CAPABILITY STATEMENT. precast and prestressed products engineered for efficiency

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1 CAPABILITY STATEMENT 2013 Infrastructure PERMAcast Mining 2013 & Resource Oil and Gas Structural precast and prestressed products engineered for efficiency

2 Quality Management The quality and reliability of PERMAcast products and services are the foundation of the success of the organisation. We aim to constantly develop and improve the business, whilst striving to continually meet or exceed the expectations of our customers. PERMAcast s exponential growth is made possible with the aid of a well organised, Certified QMS. 2

3 Quality Management PERMAcast s Quality Management System is third party certified to ISO 9001:2008. We are committed to the ongoing implementation, development, and auditing of the fully electronic PERMAcast Quality Management System. Quality Assurance is fundamental to all work undertaken by PERMAcast. PERMAcast Quality Policy and Procedures have previously been approved for use by: BHP Woodside Rio Tinto Chevron Water Corporation Main Roads WA SKM KJV Apache Energy Leighton Contracting As the industry leader in structural precast our team of expert engineers continually produce products of the highest quality with our clients specifications in mind. 3

4 Quality Management PERMAcast meets the stringent standards required for industry representation. PERMAcast takes it role as an industry leader seriously and is pleased to be able to participate in and contribute to relevant associations, thereby further enhancing overall industry quality standards. 4

5 Health, Safety and Environment (HSE) PERMAcast is committed to protecting the safety and health of all employees, contractors, visitors and the community who are impacted by our activities and believes that all injuries, industry related diseases and incidents are preventable. Our commitment to health and safety is paramount and a vital factor in PERMAcasts expansion to date and into the future. 5

6 Health, Safety and Environment (HSE) PERMAcast recognises strong health, safety and environmental performance is vital for efficient operation of large scale precast facilities. PERMAcast s Safety & Health Management System model is based on OSHAS & ISO PERMAcast employs dedicated safety representatives and enforces a Safety and Health Policy which is widely supported and enhanced by the entire PERMAcast team. At PERMAcast we are proud that our safety performance is continually improving and we are consistently receiving complimentary comments form our major clients regarding our safety systems and initiatives. Period LTI's Man Hours AVG. Workers PERMAcast LTI Frequency Rate PERMAcast LTI Incident Rate Industry LTI Frequency Rate Industry LTI Incident Rate , ,

7 Company Introduction/History Established in mid 2006, PERMAcastcommenced operations as a specialist precast concrete panel manufacturer for the building industry. By 2008 the business had diversified, entering the structural precast market starting with the supply of drainage and custom products for various civil construction projects. In 2008, PERMAcastwere awarded a major structural precast project and since then has focussed on supplying clients with customised products designed to meet exact specifications. 7

8 Company Introduction/History Being 100% privately owned and operated the core focus of the PERMAcast business has always been on major projects within Regional key market sectors. With extensive in house engineering capacity and technical expertise PERMAcast is widely recognised as the leading industry specialist in custom design of precast concrete solutions for major projects. Add to that a large scale modern production facility and an absolutely massive storage area and it is no wonder that PERMAcast is the precast supplier of choice for the regions largest resources and infrastructure projects. Safety and Quality are the cornerstones of our company culture from which everything else emanates and grows, thus maximising our internal (and hence also our clients) project efficiencies. 8

9 Organisational Chart 9

10 Engineering and Support PERMAcast s engineering capacity and capabilities are unrivalled in the industry Our entire management team are qualified engineers with several decades of specific precast experience. Therefore, when our engineers are involved at the design stage the result is a more efficient and cost effective construction for our clients. Our team of qualified QA engineers are dedicated to ensuring the highest quality standards are met on every project. Dedicated in house design staff ensure continuity and open communication from design to production, further enhancing quality outcomes and operational efficiencies. 10

11 Engineering and Support PERMAcast Engineering Team Nigel Chamberlain Bachelor Engineering (Civil) UWA 10+ years Precast Construction Stuart Young - Bachelor Engineering (Civil) UNSW 9+ years Civil Construction Alberto Ferraro Diploma Civil Engineering 11+ years Precast Construction Sujan Sharma Bachelor of Civil Engineering 8+ years construction & 2 years precast Engineering Support Peritas Group WA based civil structural engineers Drafting Full time PERMAcast staff Gary Johnson B Tec. National Cert in Mechanical Engineering 21years drafting experience Third Party consultants 11

12 Cardup Production Facility Existing 3700m 2 factory with provision to lift products up to 25 Tonnes (T). Annual production capacity in excess of 70,000T. 250,000m 2 storage facility. PERMAcast own two 45T Yard forklifts. Access to all major road networks that service both north and south of Western Australia. Aerial wide view of PERMAcast Cardup Additional 3000m 2 storage/production area including a 25t portal crane complete with prestressing bed. 12

13 Cardup Production/Storage Facility At PERMAcast we REALLY DO have a massive storage space. The benefits for maximising project efficiencies and simplifying your project logistics are therefore as endless as our storage capacity. This provides very real cost benefits for our clients. 13

14 Location and Transport Routes PERMAcast s manufacturing facility is located 45 minutes south of the Perth CBD. PERMAcast delivers products to all areas within Western Australia. PERMAcast s factory is strategically located next to approved overwidth and over-size vehicle transit roads. Our approved road-train configurations can leave the precast yard preassembled. The PERMAcast team assists clients with all their logistical and transport requirements. PERMAcast Cardup 14

15 PERMAcast Concrete Products PERMAcast prides itself on consistent production of top quality products and leading edge design standards. We produce standard concrete infrastructure products and engineer and manufacture custom components to exact specifications. PERMAcast supplies a variety of standard products including: Precast panels Rail components Footings/Foundations Columns Tanks and silos Noise walls Box culverts Retaining structures (L-Shape) Drainage access chamber (including epoxy lined) Beams including pre-stressed Ramp and jetty components Abutment walls Marine structures including pre-stressed deck planks Tunnel lining segments 15

16 Additional PERMAcast Services Cast in/bolt on Custom Products and Protective Coatings to Client Specifications PERMAcast can procure and cast in/bolt on or apply any custom products such as epoxy coatings and steel ladders in a controlled factory environment under our Quality Management Systems thus adding further value to our clients projects. 16

17 Project Experience PERMAcast has the capacity and expertise to service key market sectors of Oil & Gas, Mining & Resources and Infrastructure 17

18 Project Experience Gorgon Civils & UG Services Precast Concrete Manholes Client: Leighton Contracting Project Period: 2011 Feb 2013 Project Specifications: - 610No Manholes (15-20T) - 610No Conversion Slabs - 610No Access Shafts Project Details: No 2 manholes the same 1591 penetrations (+/- 5mm Tolerance) Storage in excess of 330No manholes Class 2 finish to all products to comply with stringent project quarantine standards Single pour construction no joint/leaks Value adding supply and install all ladders Managed logistics co-ordination between Leighton, their nominated sub-contractor and PERMAcast 18

19 Project Experience Gorgon Construction Village Cyclone Corridor Precast Concrete Culverts Client: Thiess Decmil Joint Venture Project Period: Project Details: PERMAcast supplied 197 custom built culverts to form cyclone corridors The culverts varied in size and shape and were supplied with doorway and louver openings where required. All culverts were supplied painted to project specifications and rotated upside down to facilitate safe tie down and transport 19

20 Project Experience Gorgon LNG Camp Facilities Precast Concrete Products Client: Thiess Decmil Kentz Joint Venture Project Period: November 2009 Ongoing Project Specifications: 444No TCF Foundations 160No Site Drainage Culverts 2288No Permanent Camp Foundations 900No Cable Tray Supports Project Details: The PERMAcast project team undertook quarantine training from Chevron. Stringent quarantine procedures and documentation was required throughout the project. All products were loaded into pesticide treated sea containers and flat racks ready for transport. PERMAcast carried out residual spraying on all products PERMAcast setup a designated quarantine area inside the factory and ensured cleanliness in all aspects of production; complying with the contractors requirements. 20

21 Project Experience Chevron Gorgon Chevron Gorgon LNG Supply of Precast Components 21

22 Project Experience Woodside Pluto LNG Supply of Precast Drainage Components Client: BGC Contracting Project Period: Dec 2008 June 2009 Project Specifications: 150No AOC Manholes - Epoxy Lined (5T 15T) 8No EOF Manholes (5T 30T) 68No Firewater Valve Pits 42No Valve Pits 46No Fire Traps 91No Catch Basins 2400No Electrical Trench Units (2.45m Long) Project Details: Single pour construction = no construction joints, eliminating the possibility of potential leaks onsite. Manufacture of over 400 types of pits and manholes, where no two items were the same. Extensive rationalisation. Due to the rapid installation of the products, PERMAcast was able to accelerate the production program to turn out up to 1500t/month of products in the latter stages of the contract. All units fitted with ladders and coated with epoxy prior to site delivery. PERMAcast prepared all penetration to receive onsite grouting of GRE and concrete pipes. 22

23 Project Experience Woodside Pluto LNG Woodside Pluto LNG Plant Supply of Precast Drainage Components 23

24 Project Experience Woodside Pluto LNG Woodside Pluto LNG Plant Supply of Precast Drainage Components 24

25 Project Experience SSJV Stage 1 & 2 Supply of Precast Wall Panels and Culverts Client SSJV Project Period Feb 2010 Current Project Details: PERMAcast supplied over 31,000sqm of precast walls panels PERMAcast supplied large box culverts and lids totalling over 2,600T 100 year design life meant the components were manufactured using a S50 low heat cement mix - uncommon for precast production. PERMAcast was producing on average of 200sqm of panels per day to meet the tight construction programme. Storage of over 450 panels prior to delivery was made easy with the vast storage area available at the PERMAcast Cardup facility. 25

26 Project Experience Beenyup WWTP Supply of Post Tension Roof Panels and Ring Beams for Digester Tanks Client: W2W Alliance Black and Veatch Thiess JV Project Period: 2009 Project Specifications: 60No Post Tension Roof Panels - 9T each 36No Post Tension Roof Panels - 11T each 2No 6.5m Dia Inner Ring Beams- 26T each 4No Epoxy Lined Roof Covers - 8T each Project Details: Dimensional tolerances for all products supplied were +/- 3mm. The project was extremely technical and panels were completed with various finishes. Up to 50 cast-in products per unit. PERMAcast engineers designed steel moulds to meet the project specifications. 26

27 Project Experience RIO Dampier Salt Pump Station Supply of Precast Box Culverts, Base Slabs and L-Shapes Client: Dampier Salt Ltd Project Period: June 2011 September 2011 Project Specifications: 20No Box Culverts (15T each) 20No Box Culvert Base Slabs (6.5T each) 50No L-Shape Retaining Walls (8T each) 7No Electrical Culverts and Lids (4T each) Project Details: Tight dimensional tolerances to ensure on-site constructability. Tidal zone application required Xypex admixtures. Designed and manufactured for high live loads. Permacast assisted with detailed design of electrical culverts. 27

28 Project Experience RTIO Cape Lambert Car Dumpers Supply of Precast and Prestressed beams and Headstocks Client: DTMT Project Period: October 2012 April 2013 Project Specifications: 160No Precast Beams (9-17T each) 13No Precast Headstock Soffit (8-10T each) 121No Prestressed Beams ( T each) Project Details: Tight dimensional tolerances to ensure on-site constructability. Cast in s for ancillary services including plates and formwork connections. Designed and manufactured for high live loads. Continual liason with client to ensure logistical efficiencies. 28

29 Project Experience Apache Varanus Island Wharf Upgrade Supply of Precast Caisson Units Client: Apache Energy Limited Project Period: September 2012 December 2012 Project Specifications: 9No Caissons (45T each) 4.2m x 3.0m x 4.8m high. 9No Caissons (33T each) 4.2m x 3.0m x 3.65m high. Project Details: Highly specified S50 Low Heat mix design. Fully Galvanised reo (avg. 3.2T/reo cage). Cast in specialised SS anchors for connecting fenders and ladders. Permacast installed all fenders and ladders prior to shipment. Produce 1 unit per day to meet short project schedule. Project specific 110T crawler crane for production and 130T hydraulic crane for load out. Permacast large storage area was required pre-delivery. 29

30 THANK YOU CONTACT DETAILS ABN: ACN: E: 394 Robertson Road Cardup, Western Australia 6122 PO Box 232 Mundijong WA 6123 P: F: