Sino Iron Ore:
RMAX Environmental Expanded Polystyrene used in Sino iron Ore Project
The massive Sino Iron project is being developed at Cape Preston, 100 kilometres south west of Karratha in Western Australia's Pilbara region. It is the largest magnetite mining and processing operation under construction in Australia. The project is focused on delivering a world class magnetite iron ore development which will add value to the Western Australian economy.
The main Contractor, BGC Contracting, was required to build the foundations for 6 trains of AG Mills and Pebble crushers. The scope of work included site preparation, formwork and concrete pour in a contract valued at around $ 80 million.
Gabion in place
The problem centered on the autogenous grinding mills, each weighing in at 1,300 tonnes and which required extremely large concrete foundations. Two issues arose with the foundations - the cost of concrete and the resultant heat generated from concrete curing. BCG identified two possible alternatives – the use of gabion cages of rock or the placement of expanded polystyrene blocks held within the gabion cages inside the concrete.
Working together the RMAX staff in Perth and the BGC engineers were able to develop the Expanded Polystyrene method to achieve all their requirements in a time line that blended seamlessly with the overall Project objectives. A number of advantages were identified - superb compressive strength, lightweight and easy to use and durable and non biodegradable and non toxic.
AG Mill train installed on foundations
The gabion cages were manufactured in Perth and RMAX expanded polystyrene was inserted. The complete units were then shipped to the site at Karratha, 1,500 km north.
Six foundations measuring 30m x 22m were required. Total concrete used was around 30,000 cubic metres with around 7,500 cubic metres of RMAX Environmental Expanded Polystyrene used.
Gabion being loaded with RMAX GeoFoam in Perth
The contractor praised the work done by RMAX to meet all requirements of the project despite having to deal with scope changes during construction and accelerated deadlines.
RMAX GEOFOAM® plays it part in the Victorian Peninsula Link Project
RMAX GEOFOAM® was used as embankment fill and for use in bridge abutments in the construction of the recently completed Peninsula Link project in Melbourne. This 27 kilometre road travels between Carrum Downs and Mount Martha and was built at a cost of $759 million.
On completion the new freeway will ease traffic congestion on surrounding roads such as the Frankston Freeway and Moorooduc Highway. Peninsula Link will save motorists time with a full trip between Mt Martha and Carrum Downs taking just 17 minutes – a saving of up to 40 minutes in peak periods. Motorists will be able to travel from Melbourne's CBD to Rosebud without experiencing a traffic light.
In order to meet the construction requirements and time line, a reputable supplier was required who could deliver quality product in volume in a timely manner.
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RMAX GeoFoam® has been proven locally and Internationally
For over 30 years Expanded Polystyrene (EPS) has proven itself to be a reliable and dependable material. EPS use in civil engineering commenced in Scandinavia in 1971 and in the United States of America in 1974.
Since that time EPS has been used in geotechnical applications across the world. RMAX GeoFoam® has been used in geotechnical applications in Australia since 1992 commencing with the construction of Lynch’s Bridge in Maribyrnong, Victoria. It has been extensively researched and tested and meets many of the industry’s most rigorous standards.
Some of the projects where RMAX GeoFoam® has been in Australia used are:
Southbank Interchange Western Link Freeway,Power Street Bridge-North Abutment (4,000 cubic metres)
New South Wales:
Moore Park Tunnel construction Cross City TunnelKiama Bypass
Port Motorway Project Clem Tunnel Northern BuswayKuripla Bridges