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V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 2 of 21
Table of Contents TABLE OF CONTENTS .......................................................................................................2
1 EXECUTIVE SUMMARY...............................................................................................3
2 INTRODUCTION ...........................................................................................................5
2.1 BACKGROUND...........................................................................................................5
3 SUMMARY OF WORKS................................................................................................5
3.1 CONSTRUCTION OF NEW FORMATION AND TRACK BETWEEN 38.620KM AND 39.240KM 5 3.2 RELOCATION OF MANOR LOOP..................................................................................6 3.3 CONNECT NEW TRACK INTO MAINLINE AT EACH END ...................................................7
4 PROJECT DELIVERY ...................................................................................................7
4.1 GOVERNANCE STRUCTURE .......................................................................................8 4.2 MANAGEMENT AND DELIVERY....................................................................................8
5 PROGRAM ....................................................................................................................9
6 PROJECT RISK AND OPPORTUNITY.......................................................................10
7 BUDGET, ESTIMATE & FINANCE .............................................................................11
8 CONTINGENCY ..........................................................................................................12
9 QUALIFICATIONS.......................................................................................................12
APPENDIX A – TCE ..........................................................................................................18
APPENDIX B – RISK & OPPORTUNITY...........................................................................19
APPENDIX C – WORK SITE DIAGRAMS .........................................................................20
APPENDIX D – RISK REGISTER......................................................................................21
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 3 of 21
1 Executive Summary
The purpose of this PIP is to seek approval for the costs associated with the major works for the
execution of the Department of Transport Regional Rail Link’s Works Package F (ARTC Early
Works) for Alliance Board Approval.
The project has produced an IFC design and the construction is scheduled to start in late August
2010 with a completion date of early 2011. The overall project budget is currently $5 million which
is funded by the Department of Transport.
Approval for the preliminary costs associated with Downer’s management costs and those for site establishment and procurement of long lead materials has been granted in a previous submission.
This PIP details the costs involved to deliver the project in its current configuration are listed below. A breakdown of costs is attached.
The planning/permits, track and civil design and consultancy are being undertaken by KBR on
behalf of the Department of Transport, with Arup Solihull designing the signalling.
The Early Works for Work Package F is being performed for ARTC by Downer EDI Works through
the V1 Alliance. The work is being arranged by ARTC as an Enhanced Role under the Interstate
Infrastructure Lease (IIL). The work undertaken as part of the Enhanced Role is subject to an
Agreement between the Victorian Department of Transport and ARTC and under this Agreement
ARTC will be paid its direct costs plus a 10% margin.
The Target Cost Estimate for the works excluding ARTC margin is:
Table 1 : ARTC Budget
Stage 1 Preliminaries (approved on 20/8/2010) $1,465,842.11
Stage 2 Major Works $4,560,909.70
Project Risk $500,000.00
Stage 2 PIP Total (seeking approval) $5,060,909.70
Total Project Budget $6,526,751.81
Recommendation:
The V1 Alliance Board approves the PIP for the major works associated with the Department of
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 4 of 21
Transports Regional Rail Link’s Works Package F (ARTC Early Works), sum of $5,060,909.70 for
Alliance Board Approval.
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 5 of 21
2 INTRODUCTION
2.1 Background
The Regional Rail Link Works Package F – ARTC Early Works, have been developed as
enabling works to support Works Package F – West Werribee Junction works. Works
Package F is described in the Regional Rail Link Project Wide Scope document Revision
1.2 of 21 July 2010.
The KBR Arup Joint Venture (KAJV) has been engaged by the Department of Transport
(DOT) to undertake the design for the track & civil and signalling.
An Issued for Construction Revision 0 track and civil design package has been issued for
review to ARTC and the target cost and this PIP for major works have been completed
based on the drawings provided with this package.
An Issued for Construction Revision 0 signalling design package has been issued to
ARTC for review. This has resulted in agreement to alter the existing signalling overlaps to
comply with 300m standard. The target cost and PIP have been developed based on the
drawings provided with this package with an allowance to alter the current configuration to
provide 300m overlaps. Any change in cost will be communicated once a revised detailed
signalling design is obtained.
3 SUMMARY OF WORKS
The main construction works have been separated into 3 work zones / stages in order to
reduce the risk of delaying trains.
3.1 Construction of new formation and track between 38.620km and 39.240km
As the track is going to be slewed a considerable amount from the existing running line
the earthworks for the new track between 38.620km and 39.240km can be completed
safely without impacting trains. The site will be protected by a temporary fence 3m from
ARTC’s nearest running rail between 38.550km and 39.400km. It is estimated that these
earthworks will take 2 months to complete and will occur prior to all possessions in the
area.
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 6 of 21
It is proposed that the signalling preparation works will occur at the same time as the
earthworks. These works involve the following:
• Install pit and pipe work to new equipment locations • Install pre-fabricated signal bases • Install foundations for URR and Genset • Install cable
3.2 Relocation of Manor Loop
Manor loop will be relocated approximately 50m to the east; including associated
signalling to provide 300m overlaps. The methodology and program will be developed to
work between trains for the relocation. Application will be made for occupations on
Saturday night in accord with time tables published on ARTC website.
Saturday morning
• Closure of Manor Loop to operations. Remove the plain line track in the loop and complete all earthworks and track construction.
Saturday night
• Take possession of mainline with protection on VLine BG tracks. • Disconnect and remove point machines • Disconnect and relocate existing signals • Disconnect and relocate existing trackside equipment • Disconnect URR equipment rack and power supply • Re-locate URR hut, Genset and enclosure • Install and terminate URR equipment rack and Genset • Cut the mainline and remove associated track panels for new turnout locations. • Disconnecting the turnouts, removing points machine and rodding and securing
switch blades. The cut the switch into panels ready for lifting. • Excavate and install bottom ballast ready for turnouts. • Lift turnouts out of existing location panel by panel and install into new locations
and commence welding. • Unsecure switch blades, install existing points machines and connect to new
signalling cables. • Excavate the remainder of the mainline works and install track panels top stone
and weld out. • Connect the loop into the mainline and tamp new works.
Sunday 2100
• Loop and mainline connected. • Install existing point machines and rodding.
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 7 of 21
• Install remaining trackside equipment • Remove redundant equipment • Function test system • Commission system
3.3 Connect new track into mainline at each end
The connection of the tracks into the mainline will require a possession to complete the
works similar to the possession required for the relocation of the loop. Ideally this would
happen the following weekend after the first possession to reduce costs in mobilisation of
plant and resources and minimise disruptions to operations.
This section has no signalling equipment however signalling support will be required to
disconnect the level crossing and test the tracks once back in use. Traffic management on
the level crossing will be required whilst the signalling is affected.
4 PROJECT DELIVERY
The Rail Upgrades at Geelong Port Project works will be delivered within the same time
frame as the Regional Rail Link Works Package F – ARTC Early Works and will utilise the
delivery team for the works to allow for flexibility in programming the works.
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 8 of 21
4.1 Governance Structure
The Governance Structure for the RRL WP-F ARTC Early Works will be as
follows:
4.2 Management and Delivery
The project will be managed by the V1 Alliance with Downer EDI Works taking the lead on
the day-to-day project management to deliver all stages of the program.
Downer EDI Works will supply the services, labour, construction plant, equipment,
materials, systems and the management necessary to deliver the Construction Phase of
the project. The “Delivery Team” may agree to amend this scope where better practice is
identified, delivering “best for project” results.
Downer EDI Works are nominated as Principle Contractor for the worksite with respect to
OH&S which will be subject to both internal and external (ARTC or other) audits.
Alliance Management
Team (AMT)
ARTC Representative
Patrick Gray
RRL WP-F
Project Manager
Ewan Watson
DEW to report to AMT
Downer Construction Team
Rail Upgrades
Delivery Team
Sub-Alliance Management Team
Ben Leske - ARTC Infrastructure Manager East West
Martin Lock - Downer - V1 Projects Director
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 9 of 21
Downer EDI Works will facilitate the track hand back of infrastructure to operations and
will manage the interim condition of the asset prior to practical completion and handover to
ARTC Asset Management.
Downer EDI Works will assist ARTC in the preparation and submission of Configuration
Management documentation as required in the ARTC procedure, EGP-03-01
Configuration Management.
5 PROGRAM
The program for the works is based on the final detailed signalling design that is being
revised to accommodate ARTC Signalling Standards and the possession dates that are
yet to be announced. An indicative representation of the length of time required for the
major tasks is indicated below;
Item Work Description Days End Date
1.0 Set-up site, install rail fencing 5 days 3rd September
1.1 Complete Earthworks and track between 38.620km
and 39.240km. Including new Culvert. 50 days 5th November
1.2 Install signalling foundations for signal relocations 30 Days 5th November
1.3
Possession 1 – Relocate loop 50m east of existing
Commission signalling
Signalling Support
4 shifts
2 shifts
4 shifts
20th November
1.4
Possession 2 – Cut, remove and excavate track
(approx 340m) and link into new tracks.
Signalling Support
4 shifts
4 shifts
27th November
1.5 Remove the existing tracks and recover materials (If
required) 15 days 20th December
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 10 of 21
6 PROJECT RISK AND OPPORTUNITY
A Project Risk and Opportunity Register is being developed for the works; the main risks
associated with the works are:
1. Geotechnical report supplied by designers is only a concept design with minimal
test pits along the length of the works. The area typically has clay over a ballast
rock a varying depth. The works involves a 3m deep cutting for 300m for the tracks
slew and there is therefore a risk of encountering rock. At this stage due to the
nature of the works Downer will supply a unit price for the removal of rock. When
the grubbing is undertaken to expose the surface of the rock, a detailed survey will
allow the calculation of the volume to be removed. Pricing can then be agreed.
2. Excess spoil and contaminated waste. At this stage there is going to be a large
amount of excess spoil that can not be used due to low CBR values (typically 2%).
The DoT has indicated that excess materials will need to remain on the existing
railway corridor. If the need arises to remove such material offsite at additional
cost, DoT approval will be sought.
3. A Victrack Optic Fibre cable is situated along the Northern edge of the construction
boundary. Compliance with the asset owners plans will be adhered to by means of
non destructive digging to prove the location of this asset. Dedicated access points
will be established at several locations to permit construction traffic to pass over
this service.
4. The current location of URR appears to be suitable for the up end extension
subject to some re-working of the Cess drain. Possible $40,000 savings if the room
does not have to move. At this stage DoT have indicated that this room will require
relocation.
5. There will be the requirement for two track occupations to complete the relocation
of Manor Loop and perform the tie in to the new slewed track alignment. There is a
risk of delay to trains should the occupation be handed back late. Detailed
planning of resources required to undertake each section of the staged work will
mitigate some of this risk.
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 11 of 21
7 BUDGET, ESTIMATE & FINANCE
The Budget for the Regional Rail Link Works Package F – ARTC Early Works is to be
determined following agreement on the scope to meet ARTC Signalling Overlap
requirements, and will include project management, construction, commissioning and
contingencies. The project has been estimated on preliminary designs and may be subject
to change once the detailed signalling design is obtained. There is also the possibility of
further changes to the design and scope of works for the project that will be managed if
the eventuate.
The work will be carried out under an agreement with the Director of Public Transport for
the Regional Rail Link Project (WP F ARTC Early Works) as an enhanced role under the
Interstate Infrastructure Lease. The works will be delivered under a Cost Plus
arrangement on the basis of the direct works mechanism of the V1 Alliance Contract for
which the Downer EDI Works Margin is 12% and ARTC will be paid its direct costs plus a
margin of 10%.
The Target Cost Estimate is summarised below, which includes the preliminary costs that
have already been approved. Please find further detail attached:
Target Cost Estimate Summary
Preliminaries (approved)
• Site Establishment $259,313.50
• Management Costs $451,844.75
• Materials $597,629.35DEW Preliminary Cost (incl margin) $1,465,842.11
Stage 2 (seeking approval)
• Materials $264,111.05• Site Facilities $101,800.00• Earthworks Subcontract $1,143,122.00• Staged Track Construction $1,741,896.98• Signalling $709,157.00• Management Costs $108,753.78• DEW Margin (stage 2) $488,260.90• Project Risk $500,000.00
Stage 2 Major Works PIP Total $5,057,101.71
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 12 of 21
The price quoted for signalling allows for the expected increase in signal overlaps to 300m
required for the relocation of Manor Loop. This will be adjusted once a revised signalling
design is issued.
The price for earthworks is subject to change as the assumed volume of particular
materials will only be confirmed during the construction process.
The designers KAJV have increased the length of the new culvert required from the IFC
design. An allowance has been made for the increased cost for the extension to the new
culvert.
All pricing provided excludes any allowance for ARTC costs. Pricing within this PIP is
strictly DEW costs and margin.
The project forecast costs will be updated monthly and circulated in the project monthly
report. Any additional forecast required by either Downer or ARTC or if a major project
issue occurs that affects the forecast an update will be sent through as required.
8 CONTINGENCY
There has been a provisional sum of $500,000.00 allowed for contingency included in the
estimate. This will be reviewed following the results of the construction risk workshop. The
overall budget has not been set by the Department of Transport and the costs are fully
reimbursable it is assumed that an open book policy would be used with any variation to
the price of the works due to unforeseen circumstances will be processed prior to the
works being completed.
9 QUALIFICATIONS
The following are qualifications for the quote:
The following works are included in the quote:
Program
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 13 of 21
Downer has supplied their program for the tender process and has priced a management
team on the time frame to monitor program, attend program meetings and provide ARTC
with progress and forecast reports to the end of December 2010.
Planning and Approvals
Downer will complete the configuration change process for the works but will not be
responsible for an issues arising from comments from the relevant corridor / discipline
managers.
Site Facilities and set-up
Downer will set up a secure site compound and access roads for the duration of the works
as per the program.
Survey and peg out
Downer has allowed for survey to peg out the track alignment however establishment and
maintenance of survey datum points will be the responsibility of the designers.
Earthworks
The earthworks has allowed for indicative quantities of rock to be broken out and loose
rock to be disposed off site. The disposal dockets will be collected, correlated and
submitted to the Department of Transport with the invoice for works to ensure that there
are no disputes.
The earthworks have allowed for the placement and compaction of 1m structural fill only
(based on design and CBR values of 2%) and 150mm of capping. These materials will
meet ARTC Standards.
The earthworks has allowed for the construction of the general fill zone of the
embankment using materials sourced from on site only. If this material is unsuitable,
additional cost will be required to import and or mix a compliant material.
Track Materials
The price includes the use of all new track materials as stipulated in the design, except for
junction rails and a quantity of existing concrete sleepers in the mainline at the relocation
of Manor Loop turnouts.
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 14 of 21
An allowance has been made to dismantle the redundant standard gauge track after the
new alignment is operational. Sleepers can be transported within 100km. Rail to remain
onsite stacked in long lengths. Used ballast will be stockpiled onsite.
Rail and Welding
The price includes the unloading of 13.7m lengths of rail and Thermit welded into long
lengths. There may be an option to use the flashbutt welder to perform the welding.
The price allows for the replacement of 14No. glued insulated rail joints.
Turnout re-timbering
Downer will supply and install timbers to ensure the integrity of the turnout when it is
relocated.
Track Possession
The works has been planned and priced for 2 consecutive track possessions working
between trains. Any additional track possessions due to unsuitable track windows will
require a variation.
Signalling – Preparation Works
Install pit and pipe work to new equipment locations for 300m overlap
Install pre-fabricated signal bases
Install foundations for URR and Genset
Install cable
Signalling – Possession
Disconnect and remove point machines
Disconnect and relocate signals
Disconnect and relocate trackside equipment
Disconnect URR equipment rack and power supply
Re-locate URR hut, Genset and enclosure
Install and terminate URR equipment rack and Genset
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 15 of 21
Install existing point machines and rodding
Install remaining trackside equipment
Remove redundant equipment
Function test system
Commission system
Tamping and regulating
Downer has priced for tamping of the tracks to standard line and levels with a minimum of
2 passes.
Stressing
Downer has priced for the stressing of rails to the standard.
As-built measurements
Price includes measuring and certifying the track is constructed to the design and to
construction tolerances by a qualified track hand-back.
Follow up Tamp
A price has been included for a follow up tamp after 12 months from commissioning and
within 24 months.
The works not included in the quote:
Planning and Approvals
No allowance for participation in the Design Phase except for providing comments.
No allowance for preparing and/or procuring any relevant approvals and/or permits, other
than Melbourne Water permit to work on culvert construction.
No allowance for stakeholder and/or community consultation.
Site Facilities and set-up
No allowance for site restoration, regeneration and planting of the storage compounds.
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 16 of 21
No allowance for protection and preservation of Fauna.
No allowance for the provision of a qualified ecologist.
No allowance for relocation of any Utility Services.
Track works
No allowance for new turnouts or components.
No allowance to replace the existing junction rails.
No allowance to increase the standing room within the current configuration.
Earthworks
No allowance for supply of general fill material. It is assumed that suitable material will be
sourced onsite to be placed below the structural layer.
No allowance to remove soil off site. It is assumed that sufficient suitable area within the
rail corridor will be available.
No allowance for the removal or rehabilitation of unsuitable subgrade.
No allowance for the testing, excavation or disposal of contaminated materials.
No allowance for the specific treatment or management of soil pathogens or other
diseases.
No allowance to increase the standing room within the current configuration.
Signalling
No allowance for relocation of cabling in area of the track slew. Signalling support for this
track work is included.
No allowance for new points back drive detectors.
No allowance for new points motors or rodding. Existing materials are deemed
serviceable.
No allowance to adjust existing level crossing track frequencies.
No allowance to replace equipment within URR, relocate only.
No allowance for new signals. Existing signal masts to be relocated to new position only.
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 17 of 21
Completion and handover
No allowance for preparation of ‘as built’ drawings in CAD. All construction drawings will
be marked up by hand, with any relevant information to be updated by designers.
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 18 of 21
Appendix A – TCE
Stage 2 TCE Major WorksCost DEW Margin DEW Total
Summary of Funds Approved in Preliminary PIP (excl Margin) 12%Site Establishment 259,313.50$ 31,117.62$ 290,431.12$ Management 451,844.75$ 54,221.37$ 506,066.12$ Materials 597,629.35$ 71,715.52$ 669,344.87$ Totals Preliminary 1,308,787.60$ 157,054.51$ 1,465,842.11$
Summary of Funds Stage 2 PIPEarthworks SubcontractEarthworks 843,122.00$ 101,174.64$ 944,296.64$ Culvert 300,000.00$ 36,000.00$ 336,000.00$ Track MaterialsBallast, FCR, Timbers 264,111.05$ 31,693.33$ 295,804.37$ Construction StagesStage 1 Manor Loop Relocation 770,019.01$ 92,402.28$ 862,421.30$ Stage 2 Re alignment 260,425.45$ 31,251.05$ 291,676.50$ Stage 3 Connect Track Slew to Main Line 436,302.52$ 52,356.30$ 488,658.82$ Remove redundant Track 275,150.00$ 33,018.00$ 308,168.00$ Site Facilities 105,200.00$ 12,624.00$ 117,824.00$ Signalling 709,157.00$ 85,098.84$ 794,255.84$ Management 108,753.78$ 13,050.45$ 121,804.23$ Totals Stage 2 Major Works 4,072,240.80$ 488,668.90$ 4,560,909.70$
Cost Total 5,381,028.41$ DEW Totals 645,723.41$ 6,026,751.81$ less Preliminary PIP Approved Amount 1,465,842.11$ Add Risk 500,000.00$ Stage 2 PIP Approval Required Amount 5,060,909.70$
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 19 of 21
Appendix B – Risk & Opportunity
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 20 of 21
Appendix C – Work Site Diagrams
Mainine Layout
Works Site 1
Dn BG
Up BG36578 36700 38370 38436 38500
ARTC SGEast end West endRelocation of existing T/O 50m Relocation of existing T/O 50m
36800 Manor Loop
Works Site 2
Dn BG
Up BG38500 39465
ARTC SGfence
38620 Construct tracks 3924038741Culvert
Works Site 3
Dn BG
Up BG38500 Remove the existing track 39465
ARTC SG
38620 39240temporary level crossing
38250
V1 Alliance Board Submission Alliance Project Implementation Plan
Regional Rail Link – Work Package F (ARTC Early Works) Submission 2
Page 21 of 21
Appendix D – Risk Register
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