Camberwell Coal Mine - Singleton, NSW Camberwell Coal Mine - Singleton, NSW Camberwell Coal Mine - Singleton, NSW

Camberwell Coal Mine Singleton, NSW

Project featuring the RECO TerraPlus System.

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General Information

A surface operation owned by Vale Integra Coal. It includes both the North and South Pits. The Camberwell and Glennies Creek coal mines are located next to each other about 10km north-west of Singleton in the Upper Hunter Valley. Their operations are inter-related, as coal from the Glennies Creek mine is washed and stockpiled at the Camberwell mine before it is railed to Newcastle.

In May 1990 a RECo TerraClass reinforced earth wall was constructed to the steel hopper structure. The original reinforced earth wall only designed for approx 25 yrs, hence required upgrading. As a result the existing wall required demolition and re-placement.

Robson Civil Projects were awarded the civil works package, which included the de-construction, design & construction of a 14.58m high RECO TerraPlus reinforced earth wall. Retaining Solutions was engaged for the design/ supply and construction of the reinforced earth wall in addition to the associated membrane protection to the reinforced soil block. The reinforced concrete dump slab (125m3) was installed by Concrete Evidence Pty Ltd.

All construction operations from slab/wall demolition through to slab construction/membrane protection and installation of safety earthen bunds all had to be completed within a 4 week CHPP shutdown period (24hr operations) during the month of June 2103.

Retaining Solutions scope involved the following scope:

- Demolition of existing dump slab/deadman anchor and RECo TerrClass panel wall/strip components.

- Re-use of existing concrete footing as base of wall, due to short construction duration, precast concrete levelling pads were utilized on each wing wall step to avoid curing time of in-situ concrete placement.

Camberwell Coal Mine Singleton, NSW featuring the RECO TerraPlus System

- Installation of new TerraPlus reinforced concrete facing panels (600m2 face); REHas galvanised reinforcing strips, coupling plates and geotextile fabric to all vertical and horizontal panel joints.

- Engineered Fall from height handrail system for both panel placement and wing wall batters.

- Spreading & compaction of imported RSW select backfill material (approx. 6,800m3)

- General Backfill to rear of reinforced fill zone (approx. 3,000m3). Retaining Solutions installed the general backfill zone in conjunction with RCP earthmoving plant, utilizing excavators, tracked bobcats 40tonne articulated dump trucks.

- Chimney drain, Enkadrain SL to the rear of the reinforced fill zone (80% of wall height).

- Placement of 4% cement stabilized medium (approx 200m3) to underside of dump slab including level conformance to concrete blinding layer.

- 50mm thick bedding sand layer; HDPE 2mm thick membrane, including denso-tape sealant; geocomposite protection layer to reinforced earth block and associated mechanical fixing to the entire perimeter of the dump slab.

Careful planning from both Robson Civil Projects and Retaining Solutions ensured this critical-path works package was completed ahead of time for Integra Coal. First class engineering/ OHS risk management procedures/plans ensured the project was delivered safely/ahead of time and most importantly addressing the highest construction risk of all people/plant interaction.

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Project Specs

  • Application - Dump Structure
  • Product - RECO TerraPlus System
  • Finish - Plain Grey Smooth
  • Area - 600m2
  • Max. Height - 14.58m
  • Length - 60m
  • Loadings - CAT 789C Dump Truck (320t)
  • Design life - 30 years
  • Owner - Integra Coal (VALE)
  • Client - Robson Civil Projects
  • Construction - 1 month

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