BARANGAROO

HEADLAND PARK
ENGINEERS AUSTALIA SYDENY DIVISION,
CIVIL AND STRUCTURAL PANEL
27 August 2013
Ken ONeill BSc(Eng) CPEng NPER MIEAust, Aurecon
Andy ODriscoll BSc (Hons), Lend Lease

Presentation Overview
Speakers
Ken O'Neill - Bridges Leader NSW, Aurecon
Contact: ken.oneill@aurecongroup.com
Ken O'Neill is a Chartered Engineer and Aurecon's NSW Bridges Leader. He is also the 2013
chair of the Engineers Australia Sydney Division Civil and Structural Panel. Ken has worked on
some of Sydney's most recognised bridges including the Sydney Harbour Bridge and ANZAC
Bridge. Ken was the Design Manager for Civil and Marine works on the Barangaroo Headland
Park project.
Andy O'Driscoll - Senior Project Engineer, Engineering, Lend Lease
Contact: Andy.ODriscoll@lendlease.com
Andy O'Driscoll is Lend Lease's Senior Project Engineer for the Building and Civil Zone on the
Barangaroo Headland Park and has been involved in the project for over a year primarily in
delivering the building structure. Andy has over 10 years' experience in the industry covering a
multitude of sectors from multiple Bridges, Rail, Buildings, Roads and Earthworks. Andy has
spent the last 5 years since emigrating to Australia in Sydney working for Leighton's on the
Kingsgrove to Revesby Quadruplication (K2RQ) within the Bridges and Building zones.

Presentation Overview
Part 1 Project overview
Part 2 Civil and Marine
Part 3 Cultural Space & Construction
Questions

Part 1 Project overview

Project Overview

Project Overview

Project Overview

Project Overview

Project Overview

Project Overview

Link to animation
http://www.youtube.com/watch?v=hvx-RvLaoYY&feature=relmfu

Project Overview

Client Barangaroo Delivery Authority

Superintendent - Evans & Peck
Contactor Baulderstone (Now Lend Lease) D&C
Value - $163m with a further $35 m optional
Current scope covers Separable Parts 1&2 Headland and North
Cove
Separable Parts 3, 4, 5 & 6 covers the integration works, Central
foreshore, Central interim use, Cultural Space future use and
Harbour Control Tower design development.
Contract Award 23 May 2012
Contract Program 35 Months (includes for wet weather and some
contingency)

Project Overview
Project Award

23 May 2012

Planning/Design Phase

June 2012 - Jan 2013

CFEMP approval (Environmental)

August 2012

Main Compound Construction

Late August 2012

Construction started

November 2012

Northern Cove

September 2013

Building Commencement

September 2013

Project completed

May 2015

Project Overview

Project Overview

Project Overview

Design: Process
Discipline

Service

Consultant

Civil and Marine

Civil and earthworks

Aurecon

Civil Hydraulics

Warren Smith and Partners

Electrical

WEBB

Geotechnical

Aurecon

Landscape Architect

Johnson Pilton Walker

Marine

Hyder

Architect

WMK Architecture

Electrical

WEBB

Hydraulics

Warren Smith and Partners

Mechanical

Waterman

Structural

Aurecon

Building

Design: Process
Design program driven by construction
Safety in Design undertaken for all
packages
Maintenance and sustainability
considerations

Part 2 Civil and Marine

Civil and Marine

Retaining walls
Sewer Pump Station relocation
Stormwater/Seepage water retention
Earthworks
Harbour Foreshore

Design: Site layout

Cultural Space
Northern Ramp
RW
Counterfort RW

Pump house
SPS14
Terraced RW

Foreshore area

Southern RW

Design: Site layout

Terrace wall

Fill up for
Headland Park

Future park level

Roof for Culture

Space

Culture Space

Foreshore
area involving
caisson
demolition

Existing
ground Surface

Ground anchor
at each
buttress

Counterfort
Wall

Rock excavation to create

car park for Culture Space

Design: Retaining walls

Design: Retaining Walls

Retaining walls around Cultural Space
Counterfort wall
Southern retaining wall
Northern ramp wall

Terraced retaining walls

Northern Cove retaining walls

Design: Retaining Walls

Retaining Walls around Cultural Space

Design: Retaining Walls

Cultural Space Retaining Walls

Counterfort Retaining Wall

Extends approximately 160 m in length without

movement joints

Separates the park from the Cultural Space with a

maximum retained height of 19 m

Supports the roof of the Cultural Space

Provides restraint to the roof against earthquake

loading in the N-S direction and western direction

Supports two future floors at RL8.5 and RL13.0

Located on the western ledge of the sandstone

extraction pit

Cultural Space Retaining Walls

Counterfort Retaining Wall

Cultural Space Retaining Walls

Counterfort Retaining Wall
Vertical Buttresses 4 m deep at 6 m spacing with permanent ground
anchors
Buttresses are 550 mm thick with a widened back flange of 1000 mm by
600 mm
Base slab of 5.5 m width with 1 m toe
Shear key at heel provides additional sliding resistance and structural
stiffness to the base slab
Very efficient wall thickness

6m Lower section:
6m Middle section:
Remaining top section:

750 thick
600 thick
400 thick

Sill beam at top of wall provides vertical support to the roof and lateral
stiffness to the upper 400 mm thick wall

Cultural Space Retaining Walls

Geotechnical constraints
Made ground (demolition rubble, ripped sandstone) to an approximate
depth of 1.2 m (RL1.75)
Shallow sandstone bedrock below Made ground
Class III at approx. RL1.75 m below ground
Class II at approx. RL -1.0 to RL-1.5
Class I at approx. RL -4.0

Persistent clay seam throughout the site of varying depths

Design parameters for founding level at RL 1.0 adopted for Sandstone
Class IV

Cultural Space Retaining Walls

Counterfort Retaining wall

Shale Band

Sandstone

Footing Base

Shear Key

Cultural Space Retaining Walls

Design loading

Lateral Earth Pressure =28o, c=3-5kPa, =18kN/m3

Overburden soil = 500-800mm
In Service Live Load: 7.5 kPa
Construction surcharge : 10 kPa
Earthquake loading
Loading from two future floor within Cultural Space

Cultural Space Retaining Walls

Durability Requirements
Design Life: 100 years to AS5100.5-2004 Bridge Code
Concrete exposure classification: B1 for front face and B2
for back face in contact with soil
Drainage detailing and crack width control critical to the
design

Cultural Space Retaining Walls

Constructability Requirements
Wall constructed with a backward lean of 1:120
No movement joints
Designed for 9 m of fill without anchors to advance the fill
operations
Additional reinforcement placed at connection to base slab
for crack control

Cultural Space Retaining Walls

Key Geotechnical Design Parameters
Value

Variance
applied

angle of friction retained material ()

28

10%

density of retained material (kN/m3)

18

7%

angle of friction for sandstone

bedding or footing base ()

33

15%

angle of friction for sandstone

bedding or shale bands ()

24

15%

5000

30%

28

15%

1/3 the height

50%

Variable

Anchor capacity (kN)

Surcharge (kPa)

Water pressure behind the wall (kPa)

Cultural Space Retaining Walls

Anchors are installed and stressed at 9 m of fill (35 mm movement in
top of wall)
Narrow base slab allows an Active soil stress to be achieved
3D Plaxis model was used to:

Investigate soil-structure interaction and confirm Ka stress state in soil

Determine size and required stress in the anchors
Determine in-service deflection of the wall
Determine in-service bearing pressure demand on foundation material

Front wall slab was designed to Ko to allow geotechnical design to

always govern

Cultural Space Retaining Walls

Counterfort Retaining wall

Fill

Fill

Fill

Fill

Shale band
Excavation
Sandstone

Mode 1:

Mode 2:

Mode 3:

Mode 4:

Sliding Along
Base or Shale
Band

Overturning
About Toe

Overturning
About Anchor
Head

Bearing
Capacity
Failure

Cultural Space Retaining Walls

Plaxis 3D Model

Assessed Vertical Soil Stress

Assessed Lateral Soil Stress

Cultural Space Retaining Walls

Sill beam

Buttresses

Top of base
slab

Behaviour of front wall

Cultural Space Retaining Walls

Cultural Space Retaining Walls

Cultural Space Retaining Walls

Southern Retaining Wall

Cultural Space Retaining Walls

Northern Access Road Retaining Wall

Cultural Space Retaining Walls

Northern Access Road Retaining Wall
Designed as a propped beam
Utilises rock mass on other side for
stability
Varies in height and thickness over
length
Ground anchors stabilise the base
Waterproofing behind wall
Designed for K0 soil pressure due to
rigid prop at top of wall
Semi-integral connection to roof to
allow precast girders to remain simply
supported

Cultural Space Retaining Walls

Northern Access Road Retaining Wall

Terraced Retaining Walls

Terraced RW

Foreshore area

Terraced Retaining Walls

Conforming Design

Tender Design

Terraced Retaining Walls

Key considerations
Robustness of walls to deal
with tree roots
Aperture of geogrid through
the landscape zone
Size of units for lifting into
place
Colour and finishes

On site trial

Terraced Retaining Walls

Magnumstone RSW

Terraced Retaining Walls

Terraced Retaining Walls

Terraced Retaining Walls

Terraced Retaining Walls

Terraced Retaining Walls

Global Stability in Slope-W

Northern Cove Retaining Walls

Precast L-shaped retaining walls

Northern Cove Retaining Walls

Precast L-shaped retaining walls

SPS 14 Relocation

SPS 14 Relocation

SPS 14 Relocation

SPS 14 Relocation
Key considerations

Condition of the wet well

Fragile brickwork structure given its age
Minimising deflections to control cracking
Condition of brickwork for lifting
Constructability

SPS 14 Relocation

SPS 14 Relocation
Simplified analysis

SPS 14 Relocation
Steelwork modelled separately to size members

SPS 14 Relocation
Contact analysis

Water retention tanks

Key considerations

Safety issues below water table

Interface with other construction works
Separation of seepage water and stormwater
Buoyancy

Stormwater retention tank = 1250 m3

Seepage water tank = 220 m3
Pump room = 50 m2

Water retention tanks

Detailed design

Water retention tanks

Changing site conditions dictated the sandstone
excavation pit needed to go deeper.
This led to an innovative design alternative being
pursued.
All tanks including a seawater heat exchange
chamber previously located in the foreshore were
relocated into the Cultural Space.

Water retention tanks

Final design

Water retention tanks

Water retention tanks

Water retention tanks

Water retention tanks

Revised key considerations

Flooding within Cultural Space Carpark

Durability of pipes under 18 m of fill
Separation of seepage water and stormwater
Buoyancy
Integration with Cultural Space columns
Interface with sandstone extraction program
Interface with the counterfort retaining wall

Water retention tanks

Risk mitigation
Penstock at foreshore with overflow to Harbour
Early weather warning system to empty tanks in advance of
storm
Sealed tank with pressure lids

Earthworks
Key considerations
Maximise general fill won on site
Collect seepage water
Build up the park to underside of landscaping level

Earthworks

Earthworks

Earthworks

Marine
Key considerations

Meet landscape architects design intent

Interpretation of the original shoreline
Replicates natural jointing in sandstone
Logistics of sandstone extraction, processing and
placement
Make it constructible
Suitability of sandstone in marine environment

Marine

Marine

Marine
Innovations for sandstone placement

12D Earthworks model

3D Revit Model
Attributes assigned to each block
Individual barcode for each block
Tracked from birth to grave
GPS utilised for excavation and sandstone placement
Scaled down models
1:1 site trials

Marine
3D Revit model

Marine
Scale down model

Marine

Marine

Marine

Marine

Marine

Marine

Marine

Marine

Marine

Marine
3D Revit model

Marine

Marine

Marine
Cutting existing caissons

Part 3 Cultural Space &

Construction

Cultural Space
Key considerations

Maximise use of precast concrete for safety

Long span roof beams to meet project brief
Construction program
Sandstone extraction pit
Future flexibility for a multiple use space

Cultural Space
Building consists of the following:
- B3 Irrigation retention tanks
- Basement car parks B2 & B1
- Cultural Space @ Ground floor
comprising of a single internal
space 120m Long, 50m wide and
15m high.
- Caf & Forecourt
- Green Roof

Cultural Space
Building Sequence
The building is unique in the manner
the external walls are all finished to
full height prior to any internal
construction.
It has an existing rock-face cutting
which forms the Eastern face and
new counterfort retaining walls on
Western and Southern elevations.

Access for construction is extremely

restrictive due to the Existing Parks
and residential to the East and the
Earthworks and Park construction to
the West.
The construction of the building has
to been sequenced utilising only the
space within its own footprint.

Cultural Space B3
B3 tanks made up of the rainwater tank,
seepage tank & Pump room.
The tank structure is integral to the
columns and foundations for the building.
The pump room has its own stair access
from B2.
The tanks are
designed to deal
with the uplift
caused by the
water pressure
at depth
All walls and
slabs are heavily
reinforced and
300mm thick.

Cultural Space B2
B2 150mm Slab
on Ground
Slab to have a
300mm drainage
layer beneath
Column pad
footings to be
founded on
sandstone.

Northern Ramps
Access for Cultural Space car parks
and loading dock is from Towns Place
in the North
Internal Ramps include an Entry B1
ramp on the east flowing through a
one way system down to B2 and then
an Exiting on the B2 ramp on the west

Cultural Space B1 Level

Post tensioned banded beam
suspended slabs are to be
utilised for both B1 and
Ground floor Slabs.
2 Stair cores are utilised one
in the north and one in the
south and a lift core in the
south servicing all levels
including the caf and roof
taken you to the heart of the
park.

Cultural Space Ground Floor

Similar system to B1 except
15kPa design live load.
Plantrooms at RL8.5 at
northern end.

Cultural Space
Caf and link to Munn Reserve

Caf @ RL13 to be located at the

southern end of the roof in a insitu
section of the main roof.
The L-shaped structure forms the
caf which has an external
forecourt opening out into the park.
The eastern structure forms a
Landbridge into the existing Munn
Reserve.

Cultural Space
Building Footprint
- The building structure starts on the
southern side of site and wraps
round the existing rockface all the
way to Towns place on the northern
edge.
- The Extraction pit is required to be
taken down to a minimum of RL ()4
for the B2 level Basement Car park
and RL ()7 for the B3 tanks.
- The main extraction pit has an area
of approx 6000 square meters
overall.
- The height difference between the
top of the building and deepest
extracted level is approx 30m.

Cultural Space
Tower Crane

Crane

JASO J380 Luffing Tower Crane to be

installed within the Building footprint
Tower to feed all construction works
within main space from Footings to
underside of Headstocks.
Scope to include all insitu works prior to
pre-cast roof stage.

Cultural Space
Pre-Cast Roof Structure
Pre-cast Elements
- 20 No. Headstocks 10.8m Long & 50T
- 57 No. Super Ts 30m long 1m Deep
- Over 300 + Pre-cast Planks and Slabs

Cultural Space
Mobile Crane Pre-cast Install
450T Mobile Crane to lift pre-cast
elements from off Ground floor
suspended slab.
Grillage beams to be utilised to transfer
point loads through building columns
Stage 1 Install Pre-cast Headstocks
and stress to columns.
Stage 2 Install Super Ts & Planks
from Gridline 5 to 15.
Stage 3 - Install 200mm Topping Slab.

Cultural Space
Future Fitout and Expansion
- The building has been designed in such a way that the option of a future fitout introducing 2 more floors at RL 8.5 and RL 13 within the main space is
possible.
- The 2 levels would add a further 10,000 m2 of usable space to the end
user.
- Provisions have been made in the design for the floors and also a northern
lift, this ability would not compromise the PT slabs and walls with the future
required penetrations.

Cultural Space
Progress to date

Sandstone Extraction Pit

Counterfort Wall 95% complete
Northern ramp wall commenced
Rock pocketing for prop beams
Footings for columns on Northern Ramp commenced

Cultural Space

Northern Approach Structure

- Northern Approach Rock

pocketing underway using
pineapple on Excavator
- FRP of Struts to tie
directly into the existing
rockface for lateral loads
from new structure

Safety
The key high risk construction work activities across the
project include: Use of powered mobile plant (people / plant separation)
Remediation of asbestos contaminated fill;
Exposure to respirable crystalline silica dust from sandstone extraction and
processing;
Work along the foreshore that involves both a risk of drowning and diving
works;
Demolition of existing foreshore cellular structure caissons that are load
bearing;
Excavation works greater than 1.5m (sewer diversion, stormwater and
hydraulics)
Work at heights with risk of significant falls (counterfort wall and building
structures);
Work in a confined space (sewer diversion and service investigation); and
Work adjacent to roadways that is in use by traffic.

Sustainability

Use of recycled products including recovered glass sand

and recycled aggregate in drainage
Average 47% of cement substituted for flyash across all
concrete mixes
FSC certified timber for counterfort wall formwork
Sandstone blocks extracted on site
Use of site won fill material
Redesign of counterfort wall to reduce concrete

Biodegradable hydraulic oil

70,000 plants including trees,
shrubs, groundcovers
Use of native and endemic
plant species
Aquatic and terrestrial habitat
creation through design

Environmental
Remedial Action Plan
material compliance
reuse of on-site materials

Environmental Management
Framework

Air Quality
Soil & Water
Noise & Vibration
Waste
Asbestos

Environmental
Monitoring

Dust - real time alerts & review

Odour
Respirable Dust
Asbestos
Water Quality
real time alerts & review for Turbidity

Mitigation Measures

Collection & treatment of site water

Silt curtains
Dust suppression
Stockpile management

Thank you

Questions