MR92 Upgrade bulee to caval, NSW MR92 Upgrade bulee to caval, NSW MR92 Upgrade bulee to caval, NSW MR92 Upgrade bulee to caval, NSW

Caval Ridge Coal Mine, Central QLD

Project featuring the RECo TerraPlus® System

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General Information

Caval Ridge is a high quality, hard coking coal mine located in the Central Queensland region, Australia. The project site is situated in the northern section of the Bowen Basin, approximately 3.7 miles (5.95km) south-east of Moranbah and 100 miles (160.9km) south-west of Mackay. The local government authority is Isaac Regional Council. The greenfield project covers an area about 6,800ha and comprises of two coal pits, namely Horse Pit and Heyford Pit. The former deposit lies north of Peak Downs Highway, while the latter is situated north of Harrow Creek. The two main components of the Caval Ridge project include the development of a new coal mine and installation of a coal handling and preparation plant (CHPP). Construction on the project commenced in the first quarter of 2012. The first coal is expected in 2014. The initial cost of the project is estimated at approximately $4.2bn. The development will create 2,000 construction jobs and about 500 operational jobs. The Caval Ridge asset is owned jointly by BHP Billiton and Mitsubishi, through their 50-50 joint venture company, BHP Billiton

Mitsubishi Alliance (BMA). The joint venture is reportedly the largest coal producer in Australia.

The mine is placed on the western section of the northern Bowen Basin, which contains a comparatively thinner collection of sediments. Minor to moderate deformation can be seen in the area. The area contains Permo-Triassic (PT) sediments arranged in stratigraphic sequences. The project aims to extract coal seams from the Moranbah Coal Measures (MCM), whose lithology broadly comprises 305m of pulverised sandstone, siltstone, mud-stone, clay-stone and coal. It targets to unearth all the seams that are greater than 11in in thickness.

Bechtel, the largest construction and engineering company in the United States, is providing engineering, construction and project management services for the Caval Ridge project. Abigroup, a subsidiary of Lend Lease Group, was awarded a $217m (A$210m) contract to carry out bulk earthworks. Sedgman participated in the design execution phase of the project.

The Reinforced Earth Company was awarded the design and supply of the North ROM, 17.3m high reinforced earth wall; whilst Retaining Solutions were engaged for the construction works described herein.

Scope of Works

Retaining Solutions scope involved the following installation of:

  • Unreinforced concrete levelling pad (165Lin.m);
  • RECo TerraPlus reinforced concrete facing panels (2,000m2 face); REHas galvanised strips (lengths varying from 7m up to 14m), 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 approx 45,000m3 of RSW select backfill material (40mm minus blend);
  • General backfill zone to rear of reinforced fill zone (approx 150,000m3). Abigroup installed the general backfill zone in conjunction with Retaining Solutions wall erection operations, utilising dozers, scrapers, compactors and up to ten 50tonne CAT 773F dump trucks;
  • Vertical drainage in form of geotextile encapsulated gravel chimney drain to rear of reinforced fill zone (approx 2200m2);
  • 5% cement stabilized medium (approx 500m3) to underside of dump slab (1m thick) including level conformance to concrete blinding layer;
MR92 Upgrade Bulee to caval, NSW

About The Project

Abigroup Contractors were responsible for the supply/form/fix the reinforced concrete dump slab, 50mm thick bedding sand layer; HDPE membrane/geocomposite protection layer and associated mechanical fixing to the entire perimeter of the dump slab; profiling batters adjacent to ROM wall and associated erosion batter protection.

Retaining Solutions was also responsible for (14tonne TEREX Franna) unloading and dynamic movement of proprietary system components (precast concrete panels and REHas bundles) from laydown area up to wall location throughout entire progression of ROM construction.

Retaining Solutions also worked closely with Abigroup to provide plant wet-hire (excavators and tracked bobcats)

for the following works: conditioning the RSW backfill for the retaining wall; rock hammer work for all oversized rock excavated on site down to 300mm maximum sizing and 14t Franna hire for general lifting works.

Retaining Solutions fleet of plant and equipment was required to meet the stringent BMA Requirements from light vehicles through to 14t Franna, excavator, bobcat, roller and compaction equipment range (14 items). All personnel had to complete respective RII competencies in addition to onsite VOC’s. The project also operated under the project specific Caval Ridge Greenfields Agreement for payment of all employees. Another key feature of this subcontract requirement was to have Supervisors interviewed and approved by the mine OCE prior to commencement. SWMS/JHA’s were completed for all activities in addition to risk assessments on each and every individual piece of plant/compaction equipment. Retaining Solutions met the above requirements with the skilled staff employed for this subcontract.

This project proceeded trouble free with a close working relationship established between Abigroup Contractors, Retaining Solutions and Bechtel Australia Pty Ltd.

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Project Specs

  • Application - Dump Structure
  • Product - RECo TerraPlus® System
  • Finish - Plain Grey Smooth
  • Area - 2000m2
  • Max. Height - 17.3m
  • Length - 165m
  • Loadings - CAT 793 Dump Truck (384t)
  • Design life - 30 years
  • Owner - BHP Billitan Mitsubishi Alliance
  • Client - Abigroup Contractors Pty Ltd

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