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People+Projects - Fulton Hogan

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					People+Projects                                                                                    Volume 5




Our People     + Dave Faulkner creates a lasting legacy
               + Fulton Hogan well represented at Roading NZ Awards                                i n e e ri n g
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Our Projects + Central Connector an Auckland showpiece project
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             + major Caloundra road project enhances regional amenity                     Years
                                                                              F U LTO N H O G A N
                  VOLUME 5 Fulton Hogan                                                                                        VOLUME 5 Fulton Hogan



                                                                                                Contents
                                                                                                5    message from the managing Director

                                                                                                6    maintaining the flow while reconfiguring
                                                                                                     New Zealand’s busiest roadway

                                                                                                9    Bendigo benefits from booming precast facility


                                                                                                10   Central Connector an Auckland showpiece
                                                                                                     project

                                                                                                12   Forestry interests help creast a greener Fulton
                                                                                                     Hogan

                                                                                                14   PRS acquisition enhances Fulton Hogan
                                                                                                     capabilities across Australia

                                                                                                18   Fulton Hogan well represented at Roading
                                                                                                     NZ Awards

                                                                                                20   Fulton Hogan helps secure Barwon’s
                                                                                                     water supply

                                                                                                22   Fulton Hogan now part of two melbourne
                                                                                                     Water alliance teams

                                                                                                24   major Caloundra road project enhances
                                                                                                     regional amenity

                                                                                                27   Dave Faulkner creates a lasting legacy

                                                                                                28   origin Alliance - Australia’s biggest road project

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                                                                                                     NZ news




                                                                                                                                                          People+Projects
People+Projects




                                          Cover:   Togia Falakoa, Auckland Central Connector.
                                                                                                31   Australian news
                                          Left:    Precast Yard in Bendigo, Victoria.
                  VOLUME 5 Fulton Hogan                                                                                                                                                                                 VOLUME 5 Fulton Hogan



                                                                                                                                       message from the managing Director

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                                                                                                                                                                     elcome to the fifth edition        range of areas. The Newmarket Viaduct
                                                                                                                                                                     of People+Projects which           project is just one example of how strong
                                                                                                                                                                     continues to showcase Fulton       relationships and a proven ability to deliver
                                                                                                                                                     Hogan’s achievements both in New Zealand           has helped Fulton Hogan win new contracts
                                                                                                                                                     and Australia.                                     in a highly competitive market. The Roading
                                                                                                                                                         Within this edition you will read about        New Zealand Annual Awards further
                                                                                                                                                     the growth of our Australian operations            validated Fulton Hogan’s ability to deliver
                                                                                                                                                     with the recent acquisition of Pioneer Road        outstanding results after winning three
                                                                                                                                                     Services (PRS); a snapshot of some of our          of the five coveted awards, including the
                                                                                                                                                     successes in project delivery; and also the        Supreme excellence Award for the Northern
                                                                                                                                                     recent retirement of our former managing           Gateway.
                                                                                                                                                     Director, Dave Faulkner.                                However, regardless of the accolades
                                                                                                                                                         Dave retired from Fulton Hogan in              Fulton Hogan receives, where we are based,
                                                                                                                                                     December 2009 after 24 years of dedicated          or what services we provide, it is our people
                                                                                                                                                     service, including nine years as managing          that have made us successful. This edition
                                                                                                                                                     Director. under Dave’s leadership the              features many of these talented people
                                                                                                                                                     company has experienced impressive year            and just as importantly the value they have
                                                                                                                                                     on year growth in profitability and staff          provided to our customers, through their
                                                                                                                                                     numbers.                                           energy and commitment to safety and
                                                                                                                                                         Dave has also played an important              innovation.
                                                                                                                                                     role in our growth and diversification into             As this is my first People+Projects as
                                                                                                                                                     Australia, which dates back to our initial entry   the newly appointed managing Director, I
                                                                                                                                                     into Queensland in 1981. Since this time,          look forward to continuing the tradition of
                                                                                                                                                     our Australian operations have continued           delivering excellence in all that we do at
                                                                                                                                                     to grow both organically and through               Fulton Hogan. 2010 will be a year of change
                                                                                                                                                     acquisition, from less than 40 employees to        for our Australian operations as we integrate
                                                                                                                                                     over 2000 today.                                   PRS into Fulton Hogan. I know the end result
                                                                                                                                                         With the recent acquisition of PRS – the       will provide you with an innovative business
                                                                                                                                                     largest acquisition in the company’s 76 year       that offers real value and quality across all
                                                                                                                                                     history – we are now Australasia’s most            our services.
                                                                                                                                                     capable asphalt and surfacing company. It               over the coming months I hope to
                                                                                                                                                     also strengthens our vertically integrated         meet with many of you, our customers
                                                                                                                                                     business model and allows us to build on PRS’      and suppliers, to reinforce my commitment
                                                                                                                                                     geographic footprint to broaden the range of       to continuing and building long term
                                                                                                                                                     services we can provide to customers from          relationships and solutions that drive value
                                                                                                                                                     these locations, particularly in the areas of      creation in our respective organisations.
                                                                                                                                                     maintenance and construction.
                                                                                                                                                         While our Australian operation grows




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                                                                                                                                                     and diversifies, our well established New          Nick miller




                                                                                                                                                                                                                                                        People+Projects
                                                                                                                                                     Zealand operation continues to showcase
People+Projects




                                                                                                                                                                                                        managing Director
                                                                                                                                                     the company’s capabilities across a broad

                                                                                           Six new bus canopies were erected as part
                    Fulton Hogan’s asphalt plant is the most advanced in South Australia   of the 5km Central Connector Project.
                  VOLUME 5 Fulton Hogan                                                                                                                                                                                    VOLUME 5 Fulton Hogan



                  maintaining the flow while reconfiguring New Zealand’s busiest roadway
                                                                                                                                                                                                           “As if the engineering
                                                                                                                                                                                                           itself was not
                                                                                                                                                                                                           challenging enough, the
                                                                                                                                                                                                           location and significance
                                                                                                                                                                                                           of this project requires
                                                                                                                                                                                                           a very comprehensive
                                                                                                                                                                                                           project management

                                                         T
                                                                 he most heavily trafficked
                                                                 stretch of road in New Zealand,                                                                                                           planning approach
                                                                 the Newmarket Viaduct carries                                                                                                             that addresses an
                                                      over 160,000 vehicles a day in and out of
                                                      Auckland.                                                                                                                                            extraordinary range of
                                                          When completed in 1965 it was                                                                                                                    considerations.”
                                                      considered a pioneer design, as the first
                                                                                                       Preparating one of the north-bound pier foundations used to accommodate the steel                   Ian Harbeck, Project Manager
                                                      bridge in New Zealand to use a prestressed
                                                                                                       reinforcement cage.
                                                      continuous box-girder design, Freyssinet
                                                      concrete hinges at the base and cantilever
                                                      construction techniques.                         a replacement structure would be the                   Being such a highly visible and functional   landscape from the bridge of the volcanic
                                                          Today, with increasing volumes of traffic,   best solution to resolve these issues and         part of the city, an aesthetic and practical      cones Rangitoto, maungawhau/mt eden
                                                      the bridge has not been able to cope with        that the existing bridge would need to be         design is essential to ensure the bridge          and Remuera/mt Hobson.
                                                      modern demands and is starting to show           demolished as it did not have the ability to      remains operational and integrates into the            “To minimise commuter disruption
                                                      its age, with traffic capacity, strenght and     be upgraded or widened.                           city skyline,” explained Project manager, Ian     meticulous scheduling is essential to keep
                                                      seismic limitations the busy Newmarket               The Northern Gateway Alliance                 Harbeck.                                          everyone moving – it is important to keep
                                                      area below. It also has a host of other issues   (NGA), responsible for construction of                 “It is challenging working with an           the motorway operating at full capacity
                                                      including:                                       the award-winning Northern Gateway                established structure with such a high            throughout the project, with all three lanes
                                                      •	 edge barriers not sufficient for current      Toll Road completed in January 2008,              frequency of use,” said Ian. “We understood       open in both directions. To do this the
                                                          safety standards expected by the             was invited to construct the Newmarket            that the bridge needed to blend into              Alliance settled on developing a staged
                                                          community;                                   Viaduct Replacement Project. Their strong         its surroundings and as such, visual              approach to the build.”
                                                      •	 narrow shoulders limiting emergency           relationship with the client and proven ability   appearances would be a core component                  Key stages include:
                                                          access with incidents readily blocking       in building similar viaducts ultimately saw       of its success.                                   1. Build new southbound bridge on the
                                                          the motorway;                                them awarded the NZ$215 million project                “Careful attention to detail was paid,            eastern (harbour) side of existing
                                                      •	 seismic retrofitting is needed to meet        with work commencing in November 2008.            during the design phase, to subtly hide                viaduct.     This   new        structure
                                                          modern codes;                                    The Alliance, now known as the                stormwater pipes. The design also follows              accommodates an extra fourth lane.
                                                      •	 a lack of stormwater drainage; and            Newmarket Alliance, comprises NZTA as             the contour of the existing structure and         2. Demolish existing south-bound viaduct.
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                                                      •	 temperature variations causing high           both client and Alliance participant, along       features slender columns that will the help       3. Build new north-bound bridge to replace




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                                                          structural stress.                           with Fulton Hogan, leighton Contractors,          us create an elegant structure some 13m                old south-bound viaduct (resulting in
                                                          Following an extensive study by the          Beca Infrastructure, VSl New Zealand, uRS         east of the existing bridge.”                          new seven lane superstructure).
                                                      New Zealand Transport Agency (NZTA),             New Zealand, Tonkin & Taylor, and Boffa                A number of other parties collaborated       4. Demolish existing north-bound viaduct.
                                                      which started in 2002, it was agreed that        miskell.                                          with the Alliance to maintain the visual
                  Night works at Newmarket Viaduct.
                  VOLUME 5 Fulton Hogan                                                                                                                                                                                                                                                  VOLUME 5 Fulton Hogan
                  Construction                                   Deconstruction                                 importance to the team.
                      The Alliance team selected a precast,
                  match-cast segmental balanced cantilever
                                                                     once the first part of the new structure
                                                                 has been built, deconstruction will
                                                                                                                     “As if the engineering itself was
                                                                                                                not challenging enough, the location                  Bendigo Benefits from Booming Precast Facility
                  approach for the new viaduct’s construction.   commence in the fourth quarter of 2010.        and significance of this project requires a



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                  This involves building simultaneously from     This is a significant undertaking with deck    very comprehensive project management                             he central Victorian town of               “This means that our customers are           equating to a total of 46,000 individual
                  either side of a pier using an overhead        spans ranging in length from 33.5m to 61m,     planning approach that addresses an                               Bendigo is one of the many             consistently benefiting from higher quality      segments. manufacturing commenced
                  launching gantry.                              20m above existing ground level.               extraordinary range of considerations,”                           stakeholders who have benefited        products and in some instances are able          in march 2008 and will be completed by
                      These spans are extended until the             “Similar to the construction phase the     said Ian.                                             from Fulton Hogan acquiring the region’s           to have access to precast elements earlier       June 2010.
                  midpoint is reached, at which point they       segments will be meticulously excised               “As well as the full range of traffic, safety,   precast operation in 2006.                         than initially scheduled.”
                  are attached to identical half-deck spans      using the overhead launching gantry in         engineering and design considerations, the                With over 120 employees now working                It is this leadership in the industry that   Adelaide Desalination Plant, Client
                  built out from adjacent piers. At the two      a balanced cantilever sequence, in the         team has to address other concerns like               from the five hectare facility, Fulton Hogan       has seen Fulton Hogan become the first           Adelaide Aqua
                  end spans, temporary supports are used to      opposite sequence from construction -          utility integration, visual impacts, noise, dust,     is one of the region’s major employers             Victorian precast operation to incorporate           Fulton Hogan is manufacturing and
                  construct the spans.                           starting from the midspan joint and working    changing land uses and sustainability.”               and operates a round-the-clock operation           this new technology into their operations.       supply 2.4km of 2.8m diameter segmented
                                                                 back towards the pier,” said Ian.                                                                    to meet the diverse demands of our                                                                  rings for the desalination plants intake
                                                                                                                                                                      customers.                                         Highlights                                       and outfall tunnels. each ring consists
                  “We have adopted                                                                                                                                        Initially the precast operation focused        Northern Sewer Project, Client John              of six segments and equates to around
                  a reduce, reuse                                                                                                                                     on supplying bridge beams for road                 Holland                                          12,000 individual segments. The $1.83b
                                                                                                                                                                      projects in Victoria. However, over the past           Fulton Hogan is manufacturing over           desalination plant will supply around 25% of
                  and recycle waste                                                                                                                                   four years substantial capital investment          7500 tunnel rings with a 2.4m of 3.4m            Adelaide’s future water needs. manufacturing
                  approach across the                                                                                                                                 in new technology, equipment and the               diameter to facilitate the construction          commenced in September 2009 and will be
                                                                                                                                                                      improvement of quality processes, has seen         of the Northern Sewer Project in melbourne.      completed by April 2010.
                  team. Sustainable                                                                                                                                   the operation expand into a broader range          each ring consists of six segments
                  procurement methods                                                                                                                                 of precast elements including:
                                                                                                                                                                      •	 segment	 systems	 –	 pipeline	 tunnels,	
                  and encouraging                                                                                                                                         road and rail tunnels and arches;
                  team members to use                                                                                                                                 •	 bridge	 systems	 –	 beams,	 parapets,	
                                                                                                                                                                          headstocks, piers and wingwalls; and
                  alternative transport                                                                                                                               •	 other	 related	 infrastructure	 and	 special	
                  to and from work is                                                                                                                                     once-off products.

                  part of our day-to-day                                                                                                                              “Fulton Hogan uses a
                  approach.”                                                                                                                                          leading-edge process
                  Ian Harbeck, Project Manager                                                                                                                        control technology
                      “This approach is very familiar to the     Managing the project                               By combining these elements into                  to guarantee quality
                  viaduct on the Northern Gateway Toll Road.         This project is not only big, ambitious    the management and construction of the
                  We have also been able to recycle some         and highly complex, it has the potential to    Newmarket Viaduct, Fulton Hogan will
                                                                                                                                                                      products are always
                  major equipment such as the launching          impact on many people’s everyday lives         deliver this complex project on time and              produced. This system
                  gantry which has contributed to substantial    until work is complete in December 2012.       on budget, with the support of the local
                  savings for the community,” said Ian.              Being one of New Zealand’s busiest         community.
                                                                                                                                                                      closely monitors curing
                      “This overhead self-launching gantry       roadways, the Alliance team knows it has                                                             temperatures and
                  is a major engineering achievement in its      to keep functioning effectively during the
                  own right and weigh some 750 tonnes and        construction, deconstruction and completion
                                                                                                                                                                      controls the amount of




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                  spans 140m. It can launch spans up to 62m      phase. effective communications and good                                                             steam used during the




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                  and has already demonstrated its worth on      relations with a number of neighbours
                  previous projects.”                            and other stakeholders is of critical
                                                                                                                                                                      manufacturing process.”
                                                                                                                                                                      Murray Stephens, Precast Manager                   Fulton Hogan is manufacturing over 7500 tunnel rings for the Northern Sewer Project.
                  VOLUME 5 Fulton Hogan                                                                                                                                                                                                                                       VOLUME 5 Fulton Hogan



                  Central Connector - an Auckland showpiece project

                      A
                             classic job with the lot – ultra busy       At the opening ceremony of the Central      vital. over 1000 safety inductions were         Works carried out included:
                             site, extensive scope, technical        Connector, Auckland, September 2009, one        carried out and regular opportunity for         •	 raising the pavement and protecting
                             complexity, diverse workforce           month ahead of the contractual completion       improvement sessions held, to discuss              the 130 year-old Plane trees through the
                  and stakeholder involvement that                   date, Tim manning, Project manager,             progress, feedback, to recognise good              university corridor;
                  culminated in a successful project due             thanked Fulton Hogan team members for           performance and to maintain a ‘one team’        •	 constructing a 7m deep 1050mm diameter
                  to the dedication and diligence of all             an outstanding effort.                          focus and approach.                                stormwater pipe through the middle of
                  involved.                                              “An additional 40% work was added                effective community consultation              Park Rodd right next to the (vibration-
                         When the project started out for            to the job, but we still finished ahead of      was crucial to the project’s success and           sensitive) hospital laboratory;
                  Auckland City Council, changes in scope            program, due to the hard work invested by       maintaining Fulton Hogan’s reputation.          •	 laying 600m of Vector Trefoil trench
                  requested by the client saw the project            the whole team. This resulted in 33 weeks       A dedicated stakeholder liaison manager            though the middle of Symonds Street over
                  value increase by 43% to NZ$37m, but this          where we worked every day of the week           was appointed to communicate all                   five days during the Christmas holidays;
                  did not daunt Fulton Hogan.                        to meet the deadline,” he said. “There have     progress, with a weekly email                   •	 reconstruction of all footpaths;
                      Instead the project team lead by Tim           been 506 work days since we started, with       update sent to approximately 70,000             •	 substantial concrete repairs to the
                  manning, got on with the job of:                   an average of 50 people working each day.       stakeholders. When the central arterial            original underlying concrete road (Anzac
                  •	 construction of a 5km long bus                  That’s 74 weeks and 250,000 man-hours           route through the Auckland CBD, Symonds            Avenue and Park Road), plus crack
                      and cycle route from downtown                  worked with zero lTIs – an outstanding          Street, was completely shut on two separate        sealing;
                      Auckland to Newmarket;                         achievement.                                    occasions, not one complaint was made.          •	 deep lift asphalt in two intersections;
                  •	 diversion and renewal work for up to 12             “The high pressure of an environmentally         “According to Auckland City Council        •	 pre-levelling and asphalt resurfacing the
                      different types of services;                   and culturally sensitive location made          this project set the standard for community        rest of the route;
                  •	 sewer/stormwater separation to 76               the work even more challenging. The site        and stakeholder involvement,” Tim               •	 erecting six large bus stop canopies (6m
                      properties in the Grafton area, requiring      included a 5km long – 10km counting             manning stated. “At a meeting regarding            foundations);
                      pipes up to 1050mm diameter, placed            both sides of the road – road through           another (non Fulton Hogan) project in the       •	 constructing cantilevered kerb structures
                      7m deep in and around Auckland                 Central Auckland, past shops and hotels,        vicinity, stakeholders asked why it could          over existing protected tree routes; and
                      Hospital;                                      right through the middle of the university      not be approached in the same way as            •	 25,504m of utility services renewed or
                  •	 full streetscape upgrade with significant       of Auckland and right past the Auckland         the Central Connector Project!                     diverted through the route.
                      bus canopies; and                              Hospital. on some days as many as 2600               “The positive responses from the general
                  •	 mixture of road resurfacing and renewal         buses and 30,000 pedestrians passed             public and others such as The university        “The challenge
                      such as concrete pavements, concrete-          through the area.”                              of Auckland, Auckland City Hospital and
                      treated base course pavements and                  With 26 different participating organisa-   even the Auckland City Arborists, are
                                                                                                                                                                     isn’t always about
                      structural asphalt pavements.                  tions, maintaining the safety culture was       testimony to a very successful job.”            engineering solutions,
                                                                                                                                                                     but also implementing
                                                                                                                                                                     effective stakeholder
                                                                                                                                                                     communications and
                                                                                                                                                                     consultation that will
                                                                                                                                                                     facilitate works and
                                                                                                                                                                     deliver the desired
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                                                                                                                                                                                                                                                                                                      People+Projects
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                                                                                                                                                                     end result.”
                                                                                                                                                                     Tim Manning, Project Manager
                                                                     New bus canopies as part of the streetscape upgrade.                                                                                                                                      Danny Parkinson Project Manager
                                                                                                                                                                                                                    A 5km bus and cycle route was constructed from Auckland to Newmarket.
                  VOLUME 5 Fulton Hogan                                                                                                                                                                                                                                           VOLUME 5 Fulton Hogan



                  Forestry interests help create a greener Fulton Hogan
                                                                                                                    Carbon Pollution Reduction Scheme currently      our stakeholders. Fulton Hogan has always       History of Fulton Hogan Forestry
                                                                                                                    in development, carbon costs are forecast        maintained this promise; as such our            •	 In 1981 Fulton Hogan decided to make
                                                                                                                    to have a significant impact on industries.      investment in forestry, over 25 years ago, is      a long-term investment and secure
                                                                                                                         To help better understand our energy
                                                                                                                    requirements an ambitious project to
                                                                                                                                                                     something many people are not aware of.”
                                                                                                                                                                          In the early 1980s Fulton Hogan invested
                                                                                                                                                                                                                        future income flow from the sale of
                                                                                                                                                                                                                        logs.
                                                                                                                                                                                                                                                                    “The energy review
                                                                                                                    conduct third party audits of 64 of Fulton       heavily in forestry in otago, New Zealand.      •	 At the time it was a means of deploying     process has given
                                                                                                                    Hogan New Zealand’s highest energy using
                                                                                                                    sites was conducted in 2009.
                                                                                                                                                                     The initial objective was to offset the
                                                                                                                                                                     seasonal nature of surfacing and sealing
                                                                                                                                                                                                                        the sealing and construction crews into
                                                                                                                                                                                                                        forestry work during the winter months
                                                                                                                                                                                                                                                                    Fulton Hogan
                                                                                                                         over a six month period environmental       works by providing ongoing employment              and thus be socialy responsible by          employees an insight
                                                                                                                    experts visited over 40 sites, with remaining
                                                                                                                    sites submitting energy use information
                                                                                                                                                                     for its people. The advent of the eTS by
                                                                                                                                                                     the New Zealand government in 2009 has
                                                                                                                                                                                                                        providing continous employment.
                                                                                                                                                                                                                     •	 By the mid 1980s new technology
                                                                                                                                                                                                                                                                    and incentives to
                                                                                                                    for desktop audits. The reports summarise        initiated a change of focus in terms of its        allowed sealing during winter. Contracts    operate more efficiently
                                                                                                                    energy use at each site and provide a series
                                                                                                                    of recommendations for improvements from
                                                                                                                                                                     forestry resources and revenue for Fulton
                                                                                                                                                                     Hogan. Today, the venture puts the company
                                                                                                                                                                                                                        were also being won off shore so there
                                                                                                                                                                                                                        was no longer a need to find off
                                                                                                                                                                                                                                                                    and in unison with our
                                                                                                                    changing light bulbs and timing switches         in the enviable position of being able             season work for staff.                      environment.”
                                                                                                                    to converting manufacturing plants to            to offset a large percentage of its carbon      •	 Fulton Hogan’s forest holdings consist of
                                                                                                                                                                                                                                                                    Mike Leroy-Dyson,
                                                                                                                    natural gas and insulating bitumen heating       obligations by utilising the carbon credits        eight separate large blocks located in
                                                                                                                                                                                                                                                                    Sustainability Manager, New Zealand
                                                                                                                    equipment.                                       from sequestration of carbon in conjunction        the otago province (Dunedin City District
                                                                                                                         With 71% of audit reports now received,     with the eTS.                                      and Clutha District) plus several other
                                                                                                                    opportunities for energy savings in excess            79% of Fulton Hogan’s forest estate           small areas planted at quarry sites
                                                                                                                    of 3.5 million kWh have been identified, with    (2159ha) has been registered as Carbon             around NZ.
                                                                                                                    many options being free to implement and         Accounting Areas which qualify for the
                                                                                                                    most presenting a less than one year pay         claiming of carbon credits derived from
                                                                                                                    back period on investment.                       the assessed sequestration of carbon in
                                                                                                                                                                                                                       Facts
                                                                                                                                                                                                                       Total planted area (Otago):                      2739ha
                                                                                                                         In Australia, 60% of Fulton Hogan’s         the forest estate. It is estimated the annual
                                                                                                                                                                                                                       Species:                   Pinus radiata         2320ha   (84%)
                                                                                                                    greenhouse gas emissions nationally arise        credits will be 40,000 tonnes of sequestered                                 C. macrocarpa         319ha    (12%)
                                                                                                                    from the consumption of diesel in plant and      carbon dioxide. With the harvesting                                          Douglas-fir           100ha    (4%)
                                                                                                                    equipment. Another 30% of our emissions          scheduled for 2011, these carbon credits
                                                                                                                    come from using natural gas. These two           will be used to offset emissions with the
                                                                                                                    fuels are key areas of focus in Fulton Hogan’s   objective of reducing Fulton Hogan’s carbon
                                                                                                                    Australian energy efficiency strategy.           footprint.
                                                                                                                         “Fulton Hogan has been operating for             As a company Fulton Hogan maintains
                                                                                                                    over 75 years and to continue this tradition     the foresight and intuition to seek
                                                                                                                    we need to look at ways to operate in a          sustainable business solutions that will
                                                                                                                    sustainable and cost-effective manner that       benefit the company as a whole and
                   Otago Forest, New Zealand.
                                                                                                                    is beneficial to our clients, our business and   provide value throughout all its services
                                                                                                                    the communities in which we operate,” said       to the customer, its employees and the



                     W
                                 ith a growing understanding    improve environmental performance across            mike leroy-Dyson, Sustainability manager,        community. our investment in forestry
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                                                                                                                                                                                                                                                                                                                13
                                 of the relationship between    its operations.                                     New Zealand.                                     has enabled us to do just that by building
                                 energy consumption and              With transport fuels, electricity production




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                                                                                                                         “This requires total commitment to and      our business and playing our part
                  our impacts on the environment and            and industrial processes entering the New           investment in the communities in which we        creating environmental balance and future
                  stakeholders, it made good sense for Fulton   Zealand emissions Trading Scheme (eTS)              operate by helping to build a sustainable        generations.
                                                                                                                                                                                                                     Forestry Committee: Guy Pierce (Chairman), Richard Fulton (Dunedin Regional Manager) and
                  Hogan to reduce energy consumption and        this year and the Australian government’s,          working environment for the business and                                                         Eion Mills (Forestry Manager).
                  VOLUME 5 Fulton Hogan                                                                                                                                                                                                                                        VOLUME 5 Fulton Hogan



                  PRS acquisition enhances Fulton Hogan capabilities across Australia

                     T
                             he acquisition of the remaining
                             50% of Pioneer Road Services
                             (PRS) from Shell Australia, heralds
                  Fulton Hogan’s elevation as a major player
                  in the Australian asphalting and surfacing
                  sector.
                      Already well established in Australia as
                  a major civil contractor in the land transport
                  and water infrastructure sectors, the full
                  acquisition of PRS strengthens Fulton
                  Hogan’s asphalt manufacturing and surfacing
                  capabilities with the addition of an extra 35
                  locations across Australia.
                      mr Nick miller, Fulton Hogan’s managing
                  Director, highlights that the purchase of PRS
                  will provide the platform for the long-term
                  growth of Fulton Hogan’s operations in
                  Australia.



                  “The addition of
                  new plants and
                  facilities will generate
                  greater efficiencies
                  in manufacturing
                  processes, by using                                                                                                                                                                                                                 Pinjarra Road interchange, Perth-Burnbury Highway.

                  these economies of                               customers across regional Australia by       plants located across the North and South      Key facts                                        •	 5500 employees across Australasia,           Exceptional expertise in airports
                  scale and best practice                          strengthening our vertically integrated      islands to meet the broader requirements           Fulton Hogan is Australasia’s most              with more than 2000 people located in        and major roads
                                                                   business model. This unique combination of   of our customers and complement                capable asphalt and surfacing company               Australia;                                        Fulton Hogan has a long association
                  we will be able to                               quarrying, manufacturing and construction    our construction operations.”                  with:                                            •	 technical laboratories accredited to NATA    with PRS through its 10 year joint venture
                  provide added value to                           generates many advantages that we can            The increased size of Fulton Hogan’s       •	 55 asphalt plants across Australasia,            standards in all mainland states;            arrangement in RoadCare Pty ltd, which
                                                                   pass on to our customers.                    footprint across Australasia provides              with over 40 of these located in             •	 largest airport expertise in Australasia;    is delivering the Southern Roads Services
                  our customers.”                                      “until the PRS acquisition, Fulton       many advantages to both Fulton Hogan               Australia;                                   •	 fleet of modern mobile asphalt plants        Alliance in South Western Australia.
                                                                   Hogan’s vertically integrated business       and PRS customers.                             •	 11 emulsion manufacturing plants in              to service major projects and remote              This relationship has exposed Fulton
                  Nick Miller, Managing Director
                                                                   model in Australia was limited. We had           Fulton Hogan is the prominent vertically       Australasia, with six of these supplying        works;                                       Hogan first hand to the depth of PRS’




                                                                                                                                                                                                                                                                                                               15
14




                                                                   five high capacity plants located in         integrated contracting company that has            all Australian states and territories;       •	 access to internal construction expertise    capabilities and the calibre of their




                                                                                                                                                                                                                                                                                                               People+Projects
People+Projects




                       Nick said: “The acquisition of PRS and      Adelaide, melbourne, Sydney and              the expertise and capability to take on the    •	 spray seal operations based at 17 sites          and services to provide a holistic project   committed people that has allowed them
                  its inclusion into the Fulton Hogan brand        Brisbane supplying to our customers.         most challenging projects in Australasia.          around Australia that are capable of being      management service; and                      to deliver outstanding results in major road
                  allows us to service a broader range of          In New Zealand we have 17 asphalt                                                               quickly mobilised to any location            •	 strong financial position, with major        and airport projects.
                                                                                                                                                               nationwide.                                         shareholding by the founding families.
                  VOLUME 5 Fulton Hogan                                                                                                                                                                                                                                                VOLUME 5 Fulton Hogan
                      In Western Australia, Graham Henderson
                  PRS’ General manager, and his team
                  have been steadily adding to the company’s
                  reputation and portfolio with the delivery
                  of impressive projects such as the
                  surfacing      of     the      Perth-Bunbury
                  Highway and the Tonkin Highway and
                  the Sturt Highway in South Australia.
                      The Perth-Bunbury Highway Project is
                  one undertaking that demonstrates just
                  what the business can do. At its peak, this
                  Au$43m surfacing project saw 5000 tonnes
                  of asphalt manufactured and placed each
                  day. The contract required 270,000 tonnes of
                  asphalt surfacing over 48km of dual alignment
                  and spray seal over a further 22km section,
                  giving the project a total surfacing length
                  of 70km.
                      According to Graham Henderson: “It
                  was the biggest asphalting project anyone
                  has ever undertaken in Western Australia
                  and one of the most successful. Getting
                  transportable plant and product onto site,
                  and then managing the logistics of placing
                  as much mix as fast as possible, were just
                  two of the biggest challenges we were
                  faced with.

                  “With the acquisition                           to deliver the long-term performance           customers, but deliver them in some pretty           Resurfacing Darwin Airport, Australia’s longest runway.
                  of PRS we now have                              required.”                                     demanding and remote locations – and that
                                                                      In this case a deep lift mix with low      presents a whole range of extra challenges,”
                  50 asphalt plants and                           permeability and resistance to stripping had   said Wayne.                                          required 16,000 tonnes of asphalt, and the      presents a whole range of challenges,”           the cyclic construction sector.
                  substantial spray seal                          to be designed. With the assistance of the         “over the last three years, PRS has been         RAAF Base at Tindal, near Katharine in the      said Wayne Boston.                                    Nick miller, managing Director, concludes:
                                                                  company’s extensive in-house technical         awarded some 80% of the major airport                Northern Territory, where many of Australia’s        “Part of the company’s continuous           “The acquisition of PRS gives Fulton
                  capabilities, servicing                         capability, pavement mixes were designed       contracts across the nation and that has             front line FA-18 multi-role fighter planes      success in both the airports and major           Hogan a competitive edge in not only
                  customers, from one                             at our NATA-accredited laboratories in New     included 10 significant projects.”                   are based. Tindal is an ongoing contract        roads sectors is our complete understanding      the surfacing sector, but also the major
                                                                  South Wales, Victoria and Western Australia        one of the largest and most important            for the company with over 52,000 tonnes of      of what is important to a client and our         projects sector.
                  side of Australia to                            as well as the Sydney laboratory and           of these was a complete resurfacing of               asphalt to be placed.                           commitment to doing what we say. using                “over the next six months the PRS
                  the other.”                                     research centre.                               Australia’s longest runway at Darwin Airport              PRS also completed the resurfacing of      this approach and with the inclusion of Fulton   brand will be replaced with Fulton Hogan
                                                                      “PRS has also established a track record   for the Department of Defence in 2007.               the airport runway in Alice Springs, in April   Hogan’s people, systems and processes            and I know that with this change we
                  Nick Miller, Managing Director                                                                                                                      2009, a job that required 22,000 tonnes of                                                       will be able to provide customers with value
                                                                  in the airport sector that includes some of    one of the most strategically important                                                              we have continued to excel in this sector
                                                                  the biggest and most challenging jobs in       airport facilities in Australia, this job involved   asphalt.                                        in recent months and were awarded the            added solutions that are clearly focused
                                                                                                                                                                           “Airports require certain types of high    resurfacing contract for Adelaide Airport.”      on building and maintaining long-term
16




                                                                                                                                                                                                                                                                                                                         17
                      “It is more than just spreading a lot of    the country said Wayne Boston, PRS’ Airport    some 30,000 tonnes of asphalt over a
                  material quickly we need to get the quality     manager.                                       runway length of 3.35km.                             tolerance asphalt mixes and getting these          The acquisition of PRS signals a new          relationships.”




                                                                                                                                                                                                                                                                                                                         People+Projects
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                  right. The correct mixes need to be carefully       “our airport surfacing track record            other jobs for the Department of                 just right at remote locations and being        chapter for Fulton Hogan in Australia as it
                  designed so they can be manufactured,           showcases our ability to not only carry        Defence include the resurfacing of                   able to deliver thousands of tonnes to          continues to grow its asphalt and surfacing
                  transported and applied properly in order       out large scale, high standard projects for    runways at Townsville Airport, which                 site at the right time in the right condition   streams to become less dependent on
                  VOLUME 5 Fulton Hogan                                                                                                                                                                                                                                      VOLUME 5 Fulton Hogan



                  Fulton Hogan well represented at Roading NZ Awards

                                                                                                                                                                                                                 “The awards are strong evidence of Fulton
                                                                                                                                                                                                                 Hogan’s ability to deliver quality projects of all
                                                                                                                                                                                                                 sizes throughout New Zealand. They are also a
                                                                                                                                                                                                                 tribute to the hard work of all involved.”
                                                                                                                                                                                                                 Bill Perry, CEO New Zealand Contracting




                       The 2009 Roading NZ Awards in              an extension of State Highway one, 30km          important, with Fulton Hogan joining NZTA    transport route, this strategic highway is an    Top left: NGA awarded the RNZ Supreme Award for a Major Road Project.
                  Wellington, New Zealand, saw Fulton Hogan       north of Auckland. The road was opened           and GHD to finalise the design, working      essential lifeline for the east Coast.           Top right: SH60 Eureka Bend Reinstatement awarded the Excellence Award for a Minor Road
                                                                                                                                                                                                                 Project.
                  scoop the pool with a myriad of awards,         ahead of schedule in January 2009.               through Christmas so that physical works          undertaken as emergency work,
                                                                                                                                                                                                                 Below: Oamaru Monument Relocation, Highly Commended.
                  including the Supreme Award for the                 The project displayed outstanding results    could begin just four weeks after tenders    construction started in November 2008 and
                                                                                                                                                                                                                 Bottom: SH35 Goldsmiths Realignment, Highly Commended.
                  Northern Gateway Toll Alliance.                 across all categories and was evaluated on       closed.                                      was completed in just eight months for a
                       of 26 entries, there were 11 finalists     the three key themes of innovation, best             The slip zone was secured with           cost of NZ$3.5m.
                  selected to compete in the five categories,     practice and collaboration. The judges           2200 lineal metres of soil and 6300m3 of          Category: Goughs excellence Award for
                  with Fulton Hogan ultimately receiving three    considered the project an excellent example      mechanically stabilised earth slope was      a minor Road Project.
                  of these awards and two highly commended.       of meticulous planning and collaborative         constructed. The project required 14,000          Highly Commended: oamaru monu-
                  The categories included:                        execution and worthy of the award.               tonnes of rock to be imported, placed and    ment Relocation and Thames Street (SH1)
                  •	 InfraTrain New Zealand Industry                  The road is a visual showcase of             compacted. estimated value of construction   Improvements – Fulton Hogan, opus
                       Best Practice - People and environmental   environmental and engineering excellence,        (including fees) at design stage was         International Consultants and NZTA.
                       Sustainability;                            passing through a historically rich and          NZ$3.65m; but due to the collaborative            This NZ$3.3m project involved safety
                  •	 Shell Bitumen excellence Award for a         diverse landscape with steep topography,         working environment this was reduced to      improvements to the main street of oamaru,
                       major Road Project;                        native bush, significant waterways and           NZ$3.29m, with all works completed on time   which is also State Highway 1 and carries
                  •	 Goughs excellence Award for a minor          farmland, making it one of New Zealand’s         before the onset of winter.                  18,000 vehicles per day across four lanes.
                       Road Project; and                          largest and most challenging road projects.          Category: Gough’s excellence Award for   existing roundabouts were replaced by
                  •	 Roading New Zealand Supreme Award.               Category: Goughs excellence Award for        a minor Road Project.                        traffic lights among a variety of other multi-
                       Category: Shell Bitumen excellence         a minor Road Project.                                Highly Commended: SH35 Goldsmiths        modal traffic management tasks, as well as
                  Award for a major Road Project and the              Winner:       SH60       eureka      Bend    Realignment – Fulton Hogan, opus             managing underground utility services and
                  Supreme Award.                                  Reinstatement - Fulton Hogan, GHD & NZTA.        International Consultants and NZTA.          relocating mature Siberian elms.
                       Winner: Northern Gateway Toll Road             The notorious State Highway 60 at                The Goldsmiths Realignment Project            A 450 tonnes, 13m high Boer War stone
                  Northern Gateway Alliance: Fulton Hogan,        Takaka Hill, in the Tasman region, traverses     involved the construction of a new 900m      monument was completely dismantled,
                  leighton Contractors, uRS, Tonkin & Taylor      steep mountainous terrain and provides the       section of State Highway 35 near Ruatoria    refurbished and relocated 60m away from
18




                                                                                                                                                                                                                                                                                                           19
                  and Boffa miskell with NZTA as the owner.       only road access to Golden Bay. A major slip     (north of Gisborne) in a known active        the busiest intersection in town. The marble
                       The Northern Gateway Alliance (NGA)        in November 2006 threatened to completely        landslide area. Frequent road closures       water feature was also upgraded.




                                                                                                                                                                                                                                                                                                           People+Projects
People+Projects




                  was engaged by New Zealand Transport            isolate this small rural paradise and severely   have in the past disrupted access between         The result was a simplified, safe and
                  Agency (NZTA) in march 2004 to design and       damage the local economy.                        small communities and essential regional     efficient traffic and pedestrian management
                  construct the Northern Gateway Toll Road,           early contractor involvement was             commercial hubs. With no alternative         system through oamaru.
                  VOLUME 5 Fulton Hogan                                                                                                                                                                                                                                 VOLUME 5 Fulton Hogan



                  Fulton Hogan helps secure Barwons Water Supply
                                                                                                                                                     rock access track into the existing basin            hypochlorite, lime, polymer and                   The scope of works being undertaken
                                                                                                                                                     to facilitate the baffle fence construction          potassium permanganate;                       by Fulton Hogan at the borefields included:
                                                                                                                                                     presented two major challenges.”                •	   construction of a relift pump station,        •	 construction of above and below
                                                                                                                                                         other challenges faced by the team               including the supply and installation of          ground pipework to connect the bore to
                                                                                                                                                     included managing the diverse range of               two relift pumps;                                 the collection pipeline
                                                                                                                                                     subcontractors and suppliers required to        •	   construction of an oxidation tank and         •	 construction of a concrete discharge pit
                                                                                                                                                     deliver the project. However, the project            two flocculation tanks;                       •	 construction of concrete and crushed
                                                                                                                                                     team found that by engaging subcontractors      •	   construction of baffle fencing within the         rock pavements
                                                                                                                                                     and suppliers early, by communicating                existing Anglesea Basin;                      •	 installation of electrical, instrumentation
                                                                                                                                                     regularly with impacted stakeholders and        •	   construction of a transfer pump station           and control systems
                                                                                                                                                     by developing a close working relationship      •	   construction of various pipelines                 The project is significant to Fulton Hogan
                                                                                                                                                     with BRWC, it enabled Fulton Hogan to                associated with the pre-treatment plant       as it has reinforced our expertise in the
                                                                                                                                                     achieve exceptional results.                         site;                                         water infrastructure industry and provided
                                                                                                                                                           The scope of works being undertaken       •	   construction of access roads and              us an opportunity to work with BRWC for
                                                                                                                                                     by Fulton Hogan at the pre-treatment plant           hardstands;                                   the first time.
                                                                                                                                                     site included:                                  •	   construction of stormwater drainage;
                                                                                                                                                     •	 construction of an aerator;                       and
                                                                                                                                                     •	 construction of a chemical building,         •	   installation of electrical, instrumentation



                      T
                                                                                                                                                         including the supply and installation            and control systems.
                             he Anglesea Borefield project is a
                             prime example of the breadth and
                                                                     gradually percolates down to these layers.
                                                                         Fulton Hogan was engaged by BRWC to
                                                                                                                     “Fulton Hogan’s strong              of four chemical dosing systems –

                             depth of Fulton Hogan’s diverse         construct the pre-treatment plant, transfer     culture helped us
                  capabilities.                                      pump station and borefield component of
                                                                                                                     successfully build
                      This Au$10m contract was awarded to
                  Fulton Hogan in September 2008, to construct
                                                                     the project. Works at the pre-treatment plant
                                                                     site and three of the bore sites commenced      working relationships.                                                                                                              “It has been a
                  a pre-treatment plant and seven bores to           in September 2009, with only four bores to
                                                                                                                     In particular our safety                                                                                                            pleasure to work with
                  boost Barwon Region Water Corporation’s
                  (BRWC) supply of drinking water.
                                                                     be completed by may 2010 and water supply
                                                                     to the region already commenced.                outcomes have been                                                                                                                  BRWC to deliver this
                      The Anglesea Borefield project plays an            The boreholes range in depth from
                                                                                                                     exemplary with no lost                                                                                                              incredibly important
                  important role in future proofing the growing
                  greater Geelong region’s water supply. With
                                                                     350m to 700m and this untreated water is
                                                                     transferred from five bores by the Borefield    time injuries during                                                                                                                project. When water
                  water reserves well below 20% capacity, the        Collection Pipeline to the pre-treatment
                                                                                                                     15 months on site.”                                                                                                                 first flowed through
                  delivery of this project on time is particularly
                  important for Fulton Hogan, not just as a
                                                                     plant and then discharged into the Anglesea
                                                                     Basin. Two more production bores are            Joe Ziccardi, Project Manager
                                                                                                                                                                                                                                                         the pipeline I was
                  contractor, but as a company that operates         located in the Northern Borefield, one at                                                                                                                                           proud to have been
                  within the region, with the project estimated
                  to supply one fifth of the region’s current
                                                                     the pre-treatment plant site itself, and one
                                                                     approximately 1.8km north, with its own
                                                                                                                                                                                                                                                         able to play my part
                  water requirements.                                connecting pipeline to the pre-treatment                                                                                                                                            in securing the region’s
                      The borefield operates by extracting           plant.
                                                                                                                                                                                                                                                         future water supply.”
20




                                                                                                                                                                                                                                                                                                         21
                  groundwater from the lower eastern view                “As with any project, we were faced




                                                                                                                                                                                                                                                                                                         People+Projects
People+Projects




                  formation aquifer, near Anglesea Township.         with some diverse engineering and project                                       Angelsea Borefield will supply one fifth of Geelong’s future water requirements.                    Joe Ziccardi, Project Manager
                  Groundwater accumulates in aquifers, which         management challenges,” said Joe Ziccardi,
                  are comprised of porous materials such as          Project manager. “The confined site footprint
                  sands, gravel and sandstone, as the rainfall       and the construction of a permanent crushed
                  VOLUME 5 Fulton Hogan                                                                                                                                                                              VOLUME 5 Fulton Hogan



                  Fulton Hogan now part of two melbourne Water alliance teams

                     W
                                  ith melbourne predicted to      in the Dandenong Creek Wetlands has             Pipelines (Sewerage and                           Werribee River. The innovative solution was
                                  become the largest city in      been extensive. We even had a visit from        Drainage) Alliance                                an incrementally launched solution that was
                                  Australia by 2049, melbourne    the Prime minister of New Zealand, the              With $145m of sewerage and drainage           safe and cost-effective.
                  Water Corporation is upgrading the city’s       Honourable John Key, in August 2009.”           improvements works to be completed                    “This is first time in Australia that
                  infrastructure with over Au$1b worth of              “The Prime minister joined melbourne       over a five year period, the Pipelines Alliance   a sewerage aqueduct has been
                  capital projects to support the booming         Water’s former chair, Cheryl Batagol, the       is a hive of activity at any given time.          incrementally launched and the Alliance
                  population.                                     Alliance and Fulton Hogan to see first-             With a variety of sewerage and drainage       believes it to be the largest in the world.”
                       With the help of Fulton Hogan, melbourne   hand how exceptional results in terms of        projects, including bridges, tunnels, beach           With this project already well into
                  Water is undertaking vital improvements to      value for money, innovation and quality are     outlets, emergency release outlets and            construction, the Alliance has also
                  sewerage and drainage infrastructure and        being achieved through collaborative            launch shafts earmarked for attention,            started a major tunnelling project in the
                  enhancing environmental outcomes through        contracting.”                                   the Alliance choose the complex                   south-eastern suburbs of melbourne.
                  two long-term maintenance alliances. These           “The visit from the Prime minister of      reconstruction of the Werribee Aqueduct as
                  include:                                        New Zealand certainly was a significant         their first key project.
                  •	 Waterways Alliance: Consisting of            milestone for Fulton Hogan. It demonstrated         The aqueduct, which has reached
                      melbourne Water, Fulton Hogan, SmeC         Fulton Hogan’s capabilities as a credible,      the end of its life cycle, takes up to
                      and ecodynamics. over five years, the
                      Alliance aims to improve the conditions
                                                                  reputable and strong contributor in the
                                                                  Australian construction industry.”
                                                                                                                  60% of melbourne’s sewerage to the
                                                                                                                  Western Treatment Plant in Werribee and
                                                                                                                                                                    “At the Alliance we are
                      of rivers and creeks by 50% by reducing          The wetland, which covers a 48 hectare     is a critical asset in melbourne’s sewer          always looking for new
                      nitrogen loads and increasing stormwater
                      quality.
                                                                  floodplain area in the eastern melbourne
                                                                  suburb of Scoresby, required over 315,000m3
                                                                                                                  system.
                                                                                                                      Domenic DeFazio, Pipelines Alliance
                                                                                                                                                                    ways to do things. We
                  •	 Pipelines, Sewerage and Drainage             of earthworks and the planting of 1.6 million   Project manager, said: “A major challenge         challenge our Alliance
                      Program Alliance: Consisting of
                      melbourne Water, Fulton Hogan, Jaydo
                                                                  trees and shrubs. It is just one of the many
                                                                  projects being delivered to help protect and
                                                                                                                  for the Alliance was to determine how
                                                                                                                  to construct this massive 5.4m square
                                                                                                                                                                    teams to develop
                      Constructions and GHD. The Alliance will    improve the waterways around the bay.           aqueduct safely across the 70m wide               innovative and cost-
                      improve sewerage and drainage assets,
                      over a five year period.
                                                                                                                                                                    effective solutions.”
                                                                                                                                                                    Domenic DeFazio,
                  Waterways Alliance                                                                                                                                Alliance Project Manager
                      2010 will see the Alliance enter into
                  its second year of operations and already
                  the team is well versed in stakeholder
                  consultation, due to the sensitivity of a
                  number of projects they are undertaking.
                      one such project, the Dandenong
                                                                                                                                                                    Left to right: Nick Marinelli (General Manager
                  Creek Wetland, possibly Victoria’s largest                                                                                                        Development), Nick Miller (Managing
                  man-made wetland, is part of the                                                                                                                  Director), Hon. John Key (Prime Minister
                                                                                                                                                                    of New Zealand), Jules Fulton (General
                  Au$75m five year alliance and has seen
                                                                                                                                                                    Manager Corporate Services) and Chris
                  the team consult with a broad range                                                                                                               Gallaher (Chief Financial Officer).




                                                                                                                                                                                                                                             23
22




                  of stakeholders including Parks Victoria,




                                                                                                                                                                                                                                             People+Projects
                  local     authorities,    heritage    and
People+Projects




                                                                                                                                                                    On the job: Hon. John Key (Prime Minister
                  environmental bodies.                                                                                                                             of New Zealand), (left) Nick Miller (Fulton
                      Nick miller, managing Director, said:                                                                                                         Hogan Managing Director) and (right) Cheryl
                                                                                                                                                                    Batagol (Melbourne Water’s Chairman).
                  “The interest from a range of stakeholders
                  VOLUME 5 Fulton Hogan                                                                                                                                                                                                                                                  VOLUME 5 Fulton Hogan



                  major Caloundra road project enhances regional amenity
                                                                                                                       The project was delivered for the
                                                                                                                   Department of Transport and main Roads,
                                                                                                                   Queensland, some two months ahead of
                                                                                                                   schedule and within budget.                                                                                                                           “Coordination and
                                                                                                                       Apart from the enormity and complexity
                                                                                                                   of the task, according to Theo Kyrakou,                                                                                                               cooperation between
                                                                                                                   Project manager, the prevailing conditions                                                                                                            the team, by hosting
                                                                                                                   themselves presented a number of
                                                                                                                   challenges to the project team. This included                                                                                                         workshops to discuss
                                                                                                                   working under live traffic conditions, careful                                                                                                        ideas and come up
                                                                                                                   environmental stewardship and effective
                                                                                                                   and proactive community relations.                                                                                                                    with the best solutions,
                                                                                                                         “mother Nature really didn’t want to                                                                                                            helped us to work
                                                                                                                   make this an easy task for us, by throwing
                                                                                                                   a few challenges into the mix. Soft ground                                                                                                            through all our issues.”
                                                                                                                   conditions under part of the mmTC section
                                                                                                                                                                                                                                                                         Theo Kyrakou, Project Manager
                                                                                                                   and heavy rainfall, kept us all on our toes,”
                                                                                                                   said Theo. “It was certainly one of the wettest
                                                                                                                   jobs I’ve ever worked on, with four metres
                                                                                                                   of rain over the 34 month construction
                                                                                                                   period and really made us seek innovative         Local flora was planted as part of the environmental practices implemented during the
                                                                                                                                                                     project.
                                                                                                                   solutions.”
                                                                                                                       Caloundra Road is the only connecting
                                                                                                                   arterial between the thriving town of             groups such as the Corbould Park Raceway         to flourish in the area,” said Theo Kyrakou,       total, 92,000 tonnes of heavy duty asphalt
                                                                                                                   Caloundra and Bruce Highway. The volume           (Sunshine Coast Turf Club), meridan Plains       Project manager.                                   pavement and 67,000m3 of bound and
                                                                                                                   of traffic in the area can be extremely           College and Halcyon Park Retirement                  A diverse variety of landscaping works         unbound pavements were laid during the
                                                                                                                   intense with 25,000 vehicles travelling           Village.                                         were also undertaken on the project                project,” stated Theo.
                                                                                                                   through the site every day. This increases             With strong environmental practices         including rock pitching, 120,000m2 of                   The project also required a considerable
                                                                                                                   even more during the peak tourist season.         in place for water quality, air quality, fauna   hydroseeding, planting of 100,000 plants,          amount of structural work, including six
                                                                                                                   Good traffic management helped to create          protection and noise control, the project was    97,000m2 of mulching and 17,600m2 of turfing.      bridges. Two of these were constructed over
                                                                                                                   safe working environs whilst minimising           able to report high levels of environmental      A number of permanent environmental                live traffic across Caloundra Road using two
                                                                                                                   disruptions to traffic. This was achieved         performance across the board.                    control measures were also installed               span T - girders with two interlocking block
                                                                                                                   by detailed planning as well as effective              With a diversity of local fish, native      including grouted rock pitching and wire           protection elements at each abutment.
                                                                                                                   ongoing communication with the travelling         animals and livestock inhabiting the             mattresses.                                        Three pre-stressed concrete deck bridges
                   Caloundra road project, on the Sunshine Coast, was successfully delivered two months
                   ahead of schedule.                                                                              public.                                           surrounding area, the project design included        “earthworks included 66,000m3 of               were also constructed. The bridges ranged
                                                                                                                       The success of this effective traffic         the construction of fauna overpasses             imported fill material, 400,000m3 of cut to fill   from three span (50.8m x 11m), to six span
                                                                                                                   management planning is demonstrated by            and underpasses, koala fencing and the           works and 542,000m3 of general excavation.         (74.6m x 11m) to eight span (119.7m x 11m).



                     T
                           his Au$95m project involved not       the construction of a new 4.5km section           the project’s outstanding safety record, with     relocation of frog wallums. The fauna culvert    Some 117,000m3 of unsuitable material was               The meridan Way overpass nine span




                                                                                                                                                                                                                                                                                                                         25
24




                           only the duplication, under live      of Caloundra-mooloolaba Road along the            more than 233,600 man-hours worked with           underpass across Caloundra Road even             excavated for disposal,” explained Theo            bridge (199.3m x 11m) was constructed
                                                                                                                                                                                                                      Kyrakou.                                           using a pre-stressed concrete deck with a




                                                                                                                                                                                                                                                                                                                         People+Projects
                           traffic conditions, of the existing   multi-modal transport corridor (mmTC). Six
People+Projects




                                                                                                                   zero lost time injuries and just one medical      included skylights.
                  Caloundra Road to a dual carriageway 4km       bridges, landscaping, lighting, ITS and traffic   treatment injury. effective community liaison          “Following our careful works and                “The client also benefited from our            1.1m traffic barrier. This package included
                  between the Bruce Highway and Pierce           signal installations were also constructed as     protocols used by the project team saw            environmental considerations we are very         use of a mobile crushing plant in the cut          the construction of a reinforced soil
                  Avenue in Caloundra, Queensland, but also      part of the project.                              them interact with a broad range of interest      happy to see the local wildlife has continued    to reduce the imported fill required. In           structure at the southern abutment and the
                  VOLUME 5 Fulton Hogan                                                                                                                                                                    VOLUME 5 Fulton Hogan
                                          installation of a pedestrian underpass.

                                                                                          Dave Faulkner creates a lasting legacy
                                              The project had an extremely long and
                                          detailed to-do list (in addition to items
                                          already mentioned):
                                          •	 concrete-piled retaining walls across                                                                                                          of Fulton Hogan’s Board and will provide
                                              and along Caloundra Road;                                                                                                                     support to the current leadership team.
                                          •	 8,000m3 concrete works;                                                                                                                            on behalf of the board, ed Johnson
                                          •	 pre-cast concrete batter chutes;                                                                                                               thanks Dave for creating a legacy for our
                                          •	 road lighting installation (including                                                                                                          shareholders and customers which will
                                              directional boring under live traffic);                                                                                                       benefit them for many years to come, whilst
                                          •	 removal or demolition of road furniture,                                                                                                       also creating a company that people will
                                              culverts, end structures, concrete kerb                                                                                                       continue to be proud to work for.
                                              and channel, and gullies;
                                          •	 on & off ramps at the Racecourse Road                                                                                                          Key career highlights
                                              interchange;                                                                                                                                  Dave’s 24 year career highlights include:
                                          •	 construction of maintenance bays                                                                                                               •	 commitment to growing the Australian
                                              along Caloundra Road;                                                                                                                            business and in particular the initial
                                          •	 supply and installation of a pedestrian                                                                                                           acquisition of Standard Roads and



                                                                                             A
                                              underpass;                                              fter 24 years of service at           approach. He always put people first and           Astec in January 2002
                                              With the project completed two                          Fulton Hogan, Dave Faulkner –         took great pride in their achievements.”        •	 acquisition of Pioneer Road Services
                                          months ahead of schedule and with                           managing Director retired on 31            During his nine years at the helm of          on 30 December 2009 to strengthen
                                          a significant increase in scope, due to         December 2009 leaving behind a business           Fulton Hogan Dave not only brought our             Fulton Hogan’s pavements capability
                                          the extra interchange requested by the          that has prospered under his leadership           company’s culture to the forefront of how          in Australia
                                          client, this project demonstrates Fulton        with year on year growth in profitability and     the business operates, he also increased        •	 recipient of the 2002 New Zealand
                                          Hogan’s ability to work cooperatively           staff numbers.                                    staff numbers by over 400%, with a similar         Deloitte/management             magazine
                                          with numerous parties to obtain the                 As Fulton Hogan’s fifth managing              380% increases in Group turnover.                  Company of the Year Award
                                          best outcomes for the project.                  director in its 76 year history, Dave has built        “Dave is a highly skilled and engaging     •	 relocated the Corporate head office to
                                                                                          on the considerable history and culture of        leader who has been instrumental in creating       Christchurch after 68 years in Dunedin
                                                                                          the past and further shaped our values of         new opportunities for the business. He has      •	 the recognition that systems support
                                                                                          respect, honesty and integrity within Fulton      been a member of the Fulton Hogan board            would be critical to successful growth
                                                                                          Hogan and made them an inherent part              since 1992 and, amongst other initiatives led      and the implementation of JD edwards
                                                                                          of how we operate. He firmly believes in          the initial expansion in Australia with the        accounting system in 2002
                                                                                          the importance that Fulton Hogan’s culture        purchase of the Standard Roads Group in         •	 purchase of the remaining 50%
                                                                                          differentiates it from other contracting          2002.                                              of envirowaste in 2002 and then the
                                                                                          companies and he has helped build an                   “It this leadership and foresight to          subsequent sale of envirowaste at the
                                                                                          environment that encourages innovation,           broaden the Fulton Hogan’s operating base          peak of the Private equity market
                                                                                          personal development and commercial               into Australia that has created the platform    •	 commitment to land development
                                                                                          success.                                          for further long term growth.                      which has seen Fulton Hogan, in our
                                                                                              ed Johnson, Chairman of the Board                  “embracing change as a mechanism              own right and through joint ventures, to
                                                                                          explains: “Dave is someone who truly              for growth, Dave never forgot the origins          be one of the largest developers in the
                                                                                          believes and cares about the welfare of           of Fulton Hogan,” ed Johnson continued to          New Zealand market
                                                                                          employees and he understands their                explain.                                        •	 establishment of Fulton Hogan’s Pacific
26




                                                                                                                                                                                                                                          27
                                                                                          importance to Fulton Hogan’s success”.                 “Dave always understood what made             Island business with a focus on airports
                                                                                              “one of Dave’s first initiatives when he      a company tick and inspired those around




                                                                                                                                                                                                                                          People+Projects
People+Projects




                                                                                          was appointed managing Director was to            him to employ new and not so new ways
                                                                                          revitalise Fulton Hogan’s operating style and     to deliver shareholder value.”
                                          Left: Six bridges were constructed as part of   to create a more inclusive management                  Dave continues to be an active member
                                          the Caloundra road project.
                  VOLUME 5 Fulton Hogan                                                                                                                                                                                                                                        VOLUME 5 Fulton Hogan



                  origin Alliance - Australia’s biggest road project
                                                                                                                                                                                                           ten-fold due to drilling and filling techniques          The reclaimed mine water is also treated
                                                                                                                                                                                                           required to stablise disused underground            at the onsite water treatment plant, which is
                                                                                                                                                                                                           mines under the corridor footprint.                 capable of treating up to 1 megalitre of water
                                                                                                                                                                                                                  “mine filling is not a regular practice in   per day, so that it can be reused onsite as
                                                                                                                                                                                                           Australia, so the Alliance collaborates with        Class 1 water for a variety of construction
                                                                                                                                                                “As this was the third                     overseas partners to get the best advice            activities including the production of the

                                                                                                                                                                major upgrade on the                       on how to proceed” said Brad. “each mine
                                                                                                                                                                                                           presents its own challenges and requires
                                                                                                                                                                                                                                                               grout used to fill the mines.
                                                                                                                                                                                                                                                                    The New Redbank and Westfalen mines
                                                                                                                                                                Ipswich motorway since                     different drilling and filling treatments. The      have their own issues as they contain

                                                                                                                                                                early 2007 the Alliance                    Goodna mine has an estimated volume of
                                                                                                                                                                                                           12,000m3 of filling and 31,840 drilling metres
                                                                                                                                                                                                                                                               methane gas. This gas will be purged from
                                                                                                                                                                                                                                                               the mines with nitrogen then ‘flared off’
                                                                                                                                                                team has been very                         while the New Redbank mine is the largest           using specialist equipment located onsite.

                                                                                                                                                                conscious of the impact                    mine with an estimated volume of 200,803m3
                                                                                                                                                                                                           and 37,159 drilling metres. The Westfalen mine
                                                                                                                                                                                                                                                               once this process is completed the mine
                                                                                                                                                                                                                                                               will then be filled with the grout.
                                                                                                                                                                on the community and                       has an estimated volume of 40,000m3, 3,604               Fulton Hogan’s involvement extends

                                                                                                                                                                the need to maintain                       drilling metres.”
                                                                                                                                                                                                                 The Alliance will then fill these cavities
                                                                                                                                                                                                                                                               beyond the Alliance to also being a key
                                                                                                                                                                                                                                                               supplier for the asphalt and spray seal
                                                                                                                                                                goodwill during the                        using a purpose-built grout manufacturing           components of the work. Competing against

                                                                                                                                                                construction period.”                      and mixing plant that has been constructed
                                                                                                                                                                                                           onsite. This plant has the capacity to produce
                                                                                                                                                                                                                                                               other asphalt companies, Fulton Hogan was
                                                                                                                                                                                                                                                               contracted to supply over 500,000 tonnes
                                                                                                                                                                Brad Thompson, Construction Manager        up to 1000m3 of grout paste per day, made           of asphalt to the Alliance. This is the largest
                                                                                                                                                                                                           from fly ash, cement and crusher dust. It is        asphalt supply contract Fulton Hogan has
                                                                                                                                                                                                           then transported and pumped into the mine           undertaken in Queensland and a team
                                                                                                                                                                                                           under very strict and controlled conditions.        has been integrated into the Alliance to
                                                                                                                                                                                                                 The complications do not end there            ensure the Ipswich motorway upgrade is a
                                                                                                                                                                                                           - working with such mature coal mines               success.
                                                                                                                                                                                                           creates other challenges. The Goodna mine                “Safety is our number one priority, for
                                                                                                                                                                                                           was constructed in the 1920s and as such            our people, our communities and motorists.
                                                                                                                                                                                                           very few maps or records exist to locate            All works are carefully planned from the
                  One of the most complex road projects in Australia construction on the Ispwich Motorway includes the widening of six lanes, 21 new bridges
                                                                                                                                                                                                           abandoned shafts and mines that are 30m             outset. Some risks we are managing
                  and structures and works over abandoned coal mines.                                                                                                                                      below ground level. This mine is also full of       include unexploded ordinance – a legacy
                                                                                                                                                                                                           water that contains significantly high levels       of the Redbank rifle range used during both
                                                                                                                                                                                                           of heavy metals. This means that the water          World Wars – as well as Q fever associated
                                                                                                                                                                                                           has to be pumped out at the same rate that          with the nearby meatworks holding yards



                     D
                            riving west out of Brisbane to       Queensland – with up to 100,000 vehicles       Department of Transport and main Roads,         workshops formed the origin Alliance.      the grout paste is pumped into the mine in          located in the area.”
                            nearby Ipswich, you are soon         daily – this stretch of motorway is being      Fulton Hogan, Abigroup, Seymour Whyte              This is one of Australia’s largest      order to maintain water levels and minimise              The Alliance team is determined to
                            motoring along the 8km stretch       widened to six lanes (three lanes in both      Constructions, SmeC Australia and Parsons       government-funded road projects due to     the potential for contamination of the water        successfully deliver one of Australia’s
                  of Ipswich motorway from Goodna west           directions), with 21 new bridges and           Brinckerhoff, was selected to participate in    the complexities associated with working   table or subsidence due to a change in              largest funded road projects and to achieve




                                                                                                                                                                                                                                                                                                                 29
28




                  towards Dinmore that the origin Alliance is    structures, a network of new service roads     the project using a hybrid alliance selection   over abandoned coal mines.                 pressures. The Alliance team monitors the           outstanding results for all involved.
                  upgrading for the Department of Transport      and latest technology to manage capacity       model where each non-owner participant             Brad Thompson, Fulton Hogan             water table and the water levels constantly




                                                                                                                                                                                                                                                                                                                 People+Projects
People+Projects




                  and main Roads, Queensland.                    and promote safety.                            was selected as individual companies            Construction manager, explains that        during the filling process.
                      As one of the busiest motorways in             The origin Alliance, consisting of the     and then through a series of commercial         the complexity of the project increased
                  VOLUME 5 Fulton Hogan                                                                                                                                                                                                                                               VOLUME 5 Fulton Hogan



                  NZ news                                                                                                                                             Australian news
                  Bitumen plant upgrade guarantees asphalt supply                                                    Fulton Hogan wins big on the                     AAPA Lifetime Achievement                        Sheahan Bridge accolade                         Transport, Regional Development and
                       A new 10,000 tonnes bitumen storage        storage tank is also insulated so it will retain   international stage                                   Paul DeBritt, Fulton Hogan’s National            The Sheahan Bridge Duplication project     local Government, Hon. Anthony Albanese.
                  tank has been commissioned at mt                the heat of the product and minimise energy            The International Road Federation            Asphalt manager, was awarded a life              on the Hume Highway at Gundagai in New          It duplicated the existing Sheahan
                  maunganui to ensure Fulton Hogan always         requirements.                                      (IRF) announced the winners of the               membership to the Australian Asphalt             South Wales, was the recipient of two very      Bridge over the murrumbidgee River and
                  has a reliable supply of bitumen to sustain         The plant upgrade at mt maunganui also         2009 Global Road Achievement Awards              Pavement Association (AAPA) at the 40th          prestigious industry awards in 2009.            the adjacent flood-plain on the Hume
                  its asphalting and spray seal operations.       includes the installation of new 100 tonnes        (GRAA) with Fulton Hogan winning the             anniversary celebration of AAPA on the Gold           The project won the NSW master             Highway at Gundagai. Fulton Hogan
                       This plant is capable of storing 20% of    and 150 tonnes service tanks, shifting the         Project management category, as part of          Coast in 2009.                                   Builder’s Association 2009 excellence in        successively completed the project four
                  the bitumen required annually for asphalt       load out facility, and upgrading the plant         the Northern Gateway Alliance, Northern               Paul de Britt is the longest serving AAPA   Construction Award for Civil engineering ($25   months ahead of schedule, by implementing
                  manufacturing in New Zealand.                   control system.                                    Gateway Toll Road Project.                       board member, spanning more than 15              million and over). It also won the National     an alternative design for the 24 spans
                       The tank is 28m in diameter and 20m            With a capability for this stored bitumen          At a total cost of $340m and four years in   years, and has previously held the position      Civil/Infrastructure Award (Au$25 million and   over the floodplain of precast bulb T
                  high and is heated by hot oil – with about      to be used in manufacturing approximately          the making, the Northern Gateway Toll Road       of chairman. This award recognises Paul’s        over), beating Tugan Bypass and Kingston        beams.
                  900m of hot oil piping on the floor of the      180,000 tonnes of asphalt, Fulton Hogan is         involved twin tunnels, six major bridges,        outstanding contribution and service to the      Foreshores, at the master Builder Australia,        This kind of recognition is a testament
                  tank. Two large suction heaters are used to     able to ‘future-proof’ its bitumen supply and      five major new culverts, four million cubic      industry.                                        2009 National excellence in Building and        to the outstanding results achieved by
                  extract the bitumen out of the tank into a      guarantee customers the delivery of asphalt        metres of earthworks, 60,000 cubic metres             louis Nucifora, Chief executive of          Construction.                                   Fulton Hogan in terms of innovative
                  new 100 tonnes service tank. This bitumen       on time and to the highest quality.                of concrete and, at its peak, 350 staff. The     Pioneer Road Services, was also awarded a             This $61m design and construct contract    engineering, quality of product, time
                                                                                                                     road opened ahead of schedule in early           life membership to AAPA for his long-serving     was officially opened in April 2009 by          performance, safety, community engage-
                                                                                                                     2009.                                            participation in the industry. louis was re-     the Federal minster for Infrastructure and      ment and relationship contracting.
                                                                                                                         The GRAA awards honoured 11 projects         elected as chairman of the association for
                                                                                                                     from eight different countries around the        2010.
                                                                                                                     world, each leading the way in excellence             Ceo of APPA, John lambert said: “lifetime
                                                                                                                     in its respective area of the road industry.     memberships are reserved for people who
                                                                                                                     The IRF promotes the innovative, practical,      have given outstanding service to AAPA. In
                                                                                                                     creative, cost saving and sustainable            40 years AAPA has only presented 13 lifetime
                                                                                                                     solutions the road industry provides to          achievement awards to selected members.
                                                                                                                     societies and economies across the world.        We are honoured, this year, to award two
                                                                                                                         lindsay Crossen, Ceo Australia, accepted     very accomplished members, Paul de Britt
                                                                                                                     this prestigious award on behalf of the          of Fulton Hogan and louis Nucifora of PRS.”
                                                                                                                     Northern Gateway Alliance and Fulton Hogan
                                                                                                                     at the IRF’s 2010 Annual Awards luncheon
                  Bitumen plant upgrade at Mt Maunganui.                                                             held in Washington DC in January attended
                                                                                                                     by high-level government officials and top
                  Another win for Fulton Hogan in Christchurch
                                                                                                                     road industry professionals.
                      Fulton Hogan has just been awarded          central city, so businesses and visitors can
                  the design and construct contract for the       get to the city’s economic hot spots faster.
                  Christchurch Southern motorway extension            At its peak in excess of 150 staff will be
                  Project, the first of a 10-year program of      involved in the project, with work due to start                                                                                                       Sheahan Bridge Duplication Project, Gundagai, New South Wales.
                  roading projects to improve the state highway   this year on the airport route, constructing
                  network in and around Christchurch. At a        four lanes in Russley and Johns Roads.                                                                                                               New offices in WA and SA                        WA Regional manager. This follows
                  cost of NZ$140m the Southern motorway               Project manager Tony Gallagher said                                                                                                                  Following a period of growth and            the recent establishment of a construction
30




                                                                                                                                                                                                                                                                                                                      31
                  extension was designed to improve               the wider economic benefits would be “far-                                                                                                           expansion for Fulton Hogan in the West          office in South Australia to pursue regional




                                                                                                                                                                                                                                                                                                                      People+Projects
People+Projects




                  and future-proof access to Christchurch         reaching and considerable.”                                                                                                                          Australian market, a construction operation     opportunities for the company and
                  International Airport, lyttelton Port and the                                                                                                                                                        has been established in Perth along             extend Fulton Hogan’s geographic
                                                                                                                     Northern Gateway Alliance receives
                                                                                                                                                                                                                       with the appointment of Paul Jenson,            footprint.
                                                                                                                     international recognition for project.           Louis Nucifora (left), Paul DeBritt (right).
       Fulton Hogan - New Zealand                                          Fulton Hogan - Australia
Technology Park, 29 Sir William Pickering Drive                             level 3, 369 Royal Parade
      Christchurch 8545, New Zealand                                     Parkville, Victoria 3052, Australia
         Telephone: +64 3 357 1400                                        Telephone: +61 3 9340 6200
          Facsimile: +64 3 357 1450                                        Facsimile: +61 3 9340 6299

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