In the 1970s, Gary Vermeer had a vision: if Vermeer could develop a machine that could dig in a manner similar to a mole tunnelling underneath a road, without opening up a trench, it would blow open the market, and make Vermeer an industry pioneer.
The new T815 crawler system is battery-powered, making it safer, lighter and more robust. This machine is suited to the most extreme applications, from toxic environments to conditions 100 m below sea level.
As the company continues to prove itself as an industry leader for drain maintenance and rehabilitation across Victoria and New South Wales, Rangedale is taking its capabilities further.
The Rangedale Group first introduced its civil division in 2009 when the company was primarily doing collapsed sewer dig-outs for waterboards across Melbourne.
Rangedale civil operations manager Mick Fuller tells Trenchless Australasia the division has quickly developed and upskilled into becoming a recognised industry specialist for repairs to damaged sewers and storm water pipes, and for constructing sewer pipe connections and extensions.
“Our civil team have the expertise, the experience, and the equipment to handle: Dig outs in excessive wet running sand and poor soil, plus closed timber sheeted up to 14m deep, construction of new manholes, dewatering of excavation and bypass pumping of sewer lines,” says Fuller.
“As our team continued to expand into becoming civil specialists, we were soon incorporating more skills such as tunnelling under buildings, trees, laneways and utilities, asphalt work, concrete cutting, hydro excavation and repairing sewers with relining methods.
“We started looking in concrete rehabilitation products such as industrial epoxy coatings for new manhole structures to protect the life of these pipes and drains. From here we’ve continued to expand this line of offering through our civil services which includes leak seal technology that seals infiltration on various concrete structure’s and additionally a geo polymer product to also rehabilitate deteriorated large diameter pipes as a structural liner.”
Fuller says the company currently has a strong focus on coatings and manholes, but is now wanting to add more products to expand its expertise.
“The main benefit and whole end-goal is to enhance the life of their customers assets non-intrusively. It is the trenchless way,” he says.
Fuller says with the technologies already there, the key is to work closely with partners and suppliers to get it out into the market effectively.
With the company’s longstanding philosophy “keep it running”, Rangedale offers the expertise, capability, resources and scale to take on projects large and small.
The Concrete Remediation Range provides a cost-effective solution in a timely, safe and industry-standard manner.
“Working with our partners is a really important aspect of the company – we come to the table with the technical and practical expertise. It is a winning solution,” Fuller says.
Ensuring its customers have a comprehensive service, Fuller says the Rangedale Group of companies is vertically integrated, allowing turnkey solutions utilising all in-house services.
With the scale of its fleet, personnel, industry knowledge and expertise, Rangedale is the first choice when it comes to drain cleaning, manhole construction and manhole relining, inspection, maintenance and repair, utility locating and mapping, service proofing, saw cutting, restoration, relining, NDD, CCTV, traffic management, asphalting, civil works, industrial cleaning, bulk liquid and slurry waste management.
Covering a large range of industries, Fuller says the company now has its sights set on expanding further the roads, transport and rail sectors following the addition of the Concrete Remediation Range.
The company aims to synergise more with these industries by working closely with its manufacturers and suppliers’ partners to ensure the application procedures are understood.
Fuller says this will be achieved by implementing and managing crews to ensure that they are working to a WSA approved inspection test plan.
With the overall goal to extend the life of assets, Rangedale has sufficient labour, resources and equipment which provide it with the flexibility of allocating high priority to emergency works, the ability to work 24/7 to complete works that may be located in high traffic areas or if high flows prevent day works.
“Rangedale is always on the look out for products and technology that can be of value to our customers – that is how the company has grown to what it is today. They are all driven by the needs of existing clients,” he says. “Given our specialist nature, our team have the expertise and the equipment to deal with a range of situations that many service providers wouldn’t be able to achieve.”
For more information visit the Rangedale website.
This article featured in the December 2021 edition of Trenchless Australasia. To view the digital magazine, click here.
WaterAid is an international not-for-profit determined to make clean water, decent toilets, and good hygiene accessible for everyone in the world within the space of a generation.
Taking place on 8–11 March this year, No-Dig Down Under will include a technical conference, trade exhibition, social functions, as well as training courses presented by internationally recognised leaders of their respective fields.
Teresa Ayles is the Director of Community Engagement at WaterAid Australia.
“WaterAid enables the world’s poorest people to gain access to clean water, decent toilets and good hygiene. Without all three, people can’t live dignified, healthy lives. With all three, they can unlock their potential, break free from poverty, and change their lives for good,” said Ayles.
“WaterAid Australia is thrilled to be the charity partner of No-Dig Down Under 2022.
“As charity partner, WaterAid will be presenting at the Gala Dinner during the conference and you can support our work at the various tap donation points at the registration desk for the duration of the event.”
WaterAid was involved with No-Dig Down Under 2019, with all proceeds from a charity auction at the event’s Gala Dinner and Awards Evening donated directly to the not-for-profit.
The company says in a world with so many competing priorities, it remains resolutely focused on transforming lives for good.
For more information visit the No-Dig Down Under website.
The State Underground Power Project (SUPP) was established in the early 1990’s after severe storm damage caused major power outages across the populated South West region of WA.
As a company that makes the impossible possible, IMPREG develops and produces cured-in-place pipe (CIPP) liner systems using a high-tech process for trenchless pipes and sewer rehabilitation.
Wilmot Pipelining has yet again showcased the company’s ability to deliver large scale complex infrastructure rehabilitation successfully, whilst breaking records along the way.
The Asbestos Safety and Eradication Agency (ASEA) has released guidelines to assist water and sewerage service providers in managing risks associated with asbestos in pipelines.
With 25 years’ experience and expertise in the design and construction of large HDD rigs, Prime Drilling is always working with its customers to enhance its directional drilling equipment.
Aiming for prompt and reliable delivery and service, the company has a broad international presence with equipment operating from Europe to Australia and many countries in between.
The name Prime Drilling stands for high precision and quality, coupled with continuous innovation which in turn leads to the construction and development of robust HDD systems. Using high-quality materials to develop a low-maintenance, robust and reliable drilling rig with an above-average service life, manager Ralf Kiesow says this is a result of the company’s profound know-how in drilling technique, and high production quality.
“These are the outstanding benefits for our customers and the pillars of our company´s success,” he says. “All the rigs we have built to date are still running today. There isn’t a single unit that isn’t still working out in the field. Customer focus is a key part of our ongoing service commitments and we remain in contact with each and every client that has purchased equipment from us, even after 20 years.”
Kiesow says every single rig leaving its factory is tailor-made for the customer to meet their specific requirements. He says Prime Drilling offers its customers over 200 optional features with only one objective: the manufacture of a unique drill rig. “From our inception up to the present day, commitment and enthusiasm is what has enabled us to become one of the leading manufacturers of HDD rigs,” he says.
“Driven by the desire for perfection we take pride in presenting our comprehensive range of successfully operating horizontal drilling rigs. The merging of technology and know-how result in unique products of absolute premium class.” Using only first-class materials in the development of its low-maintenance and robust drill rigs, Kiesow says Prime Drilling machines are unrivalled in performance, high production quality and perfect service.
With the company’s customers’ expressing their needs for rigs that were smaller and faster, the new generation of compact drill rigs from Prime Drilling set new standards in the performance category. Due to its perfected design and optimised components, in both weight and sizes, transport and set-up costs have been reduced to a minimum. The PD 30/12 CU and PD 45/19 CU both have a mounted CAT 7.1 ACERT power plants which incorporate the latest emission standards and adjustable cooling systems to minimise fuel consumption.
Kiesow says based on a detailed development programme and thorough the selection of quality materials and componentry, the company gets the maximum efficiency out of every part of the machine. “Further advantages to guarantee a fast, uncomplicated and economic operation for our customers include: the fully automated drill pipe magazine for 32 pipes; and the incorporation of a new hydraulic system enabling improved performance of the rig,” he says.
“As a result of the powerful on-board mud pump, these machines are capable of larger dimeter holes and ready for big jobs. We remain in continuous consultation with our customers and their requirements, as well as on the basis of Prime Drilling´s 20 years’ of experience, we have succeeded in developing a drill rig which is tailor-made to meet the user´s demands.”
By cutting down on the weight, Kiesow says it still allowed the rig to have a full magazine to ensure production was fast and efficient. He says whenever the company builds a new rig it builds three at a time, which are usually sold before they are produced due to the high demand.
However, Prime Drilling has large storage areas and can react quickly, efficiently and flexibly to customers’ wishes to ensure they can source equipment when required. Offering a comprehensive after-sales service, its customers can easily procure spare parts on the local market and carry out necessary repairs by themselves.
Kiesow says despite only selling between 20 and 30 rigs a year, Prime Drilling encourages its customers to come with a ‘wish list’ when buying a rig. “Our design team tries to meet those needs, going back and forth, until everyone is happy with the final design,” he says.
“This ensures the customer gets exactly what they want and allows for us to create something new and bespoke to the clients requirements. Our technicians and designers then go out in the field and see how things perform, talk with the drillers to make sure our customers are truly satisfied.”
Prime Drilling has also introduced a remote analysis function in its rigs to allow users to see a problem before it affects production on site. Kiesow says its service team is available at short notice and its remote maintenance service can be accessed at any time.
“This means if a problem comes up the user is able to pin-point where the issue is and see what has to be replaced. If the customer can’t find the problem, they can call us on our 24/7 hotline where the technician is able to see what the driller is seeing and find the cause of the problem,” he says.
For more information on visit the TRACTO-TECHNIK Australia website.
More and more water utilities are taking advantage of the Primus Line system for its rehabilitation projects for pressure pipes. Hunter Water has even included the German technology in its portfolio as a standard renovation technology.
Growing its national footprint to support contractors across Australia and New Zealand, KOR is succeeding in the vision to make it simple for its customers to secure and maintain world leading products.
There is increasing awareness among infrastructure asset owners that horizontal directional drilling (HDD) can provide an effective whole-of-life solution for the installation of pipelines.
Maxibor chief executive officer (CEO) and owner Rodney O’Meley provides insights into maxi-rig spreads and highlights their benefits on major projects across the various infrastructure sectors.
Maxi-rigs are HDD rigs required for the installation of pipelines with diameters between 400 mm and 1200 mm, and rated for more than 45,359 kg of thrust and greater than 9,072 kg of torque. There are four maxi-rigs in the Maxibor fleet: a Vermeer 330×500, American Auger 660, Gallagher 600 and Gallagher 660e.
The maxi-rig spread is a significant investment as it comprises much more than just the rig. A spread includes drill fluid cleaners, high volume pumps, a mud mixer, vacuum trucks, rods, tooling and excavators. All add to the onsite cost of a spread, even before a rod is turned. The purchase cost of a new spread today would not leave much change from $8 million.
The mobilisation and demobilisation can require as many as 20 loads for a prime mover and trailer, which, over long distances, can pose a significant cost. A container of spare parts is also an essential part of the spread to minimise downtime and maintain productivity especially in more remote locations.
The knowledge and capacity of the HDD industry to take on more challenging projects in Australia is certainly there particularly where you have very experienced design and construct HDD providers like Maxibor. This enables the integrated body of knowledge required to deliver the project to be involved from early design through to delivery and final commissioning and testing of the pipeline.
The length and diameter of pipelines that maxi-rigs can install will depend on the ground conditions and the pipe being installed. While they have the capacity to drill pipelines of more than 2 kms with diameters up to 1.6 m, typically maxi-rigs are used on projects around 500 m with bore diameters of + 600 mm.
Maxi-rigs are ideally suited for river crossings, ocean outfalls, hard rock conditions and multiple service bores requiring larger diameter holes. Distance is not a problem and neither is force, as the power of the maxi-rigs and the pumps are more than sufficient to overcome the most difficult ground conditions, bore lengths or other design constraints.
Bore hole assembly (BHA) selection is also important as this will drive the rate of penetration of the drill head. Less stable ground conditions such as water charged sands and cobbles are overcome with good practice drill fluid management and, if necessary, the use of casing to support the bore hole.
Maxibor used its Vermeer 330×500 maxi-rig on a 1.320 km Logan City Council project, which connected the Greater Flagstone Priority Development Area with the Cedar Grove sewerage treatment plant. Maxibor designed and delivered a 1.320 km bore, installing 500mm of PE100 HSCR PN20 to a depth of over 50 m.
Maxi-rigs proved essential to the fleet on a project to install a new 400 m section of water pipeline between Lamb and Macleay Islands in Queensland. Maxibor used one of its Vermeer 100x120s to complete the pilot hole and most of the reaming. The Vermeer 330×500 maxi-rig was then brought in to ream the bore hole to a 550 mm diameter and pull the DN400 PN20 pipe through.
Into 2022, Maxibor has several bores lined up for its maxi-rigs with distances in the 1.5 km to 2.5 km range. It is also working in the early design stage with various asset owners and principal contractors on other projects across Australia involving complex river and harbour crossings and outfall project challenges.
Maxi-rigs are selected for their ability to provide solutions to challenging infrastructure installation problems. Industry experts expect these to come to the fore in the current decade as climate change mitigation and adaptation measures grow increasingly necessary to protect against impact of severe climate events.
Electricity, telecommunications, water, sewerage and gas assets will be increasingly impacted by wind, fire, flood, erosion, drought and inundation. Many of these assets are vulnerable because of their age and above ground replacement or trenching is no longer a medium-term viable option.
With the ever-increasing congestion of utility services in metropolitan areas, the difficulties around installation are ever increasing. Maxi-rigs provide an ideal solution for installing new infrastructure assets such as data lines, charging stations and green hydrogen.
An exciting recent addition to the Maxibor fleet has been its electrified Gallagher HDD660e maxi-rig, informally known as ‘The Hulk’. The electrified spread comes with its own substation, which also connects to two powerful Gardner Denver PZ9 pumps and a large Gallagher mud recycling system.
The Hulk can drill up to 3 kms in a single shot with a diameter up to 1.6m. According to the company, electric spreads are the direction of the future for the HDD industry as it responds to the need for emissions reduction.
For more information visit the Maxibor website.
Alternative Lining Technologies’ (ALT) custom fabricated liners create a protective barrier from corrosive gases and groundwater infiltration.
Trenchless Australasia has teamed up with Australian Tenders to bring readers the latest trenchless tenders.
Central Highlands Water (CHW) has successfully completed Stage 1 of the Ballarat Sewer Build.
Stage 1 of the project commenced in April 2021 and required an investment of more than $25 million into the Ballarat region.
The team at CHW faced many challenges throughout the project including construction interruptions due to COVID-19 and severe weather events, and the company thanked the community for its ongoing patience and understanding.
“The understanding shown by both our business community and residents has made a highly complex project achievable,” a spokesperson for the company said.
Stage 1 of the project saw the installation of around 1 km of sewer pipe, between4 and 6 me beneath the CBD, along Peel Street, Eastwood Street and Anderson Streets and East and West.
The construction process involved the compaction of more than 13,000 t of rock and two micro-tunnels bored beneath critical traffic intersections.
Microtunnelling techniques were used where possible to minimise ground disturbance; however, attempts at Little Bridge Street were unsuccessful due to unstable ground conditions and open-trench methods were necessary.
Around 220m3 of concrete was poured in the three large sewer connections made into the existing network.
The project took the CHW a total of 22,000 working hours.
Stage 2 of the Ballarat Sewer Build will cover White Flat Oval to Rest Street, and is expected to commence in 2022.
When all stages are complete, the Ballarat Sewer Build will duplicate the existing sewer line from Ballarat East to South.
According to CHW, the pipeline duplication will service the community for another 100 years.
For more information visit the Central Highlands Water website.
Snowy 2.0 is a renewable energy project that will provide on-demand energy and large-scale storage in the Snowy Mountains, New South Wales.
It is the largest committed renewable energy project in Australia that will underpin the nation’s transition to a low-carbon future.
The project involves the development of a new underground power station around 1 km below ground, as well as the linking of two existing dams – Tantangara and Talbingo – through 27 km of tunnels.
Hydroelectricity is generated when falling water spins giant turbines.
Water will be pumped to the upper dam where there is surplus renewable energy production, and then released back into the lower dam to generate energy.
Snowy 2.0 will provide flexible, on-demand power while recycling the water in a closed loop and maximise the efficiency of renewables by using excess solar and wind energy to pump water to the higher dam, to be stored for later use.
Company Snowy Hydro is leading the project and has begun assembling a giant TBM ‘Florence’ ready to excavate a 16 km headrace tunnel.
Most of the 27 km of tunnel on the project will be excavated by TBM, with the concrete segment-lined tunnels reaching 10 m in diameter.
The company achieved an exciting milestone this week with the commissioning of a second TBM.
The 11 m diameter TBM ‘Kirsten’ is one of three TBMs that will excavate the tunnels for the pumped-hydro expansion.
Snowy Hydro chief executive Paul Broad said Snowy 2.0 was creating 4,000 jobs and significant training and apprenticeship opportunities for workers, while providing a major economic boost for the Snowy Mountains region and beyond.
“Our first TBM, the Lady Eileen Hudson, is already a kilometre into the mountain excavating the main access tunnel and now we have TBM Kirsten continuing the tunnelling and construction progress for this amazing project,” Broad said.
“Our growing workforce of almost 1,400 includes hundreds of people from the local region and we have invested more than $70 million with local businesses so far.”
The company is working with principal contractor, Future Generation Joint Venture, to deliver the Snowy 2.0 Rebuild Clough.
First power generated from Snowy 2.0 is expected early 2025.
For more information visit the Snowy Hydro website.
Backed by more than 30 years’ experience, Rob Carr has become a reputable name for utilities infrastructure and a market leader in microtunnelling and complex underground works.
Since it joined VINCI Group, the company has been able to improve its financial capability to bid, design and construct bigger and more challenging projects.
One of the keys to the company’s success is its fleet of 30 microtunnelling machines, with the largest diameter being 2,180 mm, covering all ground conditions.
“With our fleet of 30 microtunneling machines, we cover a range of pipeline diameters for trenchless construction,” a spokesperson for the company said.
The machines are supported by a wide ranging ancillary equipment fleet in the form of control cabins, jacking frames, slurry separation tanks and systems, gantry cranes, and more.
“These tools are fundamental when it comes to trenchless construction as it improves accuracy,” the company said.
Rob Carr uses trenchless techniques to successfully construct tunnels for pipeline infrastructure beneath major roads, railways, runways, waterways and environmentally sensitive areas.
The company uses two main techniques for mirotunnelling: slurry pressure balanced micro tunnelling, and pilot auger soil displacement tunnelling.
Recently, the company also invested in German Herrenknecht AVN technology to facilitate the growth of the business into larger scale tunnelling projects.
For more information visit the Rob Carr website.
The $99 billion Torrens to Darlington (T2D) Project has released its reference design for community feedback.
No-Dig Down Under will feature a three-stream conference program, covering rehabilitation, installation and condition assessment and utility location when it takes place in March.
Australian engineering contractor John Holland has recently completed the Sydney Metro City and Southwest Tunnel and Excavation Works (TSE).
JAYDO Construction has mobilised and commenced works at the Painted Hills Sewage Pump Station and Rising Main Project for Yarra Valley Water.
This project involves constructing a new underground pump station near the intersection of Painted Hills Road and Kyarra Drive, Doreen.
It requires 1 km of 500 OD HDPE pipeline from the pump station to the Overland Drive roundabout, under Laurimar Creek to Bradford Drive, where it will connect to the existing sewer network.
Once these works have been completed, then the existing sewer pump station and pipeline will be decommissioned.
In the top image, 49 t excavator breaking rock in the 13 m deep wet well shaft next to the Laurimar Creek wetlands.
The sewer upgrade is expected to take 12 months to complete, with estimated completion in July 2022.
JAYDO Construction was previously contracted by Yarra Valley Water along to perform trenchless and micro-tunnel boring works on the Lockerbie Main Sewer Project.
For more information visit the Yarra Valley Water website.
KOR toured parts of East Gippsland last week, demonstrating the company’s Cappellotto and Schwarze units, plus cleaning accessories from KEG Kanalreinigungstechnik.
A team from the company’s Mulgrave base, in Melbourne’s southeast, visited a number of towns as part of the trip, including Morwell, Sale, Bairnsdale and Lakes Entrance.
KOR has an extensive range of vacuum and hydro excavation and street sweeping equipment operated by a diverse base of quality customers across many different applications.
Earlier this year the company secured the exclusive distribution for Schwarze Industries Sweepers in Australia and New Zealand.
According to Managing Director Stephen Pewtress, Schwarze had been looking for a partner to strengthen its position nationally and was aware of KOR’s reputation and commitment and an agreement was reached that commenced on 1 July 2021.
For more information visit the KOR Equipment Solutions website.
TasWater has announced that George Theo will be replacing Mike Brewster as chief executive officer.
Spiecapag has begun BP’s Kewdale White Oil (KWOL) project on behalf of METRONET to relocate over 11 km of pipeline from BP’s Kwinana refinery to the Kewdale terminal of Perth Airport.
The Australasian Society for Trenchless Technology (ASTT) will once again offer 10 utility and council scholarships for attendance at No-Dig Down Under 2022.
Dr Di Lorenzo joined Melbourne Water in July 2019 as the executive general manager of service delivery and has played a critical role in reshaping the organisation.
Prior to her position at Melbourne Water, Di Lorenzo held the title of chief executive officer at City of Moreland.
She holds engineering qualifications, is vastly experienced in asset management, and has worked in the highly complex processing environment of the oil sector.
According to Melbourne Water’s chair, Prof. John Thwaits, Dr Di Lorenzo was an outstanding appointment with exceptional qualifications, and the board looks forward to working closely with her through the next phase of the utility’s history.
“In her time at Melbourne Water, the Board has been thoroughly impressed by Dr Di Lorenzo’s leadership, skills and ability to drive customer outcomes in a collaborative way,” Thwaites said.
“This historic appointment – the first female managing director in the organisation’s 130 history – builds on previous appointments of women to senior roles in the organisation.”
Di Lorenzo said she was proud to be appointed Melbourne Water’s next managing director
“I’m particularly excited about forging stronger relationships with our customers and delivery partners, especially Traditional Owners,” said Di Lorenzo.
“The sector is facing big challenges including long term water security, reducing our greenhouse gas emissions, improving the health of our rivers and catchments and making greater Melbourne an even better place to live.
“We can only meet these challenges by working hand in hand with our customers and the community.”
Di Lorenzo succeeds Michael Wandmaker, who had been the company’s MD since 2014 and will step down from the role on 30 November.
Thwaites thanks Wandmaker for his dedication and achievements over the last seven years.
For more information visit the Melbourne Water website.