CASE STUDY: Captain Cook Drive, NSW Ecoflex E Wall & E Pave Systems Project No: EAJ00264

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1 CASE STUDY: Captain Cook Drive, NSW Project No: EAJ Kalaroo Road, Redhead NSW Australia.

2 TABLE OF CONTENTS TITLE PAGE# Project Background 03 Project Specification & Design Design Drawings. 05 Engineers Certification Construction Photographs Company Information 19 Lic No: EF-2003 AELA Approved Product The recycled rubber technology employed by Ecoflex has been assessed by the Australian Environmental Labeling Association and has been awarded a Good Environmental Choice Licence by the Australian Ecolabel Program. The technology was assessed against the voluntary environmen tal labeling standard for Recycled Rubber Products: AELA-Recycled Rubber Details: Page 2

3 PROJECT BACKGROUND A report was released in October 2006 by Sutherland Shire Consulting Services to Sutherland Shire Council for the proposed road widening of Captain Cook Drive between Woolooware Rd and Elouera Rd at Woolooware, NSW. It offered four Construction Methodologies for consideration, these were Lime Cement Columns, Geogrid Reinforcement with Gabion Embankment Edge, Preloading and Ecoflex. The pros and cons of each method were detailed to Council in the report and in summary were; Lime Cement Columns- Extremely expensive with settlement practically eliminated. Geogrid Reinforcement- Expect significant overall settlement would require Gabion basket embankment edge into the tidal waters. Pre-loading- Not acceptable due to possible environmental impact for many months. Ecoflex- Advantage over the other systems include reduced road footprint, eliminates batter into mangroves or gabion into tidal salt water. The Report states that some ongoing pavement deformation will occur due to the due to the poor subgrade and its variable nature. The Council in February 2012 engaged CSG Engineering to incorporate Ecoflex Systems into their road design. Ford Civil Contracting were the successful tenderer. Site works commenced in November 2012, Ecoflex Civil Contractors supplied Ford Civil with trained supervisors to coordinate, train and supervise the placement of the Ecoflex systems to the engineers specifications. Sustainability must be high on the Council agenda as this road construction consists almost entirely of recycled materials these include recycled tyres for Ecoflex E Pave subbase and E Wall embankment retaining, recycled concrete aggregate for Ecoflex unit infill, recycled Asphalt for backfill, recycled concrete for roadbase. The recycled concrete and recycled asphalt were both available locally and suitable for the engineering design, to use quarried rock on this project would have involved trucking rock from quarries over 80 km away, this would have imposed a huge unnecessary cost to the project and added a significant Carbon Cost due to transport alone. Page 3

4 PROJECT SPECIFICATION & DESIGN Project Name: Client:: Ecoflex System: Contractor:: Project Purpose: Consulting Engineer: Captain Cook Drive Widening for Sutherland Shire Council Ford Civil Contracting Pty Ltd E Wall & E Pave Ecoflex Civil Constructions Pty Ltd Widen existing road by extending it 8 metres into the mangrove tidal region The widened road will include a pedestrian path and a cycle lane. CSG Engineering Pty Ltd The project involved construction of an Ecoflex retaining wall along the embankment edge Ecoflex pavement was then placed in varying layers to the engineering design from the E Wall to the excavated edge of the existing road which remained in service during the construction process. Ford Civil engaged ECC supervisors to work with the site manager to assist with installation procedures, delivery schedules and staff training, with the aim of keeping the project running efficiently in the trying conditions presented. The conditions encountered included varying retaining wall subbase conditions along the length of the project, tidal flows covering the work areas to depths of 200 to 400 mm along with limited access conditions of busy Captain Cook Drive. The varying conditions created varying rates of settlement as was described in the preliminary Geotechnical Report, the settlement required additional Ecoflex units to be installed to maintain finished road height. The settlement did not cause any structural deterioration to the E Wall or E Pave structures according to subsequent engineering inspection. Following the installation of the Ecoflex systems which used recycled concrete aggregate as the infill material Ford Civil placed and compacted the recycled asphalt infill followed by the placement and compaction of the recycled concrete road base. This project has utilised nearly 17,000 recycled truck tyres (Approx 85,000 EPU s) manufactured into Ecoflex Units now embedded into this permanent infrastructure project. Page 4

5 DESIGN DRAWINGS Typical Section Page 5


7 Preparation Clearing Page 7

8 Clearing Page 8

9 E Wall Footing Page 9

10 Footing Page 10

11 Tidal Conditions Page 11

12 Ecoflex Wall and Subbase with Backfill Page 12

13 Works Progress Page 13

14 E Pave Subbase Recycled Concrete Infill Page 14

15 Works Progressing Page 15

16 Works Progressing Page 16

17 Works Progressing Page 17

18 Works Continue at High Tide Page 18

19 Recycled Asphalt Backfill Placement Page 19

20 Placing Road Base Page 20

21 Tarred and Armco Installed Page 21

22 Armco Installation Page 22

23 COMPANY INFORMATION HEAD OFFICE: Newcastle 66 Kalaroo Road Redhead NSW 2290, Australia Telephone: Facsimile: Website: PATENTS International Patents cover the works and intellectual property shown in this document. All rights reserved. No part of the works and/or intellectual property may be reproduced or utilised in any form or by means, without prior written consent of ECOFLEX AUSTRALIA PTY LTD. Page 23