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18 WORLDWIDe DOWN UNDER: THE BANUT 655 aUSTRaL CONSTRUCTION HaS BOUgHT a BaNUT 655, THe FIRST IN aUSTRaLIa, FROM <strong>THYSSeNKRUPP</strong> STeeLCOM. BeTWeeN OCTOBeR 2009 aND FeBRUaRY 2010, THIS MaCHINe, WHICH CaN LOOK BaCK ON a LONg HISTORY, COVeReD aLMOST 11 000 KM ON THe aUSTRaLIaN CONTINeNT. SO THe BaNUT 655 WITH ITS HYDRaULIC FRee-FaLL HaMMeR IS WORKINg “DOWN UNDeR” IN THe TRUeST SeNSe OF THe WORD. The precursor of Austral Construction was founded back in 1979 and concentrated primarily on smaller jobs in the construction and specialist civil engineering sectors as a subcontractor. The firm has been trading under the name of Austral Construction Pty. Ltd. since 1996. The company’s experience and growth has enabled it to shake off the subcontractor image and it is now operating throughout Australia as a specialist for mining and marine projects. Following commissioning of the Banut 655 in October 2009 in Dandenong, the headquarters of Austral Construction, its first deployment was at Cape Preston, some 4500 km away in Western Australia. This project involves building a 30 km long road between a mine and the port. The road is part of the AU$ 5.2 billion “Sino Iron” project of Citic Pacific Mining. Once it is finished, the new mine and its infrastructure will be one of the largest and most modern iron ore facilities in the world. The road runs through mudflats and has to cross a tidal inlet. Austral Construction presented the client with a bridge proposal as an alternative to the planned tunnel crossing. Environmental protection requirements and the tight timetable led to the scheme proposed by Austral Construction being adopted. The new road between mine and port crosses mudflats, desert and a tidal inlet in the course of its 30 km length. Banut 655 technical data • Travel on leader: 15 000 mm • Max. pile length: 20 000 mm Leader mast displacement • Above ground: +5500 mm • Below ground: -1000 mm Leader mast inclination • Forwards/backwards: max. 18/45° • Sideways: max. 18° WORLDWIDe 19 • Pile weight: max. 8500 (optional: 12 000 kg) Weights and lengths depend on reach and leader mast inclination • Torque absorption: 18 000 daNm Line pull • Pile winch: max. 85 kN (optional: 120 kN) • Hammer winch: max. 120 kN Rope speed • Pile winch: 50 m/min • Hammer winch: 50 m/min • Weight of driving plant without attachment: 67 t
20 WORLDWIDe BRIDGE INSTEAD OF TUNNEL In order to keep up with the tight timetable, 159 piles were installed in the first five months. The timetable was very tight because the road is the only route for transporting heavy materials and equipment between the port and the mine. The bridge is 120 m long and 28 m wide and was built in less than five months. A total of 159 piles (610 x 16 mm, grade G350) were installed, most of them with a driving frame. However, a mobile machine on caterpillar tracks was necessary for the piles at the northern abutment. The Banut 655 together with the SuperRAM 8000XL hydraulic free-fall hammer installed a total of 32 tubular steel piles with a diameter of 610 mm in just over four days. The 20 m long piles can carry a load of more than 6200 kN. The geology of this site consists of an approx. 4 m deep loam stratum on top of limestone. Beneath that there are strata of dacite and andesite (both types of volcanic rock). It was in the andesite stratum, with a strength of up to 100 MPa, that driving came to stop. Once its work on this site was completed, the Banut 655 travelled a further 1500 km to the Australian Marine Complex (AMC) in Perth in order to install sheet pile walls and steel piles for a new dockside facility. This is a roll-on/roll-off installation for Chevron’s AU$42 billion “Gorgon LNG” project. This project is aimed at developing the gas field in the Greater Gorgon Area approx. 130 km off the Australian coast. Gorgon is one of the largest gas projects worldwide and the largest in the history of Australia. Besides exploiting the gas field, the project also includes the building of a gas liquefaction plant on Barrow Island and the necessary infrastructure such as pipelines. The Gorgon project requires the port and a further area covering approx. 4.5 ha as a quarantine area for materials and equipment destined for the Barrow Island project. Barrow Island is a class A natural park and this status means that extremely stringent environmental protection stipulations apply. By securing a service base and using the port facilities of AMC, Chevron is able to transport considerable quantities of materials and equipment by sea and hence reduce the amount of road transport. The Banut 655 was used here to install sheet pile walls. Austral carried out the driving work with a vibrator and used the SuperRAM 8000XL free-fall hammer fitted with a special helmet for driving to the final depth. In total, approx. 1200 t of sheet pile sections were installed in two months. In addition, six piles with diameters of 762 and 914 mm and lengths between 18 and 20.5 m were installed as anchor bollards. Dense sand strata on top of so-called Tamala limestone make up the geology of this site, typical for the coastline around Perth. The driving works were completed a month earlier than planned, which means that the entire project is now ahead of schedule. The Banut 655 completed its tour of Australia in Melbourne, where it was involved in the Victorian desalination plant. n WORLDWIDe 21 Fitted with a hydraulic free-fall hammer, the Banut 655 was able to complete the driving works one month earlier than planned.
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