Currently one of Victoria’s largest projects, the $625 million, 70 km Sugarloaf Pipeline will connect the Goulburn River near Yea to the Sugarloaf Reservoir in northeast Melbourne.

The Sugarloaf Pipeline project team is made up of an alliance, comprising Melbourne Water, John Holland, Sinclair Knight Merz and GHD. The alliance is responsible for planning and environmental assessments, engineering, design, community and landowner relations and project management associated with delivering the pipeline.

Pipe and Civil was subcontracted to construct the first 37 km of the 1.7 m diameter mild steel cement lined (MSCL) pipeline from the Goulbourn River Pump Station to the base of the Great Dividing Range at Glenburn. The scope of the works included excavation, pipelaying, welding, coating reinstatement and backfilling of the pipeline. It also included the installation of minor pipeline structures, including air and scour valves.

Pipe and Civil’s Project Manager William Weaver said, “The main challenge was the restricted access on the right-of-way (RoW). Especially, with the amount of topsoil that was cleared, the 30 m was not 30 m.

“The project involved typical pipelaying work but because of the environmental requirements, it was a little bit more than we had expected.”

Mr Weaver said that this impacted on how welding was completed on the project as an efficient production line of welders moving down the RoW was harder to manage.

“We had to be more versatile and change what we had in our head initially about how we were going to build the pipeline,” said Mr Weaver.

“The other challenge was the weather conditions; Mud, slop, heat, dust – our team have encountered it all and the team did the job with a minimum of fuss.”

Mr Weaver said that the right people with the right tools have made this large-scale project a sweet success.

Innovations

Other innovative solutions were also required due to constraints placed on the width of the construction corridor.

Pipe and Civil developed a remote controlled bedding machine, which is based on a rubber-tracked loader with a modified laser controlled, automated grader attachment. This removes the need for personnel to enter the trench, also negating the need to provide trench shoring– reducing the overall project risk.

Under normal circumstances, cutting large diameter pipe involves the use of oxyacetylene, or demolition saws that can be hazardous and time consuming. Pipe and Civil designed and commissioned an automated machine that uses a water jet cutter to make a quick and clean cut. This way pipes are cut more accurately and the use of the machine further reduces the work force required onsite.

Expansion on scope of works

The company recently expanded its business and secured the pump station pipe works contract for the Sugarloaf Pipeline project.

Pipe and Civil’s contracted works include the complete fit-out of two pump stations, Goulburn River Pump Station (GRPS) and the Sheoak High Lift Pump Station (HLPS), along with the installation of the outlet works at the Sugarloaf Reservoir.

“The average life expectancy of a pump station is about 40–50 years but these pump stations have been designed to have a life expectancy of double the average. Therefore, a much greater quality standard and care is required in terms of installation of fittings, weld preparations and welding,” said Pipe and Civil Mechanical Superintendant Lloyd Melville.

Strict controls in accordance with state and federal environmental protection legislation were implemented and maintained by the Sugarloaf Pipeline Alliance throughout the duration of the works to protect the health of waterways and aquatic life.

Different disciplines of work such as civil structure, electrical, pipeline and mechanical were carried out at the same time within a narrow construction corridor, adding constraints to the timeline. The Pipe and Civil team had to constantly plan, communicate and co-ordinate with various other teams so as not to have a negative impact on each other’s work.

The pipeline industry has gained from recent government budgets that reflect the importance and urgency of water infrastructure as Australia’s drought continues to prevail. Pipe and Civil said that there is increasing pressure to deliver these projects in a fast and safe manner, with minimal impact on the environment and community. The company has strived to achieve this while completing works on the Sugarloaf Pipeline project.

Pipe and Civil commenced work on the project on 20 October 2008. In early 2009, the Black Saturday bushfires burned right through the pipeline route, halting the project. Works recommenced after a period of three weeks, and Pipe and Civil said that a constant review of the company’s work methodology, with a focus on innovation, led to increased safety and productivity on the work front.

Looking ahead

Pipe and Civil completed its portion of the works on the Sugarloaf Pipeline project in November last year, ahead of schedule. Currently, the team is busy with works at the Gateway Upgrade and its first project as a principal contractor in Maleny, Queensland.

In Maleny, Pipe and Civil will undertake the construction works associated with the Landers Shute Water Treatment Plant to Maleny Pump Station and associated water main project.