Bulga Northern Water Dam

Hunter Valley, NSW

Construction of the Northern Water Dam (NWD) in the NSW Hunter Valley for client Glencore, to provide water storage for dewatering of open cut coal mining pits.  This will replace other water storages on the mine site that will in future, be removed due to mine expansion. 

Project duration of 12 months at a value of $15m.

Scope Of Work

  • NWD Main Embankment consisting of 16m high zoned earthfill embankment fitted with an exposed geomembrane sealing system (GSS) installed on the upstream slope
  • Controlled Release System consisting of concrete encased steel pipework, a reinforced concrete energy dissopation structure
  • Controlled Release Outlet Works; Rockfilling outlet channel and stilling basin
  • Diversion Embankment consisting of 12m high zoned earthfill embankment and spillway
  • Diversion Channel to bypass water around the north-eastern side of the NWD

Project Highlights

  • Use of geomembrane sealing system to the upstream face which is the first of its kind in Australia.  This was a high risk activity that was installed using a rope harness system on a 2:1 slope and completed without injury or accident.
  • Extensive erosion and sedimentation control measures installed along the existing creek bed including numerous temporary cofferdams, diversion drains and sedimentation basins.  These measures ensured the works were protected during peak rain events.

Bulga Haul Roads, Arches and Eastern Emplacement

Hunter Valley, NSW

Construction of three arch bridges and new mine haul road for the re-alignment of Broke Road and associated dams in the Hunter Valley for client, Glencore.  Project was completed ahead of schedule and under budget.

Project duration of 12 months at a value of $21.8m.

Scope Of Work

  • Construction of 3 concrete arch bridges including bulk earthworks with over 550,000m³ of fill
  • Construction of three mine water dams with capacity of 20ML, 30ML and 15ML respectively
  • Construction of Helcore Culverts ranging in size from 750mm diameter to dual 3300mm diameter
  • Construction of three RE wall structures using standard panels and oversized spandrels over active rail line
  • Service relocations for Hunter River raw water feed (DICL pipe) and rail signalling.

Project Highlights

  • Installation of 210 x 20 tonne arch segments and spandrel wall segments; 70 of these were installed over a three day rail shutdown
  • Bulk earthworks throughout an active mine site, managing interactions and mine wide traffic management plans
  • Diversion of Nine Mile Creek in two locations to allow construction of two new culvert crossings
  • 60,000+ man hours LTI free
  • Successful project co-ordination with four other contractors working in simultaneous operations

Moolarben CHPP Water Management Upgrade

Ulan, NSW

The Moolarben Coal Complex is situated within the Western Coalfields of NSW.

Robson completed construction of several new dams, upgrades to existing sediment dams, water diversion bunds and associated drainage channels.

Project duration of 9 months at a value of $5m.

Scope Of Work

  • Bulk Earthworks
  • Sediment Dam Construction
  • Upgrading Sediment Dams
  • Diversion Bund Construction
  • Materials conditioning utilising Bentonite Stabilising & placing geosynthetic clay liners
  • Crushing and Screening of site won rock
  • Jute Mesh and Hydromulching
  • Concrete/Shotcrete
  • Culvert placement
  • Rail Embankment Stabilisation 

Project Highlights

  • Robson worked closely with Yancoal to design & construct a staged “Blue Book” compliant water management strategy for the duration of the works. The sensitive site was bounded by Bora Creek to the West, Wilpinjong Creek to the East and all sloped toward the Goulburn River.
  • On site production of wave armour rock and gabion rock for incorporation within the works. The rock products were processed (crushed, screened & graded) from mine waste rock sourced from the Moolarben open cut mine.

Ravensworth North CHPP Bulk Civil Works

Hunter Valley, NSW

Construction of the civil works component of the duplication of Ravensworth North Mine in the NSW Hunter Valley for client, Glencore Xstrata.

Project duration of 22 months at a value of $30m.

Scope Of Work

  • 28m twin span bridge + reinforced  earth retaining wall
  • Piling works + placement of large box culverts
  • 158 Ha of clearing + stripping of topsoil management for open cut operations
  • 700,000m³ of bulk earthworks (cut to fill)
  • Stormwater/concrete lined/rock lined drains
  • Import of 90,000t of roadbase/subbase gravel
  • Import of 200,000t of select material
  • Crushing & screening production of 200,000 tonne of specified pavement materials from on-site borrow pits.
  • Excavation and backfill of 3 raw and product coal reclaim tunnels

Project Highlights

  • Following completion of works the Robson team was highly commended by Xtrata Management and recognised as one of the strongest performing constructors on site.

Mt Arthur Overburden Removal

Hunter Valley, NSW

Removal of approximately 300,000bcm per month of overburden from Mt Arthur Coal Mine with Liebherr 994 - 200 Excavator and Caterpillar 785 Haul Trucks.

Project duration of 18 months at a value of $25m.

Scope Of Work

  • Robson’s scope was to provide general earthworks and stripping services in a timely and efficient manner so that our client could uncover coal in accordance with its mine plan and optimise the use of its own equipment for the mining of coal
  • The services were performed utilising a combined fleet of Robson and Emeco Plant with Robson operators and Project Management staff

Project Highlights

  • Productivity levels exceeded client expectations with no disruption to day-to-day mining operations
  • During the life of the overburden and top soil services contracts Robson achieved 1000 Consecutive Safe Days at Mt Arthur Coal receiving congratulations for their on-site operations having successfully achieved a TRIFR (Total Recordable Injury Frequency Rate) of zero over this duration.

South Out of Pit Dam      

Mt Thorley Hunter Valley, NSW

Civil works associated with construction of 2GL storage dam at Mt Thorley for Warkworth Mining Ltd (Rio Tinto Coal Australia).

Project duration of 12 months at a value of $6m.

Scope Of Work

  • Foundation preparation
  • Key trench excavation
  • Seepage drainage construction
  • Filter zone construction
  • 400,000m³ rockfill
  • 120,000m³ clay liner
  • 50,000m³ stabilised clay protection zone
  • 3 sundry dams to control discharge, inlet and seepage
  • Discharge structures and pipe work

Project Highlights

  • To meet the clients program, 5 months of night shift was undertaken which met production targets with no reportable incidents

Bulga CHPP Surge Dam

Hunter Valley, NSW

Construction of a 3000ML CHPP surge dam in the NSW Hunter Valley for client, Bulga Coal.

Project duration of 24 months at a value of $24m.

Scope Of Work

  • An 18 metre confining embankment constructed across two gullies within the Nine Mile Creek catchment.  A stabilised clay core and sand filter zone was constructed full height of the embankment for the entire length of 1100m.
  • Two additional embankments were constructed upstream of the storage to prevent clean water runoff from entering the storage.
  • A 500mm compacted gypsum stabilised clay liner was placed over the impounded area. Clean water diversion drains were constructed upstream of the dam to divert clean water runoff around the dam to downstream clean water system & creek lines.
  • Emergency spillway and outlet channel was also constructed as part of the works.

Mangoola ROM Pad & CHPP Civil Works   

Hunter Valley, NSW

Civil works associated with construction of new coal mine facilities for Glencore Xstrata.

Project duration of 12 months at a value of $30m.

Scope Of Work

  • Site clearance
  • Design and construction of reinforced earth dump wall
  • ROM Pad construction (1.2M bcm)
  • Borrow pit materials management (500,000 tonne of select and 2.5 million tonne of general fill plus 250,000 tonne DGS/DGB)
  • Haul roads construction
  • Stormwater drainage including open drainage channels and pipe culverts
  • Electrical and water services
  • Sedimentation dam

Project Highlights

  • Robson provided early contractor involvement to Glencore Xstrata with early mine planning assistance including site access assessments, bulk materials management planning and project feasibility analysis.

Bengalla Mine ROM Pad

Hunter Valley, NSW

Construction of new ROM Pad and 45,000m² of haul roads at Bengalla Mine for Rio Tinto Coal Australia.

Project duration of 12 months at a value of $9m.

Scope Of Work

  • Construction of 45,000m² of Haul Roads & ROM Pad
  • Processing of 180,000 tonne mine-supplied raw materials for use in pavement works
  • Bulk excavation and vertical batter stabilisation
  • Construction of drainage infrastructure including 3 sedimentation dams within environmentally sensitive area.
  • Extensive detail excavation & cut to fill operations in excess of 300,000m³

Project Highlights

  • Robson were awarded a Rio Tinto Coal Australia (RTCA) Contractor Safety Award which is a globally recognised safety award across all Rio Tinto sites
  • Deployment of Robson TL 1255 Terrain Leveller which negated drill & blast evacuations and enabled compliance with stringent peak vibration requirements
  • Robson input into cost effective solutions resulted in mobilisation of crushing and screening plant to produce 180,000 tonne of SMZ pavement materials from mine-supplied overburden