November 2016 - Industry Capability Network

Melbourne Metro Rail Authority

TRIM: DOC/16/408632 1

SUPPLMENTARY CEMENTITIOUS MATERIALS Information for Suppliers MELBOURNE METRO RAIL AUTHORITY

November 2016


TRIM: DOC/16/408632 i

Document Status

PMF Classification Version 1

TRIM Reference DOC/16/408632 Status Approved

Issue Date 16/11/2016

Document and History Status

Version Date Author & Title Purpose for Issue

1.0 16/11/2016 SCMs: Information for Suppliers

Damien Kennedy FIEAust CPEng NER RPEQ

Dr Marita Berndt - Aurecon, FIEAust CPEng NER RPEQ

Stuart Beatton - Advisian

Issue for Approval

Endorsement Status

Version Issue Date

Endorsed By Title

1.0 16/11/2016 Paul Thomas Senior Project Manager - Tunnels & Station

Infrastructure


TRIM: DOC/16/408632 ii

Table of Contents

1 Introduction ............................................................................................................................... 1

1.1 Supplementary Cementitious Materials (SCM) Target ....................................................... 1

1.2 Purpose ............................................................................................................................. 1

1.3 Confidentiality .................................................................................................................... 1

1.4 Disclaimer ......................................................................................................................... 1

2 Project Background ................................................................................................................... 3

2.1 Proposed Delivery Strategy and Procurement Packaging ................................................. 4

2.2 Reference Design.............................................................................................................. 4

2.3 Construction Summary ...................................................................................................... 5

2.4 Reference Design Construction Program .......................................................................... 6

3 Reference Design Concrete Requirement ................................................................................. 7

3.1 Measuring reductions in Portland Cement ......................................................................... 7

3.2 Estimated Concrete Volume & Mix Designs ...................................................................... 7

3.3 Constituent Sources .......................................................................................................... 9

4 Response & Enquiries ............................................................................................................. 11

4.1 Timeframe ....................................................................................................................... 11

4.2 Enquiries ......................................................................................................................... 11

Appendix A Response Proforma ............................................................................................... 12

Table of Tables

Table 2-1: Delivery Strategy Procurement Packages ...................................................................... 4

Table 2-2: Proposed Reference Design Station Construction Methods ........................................... 5

Table 2-3: Milestone summary and construction dates ................................................................... 6

Table 3-1: GBCA Concrete Reference Mix Constituent Baseline Content ....................................... 7

Table 3-2: Estimated concrete volume by use and proposed mix to achieve target ......................... 8

Table 3-3: AJM JV selected mix designs by construction use to achieve Portland cement reduction target ........................................................................................................... 10

Table 4-1: Key Dates .................................................................................................................... 11


TRIM: DOC/16/408632 iii

Table of Figures

Figure 2-1: MMRP Project Overview Plan ....................................................................................... 3

Figure 2-2: MMRP indicative tunnel alignment long section ............................................................ 5

Glossary & Abbreviations

TERMINOLOGY & ACRONYMS

AJM JV Aurecon Jacobs Mott MacDonald Joint Venture

Cut & Cover Method where void is excavated and roofed over with an overhead support system strong enough to carry the load of what is to be built above the excavation.

GBCA Green Building Council of Australia

GHG Greenhouse Gas (emissions)

ISCA Infrastructure Council of Australia

MMRA Melbourne Metro Rail Authority

SCM Supplementary Cementitious Material

TBM Tunnel Boring Machine

A machine used to excavate a driven tunnel.


TRIM: DOC/16/408632 Page 1

1 Introduction

Melbourne Metro Rail Authority (MMRA) has committed to sustainable triple bottom line (social,

environmental and economic) outcomes through the Metro Tunnel project construction and

operations. MMRA’s Sustainability Policy and Vision include a statement that MMRA will commit

to “Managing resources efficiently through embedding energy, water and material saving initiatives

into the design, construction and operation of the Project.”

To deliver the commitments outlined in MMRA’s Sustainability Policy and Vision, MMRA has

prepared Sustainability Targets outlining nine (9) overarching themes with associated objectives.

Within each theme there are thirty-five (35) targets that the work package proponents will be

required to plan, implement and monitor.

1.1 Supplementary Cementitious Materials (SCM) Target

The Materials and Waste theme has set a sustainability target to reduce Portland cement content

in concrete by greater than 36% measured by mass across all concrete used in the project

compared to the Green Building Council of Australia (GBCA) reference case mix referred to in

Section 3.1. The target does not mandate that all concrete elements must have a greater than

36% reduction of Portland cement but that overall the mass of Portland cement should be reduced

by a minimum of 36%. MMRA expects that elements like the tunnel segments will have a lower

reduction of SCMs due to curing, strength and timing requirements while other elements like

station floor and wall slabs will be able to reduce and replace with SCM at percentages higher than

36%. Concrete is predicted to comprise over 50% of material-originated Green House Gas (GHG)

emissions on the project. Portland cement is the most emission intensive with an emission factor

of 820kg CO2 per tonne.

1.2 Purpose

The purpose of this document is to provide concrete suppliers with background information on MMRA’s Portland cement content target to enable them to prepare appropriately for market demand during the delivery of the Metro Tunnel project. It provides preliminary mix design information prepared by MMRA’s technical advisor, Aurecon Jacobs Mott MacDonald Joint Venture (AJM JV), based on a reference design (Section 2.2) that meets MMRA’s sustainability target.

Concrete suppliers are requested to prepare and provide appropriate mix designs and associated information to MMRA. This information will then be provided to the Metro Tunnel work package proponents for their information during the project tender and pricing periods. Suppliers may choose to supply some or all the mix types required by the work package proponents.

1.3 Confidentiality

Work package proponents are subject to confidentiality agreements however concrete suppliers should consider their own confidentiality requirements when determining what information to provide, in particular if it is of a commercial or proprietary nature. The information provided to MMRA will be provided to each work package proponent for their use without prejudice.

1.4 Disclaimer

This document is not intended to form the basis of any business decision by the recipient. No part of this document constitutes a recommendation, offer, invitation or solicitation in relation to the



Metro Tunnel project, nor is the State undertaking in any way a commitment to enter into any procurement arrangement with the recipient.

The successful work package proponents will be responsible for detailed design and the associated concrete specifications and mix designs used to meet the minimum 36% target. Their proposed design volumes and mix types for each construction use/element may therefore vary. Concrete suppliers should note that the receipt and/or provision of a response to this document does not constitute acceptance nor guarantee of any business engagement in respect of the Metro Tunnel project.

This document has therefore been provided to the recipient for information purposes only and upon the express understanding that the recipient will use it only for the purposes set out in section 1.2.

No guarantee, representation or warranty (express or implied) is given by or on behalf of the State (including without limitation its employees, agents, associates and advisors) as to the quality, accuracy, reliability or completeness of the information contained in this document or any other information supplied by or on behalf of the State or that reasonable care has been taken in compiling or preparing any information.



2 Project Background

MMRA is proposing to deliver the Metro Tunnel project to provide increased capacity and create a city-wide metro-style rail system of segregated rail corridors. The key project infrastructure comprises:

Twin nine-kilometre underground rail tunnels from South Kensington in the western suburbs to

South Yarra in the south-east connecting the Sunbury and Dandenong rail corridors.

New underground railway stations at Arden, Parkville, CBD North, CBD South and Domain.

Rail tunnel portal entrances at South Kensington and South Yarra.

Rail passenger interchanges at:

CBD North to Melbourne Central Station, and

CBD South to Flinders Street Station.

Early works required to facilitate the above including:

shaft excavation and construction,

property acquisition and demolition,

utility relocations and upgrades,

provision of electrical (HV) supply to TBM sites, and

traffic, tram and pedestrian infrastructure upgrades and diversions.

Figure 2-1 provides an overview of the Melbourne Metro Rail Project alignment key components.

Figure 2-1: MMRP Project Overview Plan



2.1 Proposed Delivery Strategy and Procurement Packaging

MMRA has developed a delivery strategy packaging the works as per Table 2-1 below.

Table 2-1: Delivery Strategy Procurement Packages

Works package Procurement model Procurement Status

Early Works

Utility service relocations and works to prepare construction sites.

Early Works Managing Contractor

Contract awarded June 2016 to John Holland. Enabling works commenced.

Tram infrastructure works Franchisee Works (Yarra Trams)

To be engaged in 2016.

Provision of construction power Utility Service Provider works To be engaged in 2016.

Tunnels and Stations

Main tunnelling works, five underground stations, station fit-out, mechanical and electrical systems and specific maintenance services for the infrastructure delivered by the package and commercial opportunities at the new stations

Availability based Public Private Partnership (PPP)

Expression of Interest issued to market 28 April 2016

Shortlist announced on 11 August 2016. Request for Proposal now released. Proposals due 23 March 2017.

Rail Infrastructure

Works at the eastern and western portals including cut and cover tunnelling, decline structures, turn backs and local reconfiguration and realignment of existing lines

Competitive Alliance Expression of Interest to be issued to market mid-2017.

Rail Systems

Rail systems design (including conventional signalling, high capacity signalling, train and power control systems and operational control systems), installation works, rail systems integration and commissioning

Competitive Alliance Expression of Interest issued to market 12 May 2016.

Shortlist announced on 15 September 2016. Proposals due 23 February 2017.

Wider Network Enhancements

Proposed to include works which are required across the wider network including track modifications, station upgrades and signalling system upgrades

Case by case Market engagement to be developed case by case.

SOURCE: 2016, Melbourne Metro Rail Authority. http://metrotunnel.vic.gov.au/about-the-project/project-delivery

2.2 Reference Design

AJM JV has developed a reference design that informs work package proponents in developing their design. The work package proponents will have flexibility to adjust the reference design provided they meet the project’s legislative, functional and technical requirements.

http://metrotunnel.vic.gov.au/about-the-project/project-delivery



2.3 Construction Summary

2.3.1 Tunnels

The proposed reference design tunnel construction strategy comprises the use of Tunnel Boring Machines (TBMs). The reference design assumes these TBMs would launch from Arden and Domain sites as shown in Figure 2-1. Mined tunnels would be constructed between CBD North and CBD South using road header machines. Domain is the proposed eastern TBM launch site. Arden has been confirmed as the western TBM launch site and is also proposed to be used for casting of tunnel precast components. Whilst MMRA has made the assumptions above, proponents may choose their own construction methodology and may seek alternative locations for casting of segments and other pre-cast elements.

Along the two tunnels alignment, the proposed rail level would be between approximately 10m to 40m below the existing ground level. The deepest point would be adjacent to Swanston Street north of the CBD with the shallowest point being above the CityLink tunnels. A variation to the proposed vertical alignment is available to pass the tunnels beneath the CityLink tunnels. The tunnel alignment would pass below the Melbourne Underground Rail Loop (MURL) tunnels to the south of CBD North station. Figure 2-2 contains an indicative long section for the tunnel alignment.

Figure 2-2: MMRP indicative tunnel alignment long section

2.3.2 Stations and Portals

Station and portal construction would comprise a combination of mined, top-down and bottom-up construction methods as summarised in Table 2-2.

Table 2-2: Proposed Reference Design Station Construction Methods

Station Construction Method

Western Portal Cut & Cover

Arden Station Cut & Cover

Parkville Station Cut & Cover

CBD North Station Mined Cavern

CBD South Station Mined Cavern

Domain Station Cut & Cover

Eastern Portal Cut & Cover/Embankment

Table Notes:

1. Cut & cover may comprise Top Down or Bottom Up techniques.



2.4 Reference Design Construction Program

Indicative timings for the delivery of the project are provided in Table 2-3. The major construction activities requiring concrete are estimated to be required from early 2017 through to 2022.

Table 2-3: Milestone summary and construction dates

Date Activity

2015-2016 Site investigations

Complete development of Melbourne Metro Concept Design

Community consultation

EES submitted, exhibited and assessment released by the Minister for Planning

Prepare and submit Business Case

Enabling works before major construction

2017-2018 Finalise planning and environmental approvals based on Minister for Planning decision.

Procurement for major construction contract

Early works before major construction

Award major construction contract for tunnels and stations

Start major construction works

Demolition of acquired buildings

2022 Civil and structural works at stations, portals and tunnels completed

2024 Station fit out and rail systems installation completed

2025 Systems integration and operational readiness

2026 Project complete



3 Reference Design Concrete Requirement

3.1 Measuring reductions in Portland Cement

To measure the reduction of Portland cement content, final mix designs will be compared to the GBCA reference mixes. The reference mixes have two components:

1. The quantity of cement in the concrete mix The baseline assumes kg/m3 as per Table 3-1.

2. The quantity of Supplementary Cementitious Materials (SCM) The baseline assumes 0% replacement of Portland cement (i.e. no SCM in included in the GBCA reference mix, as shown in Table 3-1.

Table 3-1: GBCA Concrete Reference Mix Constituent Baseline Content

Concrete Strength (MPa) Cement content

(kg/m3)

SCM content (kg/m

3)

20 280 0

25 310 0

32 360 0

40

440 0

50 550 0

65 550 0

80 610 0

3.2 Estimated Concrete Volume & Mix Designs

To inform the Portland cement reduction target, AJM JV completed a study on the potential use of SCMs and the effect on GHG emissions. AJM JV has estimated a total volume of 491,800 m3 of concrete would be required for construction of the Reference Design. Table 3-2 provides a summary of the estimated volume by construction use, Grade and proposed mix type to achieve the greater than 36% Portland Cement reduction. Note that tunnel annulus grout is not included in the GBCA reference mix and is highly dependent on surrounding ground formation conditions. It is therefore considered not possible to specify a base case fly ash content for this component. This assumption is subject to the approval of the GBCA.



Table 3-2: Estimated concrete volume by use and proposed mix to achieve target

Concrete Use Volume

(m3)

Grade (MPa)

Proposed Mix Type to Achieve 36% Reduction

Cement Content (kg/m

3)

SCM Content (kg/m3)

Fly Ash Slag

Segments

Pre Cast 87,000 50 VicRoads Mix 12% 485 0 0

Insitu (Trackform) 23,000 50 30% Fly Ash 315 135 0

Portal Shafts 3,000 50 25% Fly Ash 25% Slag Mix

225 112.5 112.5

Emergency Egress Walkway Precast

4,000 40 65% Slag Mix 140 0 260

Shotcrete

Mined Section Stations 12,500 40 20% Fly Ash 320 80 0

Mined Tunnel 17,000 40 20% Fly Ash 320 80 0

Stations

Cast Insitu Cavern Wall 30,500 50 30% Fly Ash 315 135 0

Suspended Slabs & Walls

2 189,000

Insitu 151,200 40 20% Fly Ash 320 80 0

Precast 37,800 40 25% Fly Ash 25% Slag Mix

200 100 100

Insitu Non Critical 101,500

40,600 40 25% Fly Ash 25% Slag Mix

200 100 100

60,900 40 65% Slag Mix 140 0 260

Portal Piles (Tunnels) 4,300 32 65% Slag Mix 116 0 214.5

Temporary Elements / Works

20,000 20 25% Fly Ash 25% Slag Mix

140 70 70

Total 491,800

Table Notes:

1. Mixes up to 65% slag, up to 10% silica fume, geopolymer or other ternary blends may also be acceptable for use other than tunnel segments.

2. Assumes Suspended Slabs & Walls comprise 20% precast concrete components. This is not reflected in the Reference Design however precast concrete construction is a preferred and accepted construction method in Melbourne and an estimation of 20% would be conservative.

Table 3-3 provides details on the reference design mix split for each concrete use nominated to achieve the greater than 36% reduction. Proponents may vary the volumes and mix types according to their final design but the greater than 36% target for reduction of Portland cement below the base case will be a contractual requirement. As per the table notes other mixes with up to 65% slag or up to 10% silica fume, geopolymer or other ternary blends may also be acceptable for use other than tunnel segments and should be considered.



3.3 Constituent Sources

MMRA’s commitment to sustainable triple bottom line outcomes in concrete production extends

beyond the use of SCMs. As part of the GBCA targets, work package proponents are required to

consider the sources of materials and their GHG footprint. Local supply of constituents will

therefore also be an important factor in selecting concrete mixes.



Table 3-3: AJM JV selected mix designs by construction use to achieve Portland cement reduction target

Concrete Use Concrete Volume

(m3)

Grade (MPa)

GBCA Base Mix Portland Cement (t)

AJM JV Selected Mix Portland Cement Content (t)

% Saving from Base Case GBCA

Base Mix VicRoads Mix 12%

20% Fly Ash

30% Fly Ash

25% Fly Ash 25% Slag Mix

65% Slag Mix

Segments

Pre Cast 87,000 50 47,850 42,195 12%

Insitu (Trackform) 23,000 50 12,650 7,245 43%

Portal Shafts 3,000 50 1,650 675 59%

Emergency Egress Walkway Precast

4,000 40 1,760 560 68%

Shotcrete

Mined Section Stations 12,500 40 5,500 4,000 27%

Mined Tunnel 17,000 40 7,480 5,440 27%

Stations

Cast Insitu Cavern Wall 30,500 50 16,775 9,608 43%

Suspended Slabs & Walls

189,000

Insitu 151,200 40 66,528 48,384 27%

Precast 37,800 40 16,632 7,560 55%

Insitu Non Critical 40,600 40 17,864 8,120 55%

60,900 40 26,796 8,526 68%

Portal Piles (Tunnels) 4,300 32 1,548 497 68%

Temporary Elements / Works

20,000 20 5,600 2,800 50%

Total 491,800 228,633 0 42,195 57,824 16,853 19,155 9,583 36%

Table Notes:

1. Mixes up to 65% slag, up to 10% silica fume, geopolymer or other ternary blends may also be acceptable for use other than tunnel segments.

2. Assumes Suspended Slabs & Walls comprise 20% precast concrete components. This is not reflected in the Reference Design however precast concrete construction is a preferred and accepted construction method in Melbourne and an estimation of 20% would be conservative.



4 Response & Enquiries

4.1 Timeframe

Concrete suppliers are requested to provide information on their mix designs and information regarding constituent materials sources in accordance with the target in Table 4-1 below.

Table 4-1: Key Dates

Item Response By

Concrete supplier response

(to provide early information to PPP Tenderers)

2nd

of February 2017*

* Please note: Earlier submissions are encouraged to assist Metro Tunnel work package proponents during project tendering and pricing periods.

Concrete suppliers are encouraged to provide as a minimum the information within the response schedule provided in Appendix A. The schedule may be modified by concrete suppliers to provide additional information as necessary.

4.2 Enquiries

Any enquiries related to this document should be directed to Damien Kennedy on (03) 9655 6996 or at [email protected]

mailto:[email protected]


TRIM: DOC/16/408632

Appendix A Response Proforma

Concrete suppliers to complete following table for each mix or supplier nominated mix.

Mix ID:

Property Test Method Value

Concrete grade Not applicable

Total Cementitious Content (kg/m3) Not applicable

Maximum Aggregate Size

% Supplementary Cementitious Material

(by weight of total cementitious content)

Not applicable

Water/Cementitious Material Ratio Not applicable

Minimum 3 Day Compressive Strength

(MPa)(1)

AS 1012.9


(MPa)

AS 1012.9


(MPa)

AS 1012.9

Maximum Average 21 Day Drying

Shrinkage (microstrain)

AS 1012.13

Maximum Average 56 Day Drying

Shrinkage (microstrain)

AS 1012.13

Maximum Acid Soluble Chloride Ion

Content (% by weight cementitious

material)

AS 1012.20

Maximum Acid Soluble Sulphate Ion

Content (% by weight cementitious

material)

AS 1012.20

Maximum Total Acid Soluble Alkali

Content (Na2O equiv) (kg/m3)

Various for each

constituent


TRIM: DOC/16/408632

Maximum Average 56 Day Chloride

Diffusion Coefficient (m2/s)

(2)

NTBuild 443

Maximum Average 28 Day Coefficient of

Permeability (cm/s)(3)

ASTM D 5084 or

equivalent

Maximum Alkali-Aggregate Reactivity

(average % expansion)

VicRoads RC 376.03

or VicRoads RC

376.04

Nominal Slump (mm) AS 1012.3.1

Additional costs applicable Not Applicable Y/N (likely additional cost per m3)

Product country of

origin

Country of origin of cement clinker

Country of origin of GP

Country of origin of SCM

Past Projects

Australia Description

Driver for Use (e.g. green rating, durability, eco friendly, sulphate soil, marine

exposure):

Project Name and location:

Mix used and elements poured:

Volume of concrete poured:

% Cost indicator compared to GP (ratio):


TRIM: DOC/16/408632

Overseas Description:

Driver for Use (e.g. green rating, durability, eco friendly, sulphate soil, marine

exposure):

Project Name and location:

Mix used and elements poured:

Volume of concrete poured:

% Cost indicator compared to GP (ratio):

SCM Supplier

Australian Product

Supplier

Name and Address:

Source:

Relationship with concrete supplier (e.g. subsidiary, ongoing, preferred supplier,

subcontractor, first time SCM supplier):

Certification process (description of QA process including NATA certification):

Overseas Supplier Name and Address:

Source:

Relationship with concrete supplier (e.g. subsidiary, ongoing, preferred supplier,

subcontractor, first time SCM supplier):

Concrete Supplier Interaction with O/S SCM supplier (e.g. remote, local presence,

subsidiary)

Certification process (description of QA process including NATA certification):

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