steel segments and reinforcement
Reserve to Waterview Park in the tunnel segmental lining to reduce the amount
of steel required - resulting in savings of $2.7m
• A southern tunnel portal structure incorporating
ventilation building and vent stack • McConnell Dowell coordinated drainage design
and construction which allowed removal of cement
• A northern tunnel portal structure incorporating
stabilisation from the tunnel backfill specification
ventilation building
while providing a trafficable surface adequate for
• A ventilation duct crossing Great North Road heavy haulage and relocating tunnel main drain from
to a remote vent stack invert culvert to backfill, resulting in savings of $ 1 .7m.
• A new bridge carrying Richardson Road over SH20
• A new bridge carrying SH20 across Oakley Creek
14 15
For over 50 years
customers have been
coming to us with
complex projects that
require innovative
solutions.
Riverbank Pedestrian Bridge
South Australia
May 2020 mcconnelldowell.com
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