Investigations

Costin Roe Consulting produced a civil engineering report and water cycle management strategy, including TUFLOW 2D hydrodynamic flood modelling and assessment, to support an application for industrial development within the newly-defined Aerotropolis zone which surrounds the new Western Sydney Airport.

When the NSW Government confirmed Badgerys Creek as the location for Sydney’s much-needed additional airport, it was announced that residents and workers in Western Sydney will benefit from easy access to strong local and international connections and a “24-hour economy” conveniently centred around the new airport facility.

Continuing industrial development within Western Sydney Aerotropolis zone

Strategic planning for greenfield land in close proximity to the new airport, within the zone now defined as the Western Sydney Aerotropolis, is intended to unlock opportunities to deliver new jobs and homes supported by key infrastructure whilst conserving and improving environmentally-sensitive areas and wildlife habitats. The government’s vision for the Airpotropolis includes contributing towards the creation of 200,000 new jobs for Western Sydney and a new “high-skill jobs hub” across aerospace and defence, manufacturing, healthcare, freight and logistics, agribusiness, education, and research industries.

One challenge presented in the practical delivery of facilities and infrastructure needed to realise the Aerotropolis vision is that portions of land available for development within the zone have been classified as flood-affected. However, expert civil engineering practices in accordance with sustainable water management and environmental conservation guidelines can often mitigate the risk of flooding to allow for industrial development and improve the management and quality of water in a broad area surrounding the actual development site. Such improvements have been demonstrated in some areas now deemed to be within the Aerotropolis zone which had been developed for industrial and residential purposes under previous localised guidelines.

The Western Sydney Aerotropolis LUIIP (Land Use and Infrastructure Implementation Plan), released in September 2018, sets out the statutory pathway to be used for development applications within the Aerotropolis zone. There are also individual plans for the nine newly-defined Aerotropolis precincts which are:

Kemps Creek Warehouse, Logistics and Industrial Facilities Hub - Locality Plan

The site as indicated on the Kemps Creek locality plan.

  • Aerotropolis Core
  • Northern Gateway
  • South Creek
  • North Luddenham
  • Rossmore
  • Mamre Road
  • Kemps Creek
  • Badgerys Creek
  • Agriculture and Agribusiness Precinct

Costin Roe Consulting delivered 2D hydrodynamic (TUFLOW) modelling and assessment authored by Mark Wilson, B Eng (Civil) B Surv ME CPEng, Director of Costin Roe, the submission of which contributed to rezoning and development approval for an industrial complex on a flood-affected 43.85 hectare site at 585-649 Mamre Road, Orchard Hills, in the former Mamre West Precinct, for Altis Property Partners (developer) via Hansen Yuncken (project manager), in 2016. The firm is recognised for its expertise in hydrodynamic modelling and sustainable water management practices, being Highly Commended for ‘Excellence in Integrated Stormwater Design‘ in 2017.

Kemps Creek Warehouse and Logistics Hub development application process

By 2018, when Frasers Property and Altis Property Partners (the joint venture or JV) prepared to proceed with an application for the development of the Kemps Creek Warehouse and Logistics Hub at 657-769 Mamre Road, Orchard Hills, the site had become included within the Kemps Creek precinct under the Western Sydney Aerotropolis LUIIP. Some guidelines, references, and benchmarks would differ from previous successful development applications for nearby sites. Costin Roe Consulting was commissioned by the venture partners to prepare a Civil Engineering Report & Water Cycle Management Strategy (WCMS) to support the necessary State Significant Development (SSD) Application to the Department of Planning and Environment (DP&E), encompassing a formal request for the Secretary’s Environmental Assessment Requirements (SEARs) prepared by town planning consultants, Willowtree Partners. The proposed development would first involve earthworks and infrastructure development across the entire site, carried out in two stages, followed by the construction of warehouse facilities.

Mark Wilson, BEng(Civil) BSurv ME CPEng, Director of Costin Roe Consulting, author of the Civil Engineering Report & WCMS for the 585-649 Mamre Road development proposal.

The Civil Engineering Report & Water Cycle Management Strategy authored by Mark Wilson, assisted by Costin Roe’s TUFLOW modelling specialist engineer, Mitchell Cross, provided an assessment of the civil engineering characteristics of the development site and technical considerations of earthworks and geotechnical aspects; roads and access; and the WCMS. The WCMS addressed key water cycle management aspects including the stormwater quantity and quality, water supply and re-use, flooding, and erosion and sediment control. Consistent with environmental priorities in contemporary NSW industrial development, the overall environmental considerations relevant to the proposed development were defined in the Willowtree report as including soil and water, noise, air quality, flora and fauna; waste, Aboriginal and historical heritage, traffic and transport, visual amenity and design, infrastructure and services, and socio/economic impacts. The development is intended to contribute to employment opportunities in Western Sydney through an environmentally-sensitive, ‘Six Star’ rated estate and state-of-the-art warehouse and logistics facilities featuring the latest technology.

Validating suitability of 112-hectare site for industrial development

The total site proposed by the JV for development comprises 112 hectares with 1.1km direct frontage to Mamre Road. Predominantly clear of vegetation from historic pastoral use, free of both contamination issues and critical flora/fauna habitat, the site is relatively flat with a <1% slope producing a 4-metre cross-fall from the higher side, along Mamre Road, down towards the western boundary of South Creek and the portion of land identified as flood-affected.

An example of TUFLOW 2D hydrodynamic flood modelling for the report by Costin Roe Consulting.

In accordance with the requirements of Penrith City Council and the NSW Floodplain Development Manual, and referencing the Updated South Creek Flood Study¹, the flood assessment by Costin Roe Consulting confirmed that the floor levels of the proposed buildings near South Creek would be set at 1% AEP² flood level plus 500mm freeboard. Costin Roe used MUSIC (the Model for Urban Stormwater Improvement Conceptualisation) for stormwater quality modelling to simulate the performance of proposed stormwater management systems and ensure pollutant retention requirements would be met.

The Civil Engineering Report & Water Cycle Management Strategy by Costin Roe Consulting, including the Overflow Land Reports 1-3, formed part of the 2019 package of reports, plans, and other documents submitted for consideration and decision-making by authorities, and exhibited to the public on the NSW Planning Portal as the Kemps Creek Warehouse, Logistics and Industrial Facilities Hub, a major project for NSW. Approval will facilitate the development of a warehouse, logistics and industrial facilities hub including the construction and operation of nine warehouses comprising 163,671m2 of floor space, 754 parking spaces, and a 33-lot Torrens Title subdivision.

 

¹ Updated South Creek Flood Study (rp6033rg_crt150128-Updated South Creek Flood Study (FINAL – Volume 1)
² AEP stands for the Annual Exceedance Probability – the likelihood of occurrence of a flood of a given size or larger occurring in any one year

 

FLOOD ASSESSMENT FOR 585-649 MAMRE ROAD (2016)

 

ASK ABOUT 2D TUFLOW MODELLING

 

Dux Hot Water, Moss Vale NSW

Some owners and occupants of new high-bay warehouses are concerned to find the pristine appearance of floor surfaces becoming blemished by black marks that resist cleaning. Grant Roe, BE(Hons) MEngSc MBA MIEAust CPEng NER, explains why this common problem is often misunderstood and prescribes the appropriate solution.

Dux Hot Water, Moss Vale NSW

The floor surface of a new warehouse looks pristine but can soon become blemished by vehicle traffic leaving ‘nasty’ black marks.

There can be technical misunderstandings behind trade-level advice as to what causes black marks to accumulate and persist on the surface of new warehouse flooring. Due to these technical misunderstandings, ineffective remedies can be recommended with well-meaning intentions but unsatisfactory results.

Costin Roe Consulting is one of the world’s leading engineering firms in high-bay warehouse design from both civil and structural engineering perspectives, and winners of the ACSE NSW Award for Excellence in Structural Engineering for work including the high-tech concrete pavement at Veolia complexes in Woodlawn and Banksmeadow. Europe has led the world in high-bay warehouse design and automation. Each year, the firm’s Managing Director, Grant Roe, spends time in Europe examining the latest developments in high-bay warehouse engineering, and in Australia, he is acknowledged as an engineering expert engaged with numerous successful high-bay warehouse design and construction projects. A recent Q&A session with Grant Roe, on the topic of warehouse flooring, delivered the following explanations and recommendations for warehouse flooring maintenance where cleaner appearances are required.

Cause and effect determined through physics and logic

The curing compound used in the concreting process, to achieve greater precision and efficiency, is often blamed for the ongoing accumulation of undesirable floor markings. In fact, the curing compound is formulated for rapid break-down and dissipation. “Any effects from the curing compound are gone after six to twelve months. So, whatever its contributing factor may have been for a brief period following construction, people are finding the black marks keep accumulating and resisting all the usual attempts at cleaning and preventative treatment,” Grant said. With the curing compound dismissed as the prime suspect, the discipline of engineering looks objectively at the forensic evidence and the science at work behind evident factors.

“When rubber tyres are rolling normally over warehouse floors there is no problem. However, new warehouse flooring offers less friction for tyres to maintain traction and keep rolling normally. When reduced friction causes loss of traction, the tyres slip and slide, and the rubber can heat to the point of burning. The slipping and burning actions leave behind carbon and rubber residue, appearing as black marks on the floor,” said Grant. “The problem has become more apparent in recent years because forklifts have been modified to become more powerful, the wheels are smaller in diameter, and more energy is being applied at the interface. It’s a worldwide issue, as similar concerns have been raised and solutions sought in other countries for some time.”

Grant went on to explain that white tyres had been tested as an alternative but the white rubber was found to be not as durable. Since black tyres last much longer, and perform better for heat absorption, changing to white tyres for cosmetic reasons would not make sense commercially. Yet, for some warehouse operators, aesthetic appearances will matter almost as much as performance. This is where engineers can more accurately identify the cause of problems and prescribe the most efficient means of achieving the desired aesthetic result.

Floor densification treatment the answer for increasing friction

The answer to persistent black marks on new warehouse flooring, as explained by Grant Roe, is simple, practical, and readily available in Australia.

“Floor densification is a good solution, combined with controlled surface grinding. Although this approach may sound counterintuitive, increasing the friction, and thereby minimising the loss of traction, are the keys to resolving the problem. When properly executed, the grinding modifies the surface and combined with the densification treatment, the friction properties of the floor surface are changed. The densification treatment also serves as a surface sealer, providing easier removal of any tyre markings that may occur. This combined grinding and densification treatment is used quite widely in Europe but not so much in Australia where the products and trade-skills are available but the prescriptive expertise is still emerging,” said Grant. “The answers I’ve given today are intended to assist local building owners and maintenance service providers.”


For specific assistance with new warehouse flooring projects and any remediation or maintenance issues, call Costin Roe Consulting on 02 9251 7699.

Mamre Flood Report

Commissioned by Altis Property Partners (developer), via Hansen Yuncken (project manager), Costin Roe Consulting undertook an overland flow (flood) assessment of 193 hectares of land in Orchard Hills, Sydney. The assessment was required to accompany an application for rezoning to facilitate the development of new industrial facilities on a 43.85-hectare subdivision.

2D TUFLOW hydrodynamic modelling by Costin Roe Consulting assisted in gaining the go-ahead for the proposed development – unlocking formerly unusable land to create business and employment opportunities, and improving the management of overland flow for the site and other land in the vicinity.

The assessment prepared by Mark Wilson, B Eng (Civil) B Surv ME CPEng, Associate Director (Civil Engineering) of Costin Roe Consulting, first involved building two-dimensional TUFLOW hydrodynamic modelling for peer review by Worley Parsons, the engineers of a flood study of the area by Penrith City Council. Assisting Mark Wilson with the detailed programming and configuration of the TUFLOW modelling was Mitchell Cross, one of Costin Roe Consulting’s team of flood modelling engineers with TUFLOW modelling engine expertise.

To achieve peer-reviewed validation, Costin Roe Consulting’s TUFLOW modelling was used by Mark Wilson to simulate the occurrence of a range of probable flooding scenarios on the area – in its undeveloped state – to show the accuracy of the firm’s two-dimensional modelling performance against the accepted numerical data.

2D flood modelling for report by Costin Roe Consulting

2D model of the 1% annual exceedance probability (1% AEP) flood levels in the Mamre West Precinct (before construction of the proposed development) as built by Costin Roe Consulting using TUFLOW hydrodynamic modelling technology.

Next, Mark Wilson used the validated TUFLOW modelling-build to calculate and illustrate the differences in flood levels, velocity, and general hydraulics for the same range of probable flooding scenarios following construction of the proposed development, which would happen in two stages.

Finally, the two-part assessment Overland Flow Report Stage 1 and Stage 2 by Costin Roe Consulting successfully informed the NSW Department of Planning & Environment, Penrith City Council, development partners, and various stakeholders on the mitigation and management of land overflow at the site during and after construction of each stage of the project.

As a result of the scenarios produced by the 2D TUFLOW modelling in the Costin Roe Consulting assessment, it was demonstrated that a large percentage of this flood-affected land could be developed, and was suitable for rezoning, which would allow the Altis-proposed industrial development to proceed.

Costin Roe Consulting’s mastery of the TUFLOW modelling engine, and expertise in producing two-dimensional simulations of floodwater behaviour pre/post-development, enabled everyone – including the broader community following exposure of the proposal – to more easily appreciate the benefits offered by the development proposed by Altis, and more favourably consider the statutory changes needed to allow civil works and construction to begin.

Area formerly categorised as ‘high hazard’ due to overland flow

The site proposed by Altis for the development of major new warehousing and logistics facilities was the 43.85 hectare subdivision of a larger parcel of land zoned ‘Rural Residential’. For the proposed development to be given the go-ahead, the State Environmental Planning Policy (Western Sydney Employment Area) 2009 would need to be amended, and the land rezoned ‘General Industrial’.

Located at 585-649 Mamre Road, Orchard Hills, the site lay within what is known as the Mamre West Precinct. The site was identified by Penrith City Council in the report known as the South Creek Flood Study (Worley Parsons) on the Mamre West Precinct as being affected by overland flow associated with adjacent South Creek.

During overland flow events as detailed in the South Creek Flood Study, floodwater on the undeveloped site would be shallow and of low velocity except for the north-west corner, where slow-moving water could potentially reach 1.1m in depth. This area had been categorised by Penrith City Council as a ‘high hazard’ zone.

With a residential area to the north of the proposed development, and Erskine Park Employment Area on the eastern side, Altis and its project partners would be compelled to show conclusively that the civil works planned to make the 43.85-hectare site viable for development would not increase the risk or hazard of inundation for properties neighbouring or upstream/downstream of the development when completed and the overland flow from South Creek re-occurred.

Development would provide new access road and formal drainage system

Mark Wilson, Associate Director (Civil Engineering), Costin Roe Consulting

Mark Wilson, BEng(Civil) BSurv ME CPEng, Associate Director of Costin Roe Consulting, took the lead role in the flood-modelling assessment for the proposed Altis development at Orchard Hills.

Costin Roe Consulting’s easy-to-understand TUFLOW modelling successfully demonstrated how the Altis development would ultimately mitigate and improve the management of overland flow on the site and surrounding area. This would be achieved via engineered land-filling and the building of infrastructure, including a formal drainage system, where none had existed before.

A new access road would be constructed as part of the development project and handed over to the City upon completion. Previously unusable land in a district with prime accessibility to greater Sydney would be made serviceable. More jobs would be located in the far western suburbs of Sydney, handy to residential population centres where the types of land suitable for new industrial developments are in short supply.

Rigorous examinations and consultations involving two levels of government

However, with the Department of Planning & Environment (NSW) the consent authority for zoning amendments under the State Environmental Planning Policy (Western Sydney Employment Area) 2009, and Penrith City Council as a key authority to be consulted due to Section C3.5 of Penrith City Council Development Control Plan 2014 and its guidelines for flood-liable lands, the development proposal had to satisfy rigorous examinations and consultative processes involving these authorities. This is where the external scrutiny of the Costin Roe Consulting 2D TUFLOW modelling-build by Worley Parsons helped meet the high standards of diligence applied by the two levels of government.

Positive feedback throughout the modelling process

“The Mamre Road flood assessment for Altis and Hansen Yuncken involved a high level of consultation with Penrith Council, NSW Department of Planning, and peer review by Worley Parsons. We received positive feedback throughout the modelling process,” said Mark Wilson of the Overland Flow Report Stage 1 and Stage 2 by Costin Roe Consulting. “We will be completing more 2D flood assessments of this nature in future.”

 

 

Ask about 2D TUFLOW modelling

Costin Roe Consulting was engaged by Investa, one of the largest property groups in Australia, to provide a condition report on the assets surrounding the planned redevelopment of 60 Martin Place, Sydney.

For Lee Carroll, MIEAust CPEng MEng, Senior Engineer (Remedial/Forensic), Costin Roe Consulting, this would mean first-hand examination of buildings, basements, vaults, tunnels, and some rarely-seen voids beneath the “civic heart” of Sydney.

Lee Carroll, Senior Engineer (Remedical/Forensics), Costin Roe Consulting

Lee Carroll inspects an abandoned 1920s railway tunnel beneath Martin Place, Sydney.

Vertical and horizontal stresses in the ground

The role of the engineer is essential in the project-planning of urban redevelopment. Demolishing a multi-storey building and excavating for basements removes weight from the site, which in turn relieves the vertical stresses on the subsoil and substratum below. Constructing a taller building on the same site produces greater vertical stresses than existed before. The spring-like movement of the ground during demolition and construction, if not properly assessed and managed from the outset, could potentially compromise the integrity of buildings and infrastructure nearby. Pre-development condition reports by experienced engineers are required for reliable reassurance and guidance, if necessary, to insurers, project partners, and the owners of surrounding buildings.

In urban Sydney there are not just the typical vertical stresses of demolition and construction for the engineer to consider, but also horizontal stresses caused by natural forces. There are fault lines running deep beneath the Sydney basin dating back to when New Zealand started breaking away from Australia more than 85 million years ago. The Australian continent is also moving northward, away from Antarctica, at the rate of 5.6cm per year.

“The horizontal stresses in Sydney affect rock excavation. The rocks can move between .5mm and 2mm per metre of excavation. If you excavate down 20 metres for a basement, the rock can move 20mm laterally,” said Lee Carroll.

Sixty Martin Place

Website for the $750 million “Sixty Martin Place”.

Redeveloping a non-descript building into a landmark

Investa’s proposal for the redevelopment of 60 Martin Place promised to transform an uninspiring, inefficient, 1970s-vintage office block of 28 storeys into a sustainable, contemporary 33-level complex with two additional basement levels. An international design competition was won by architects Hassell in February 2015. The condition report by Costin Roe Consulting would involve inspections of above-ground and below-ground assets within 50m of the boundary of the proposed redevelopment site.

On the corner of Macquarie Street and also Phillip Street, 60 Martin Place is right next to the heritage-listed St Stephens Uniting Church (1842) and the Seven Network’s Sydney News Centre. Just across the road, in Macquarie Street, is NSW Parliament House (1816) and Sydney Hospital (1811). The entrance to Martin Place underground railway station is virtually on the front doorstep, and directly opposite in Martin Place is the headquarters of the Reserve Bank of Australia.

By Photographic Collection from Australia (Railway Station - Martin Place) [CC BY 2.0 (http://creativecommons.org/licenses/by/2.0)], via Wikimedia Commons.

Martin Place Railway Station under construction (1951). See below for image attribution.

Underground railway tunnels and the RBA vaults

“To assess the Reserve Bank of Australia site we needed to examine the underground vaults. There were armed guards present the whole time. The report had to be written on the site, and left on the site. The security around our inspection was extreme, of course, but it was no barrier to getting the assessment done,” Lee said.

Five busy railway tunnels extend beneath the eastern end of Martin Place. There are three City Circle tunnels, two Eastern Suburbs line tunnels, and also Martin Place station (1979). For OHS/WHS and public safety reasons, these subterranean areas were inspected in the middle of the night, when the trains were not running.

“We could access the active rail tunnels between midnight and 3am only,” said Lee. “I was accompanied by surveyors and rail protection officers. It was pitch black in the tunnels after-hours but with the lighting we carried I was able to examine the condition of the tunnels as needed and assess any cracks or defects if found.”

The abandoned tunnel almost no-one has seen

Radiating from St James Railway Station are several railway tunnels which have never had a train pass through them. Built in the 1920s, the onset of the Great Depression and then WWII meant these tunnels were never connected to the main lines. The tunnel structures are so solid they were used as mass bomb shelters during WWII. The army’s attempts to blow up the tunnels after the war were unsuccessful and so they remain today, completely closed to the public, and almost never intruded upon.

One of these tunnels extends about 1 km from St James towards Martin Place. Lee Carroll was required to go underground and inspect this cavernous, abandoned stub of a tunnel on his own – taking a selfie (above right) as a memento of this rare and perhaps once-in-a-lifetime experience.

“We inspected the tunnel linings for cracking, spalling, leaking or any other kind of defects and prepared detail drawings showing their locations to enable comparison at future stages of the project,” Lee said. “It’s also a credit to the city that we encountered no rats.”

Sixty Martin Place (commercial)

The new building was designed by architects Hassell.

Condition report facilitates start of transformation

With the inventory of assets in the zone surrounding 60 Martin Place satisfactorily detailed and assessed in the Costin Roe Consulting condition report, the redevelopment by Investa Property and Gwynvill Group (the “owners”) would begin with demolition work starting in early 2016. Project completion is set for 2019.

The new development, named “Sixty Martin Place“, will offer more than 40,000m² of commercial and retail space at one of Sydney’s most desirable and accessible CBD locations. Supporting both Council’s Sustainable Sydney 2030 vision and the objectives of the Martin Place Owner’s Group, the owners’ aim is for the Sixty Martin Place building to achieve 6 Star Green Star/5 Star NABERS ratings for environmental efficiency.

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Image of Martin Place Railway Station by Photographic Collection from Australia (Railway Station – Martin Place)
[CC BY 2.0 (http://creativecommons.org/licenses/by/2.0)], via Wikimedia Commons.

Tree roots Opera Australia building

When the roots of street trees were suspected of causing damage to a building at Alexandria occupied by Opera Australia, the City of Sydney commissioned Costin Roe Consulting to investigate and report.

Like most suburbs of inner Sydney, Alexandria showcases streets lined with trees of considerable size and age. The narrowness of inner-Sydney streets will often mean that trees, only small when first planted, have reached maturity within close proximity to residential buildings and commercial properties.

Tree roots Opera Australia building

Large street trees grow in close proximity to the Opera Australia building in Alexandria, Sydney. The encroachment of tree roots is a common problem in densely built inner-city areas.

The City of Sydney values the trees on Sydney’s public and private land as public assets. The city’s Urban Forest Plan 2013 commits to a sustainable Sydney by 2030 and ongoing improvement in the diversity of the urban canopy. So, when trees become a problem for the built environment, remedial works must be undertaken with great sensitivity, and in close consultation with the City Of Sydney. Costin Roe Consulting are experts at devising remedial engineering solutions where commercial requirements and stakeholder interests need to be managed within the broader context of environmental preservation.

At 58-66 Euston Road, Alexandria, a commercial property occupied by Opera Australia, Costin Roe Consulting found that the roots of two large trees, growing in the street outside the building, had penetrated the ground beneath the basement floor slab.

Just below the front entrance to the building, the basement floor slab had lifted by approximately 100mm over an area of 8 metres x 3 metres. The investigation also revealed that tree roots were blocking an in-ground cast iron stormwater pipe connecting the building downpipe and the street gutter.

Remedial works recommended by Costin Roe Consulting included the removal and replacement of the affected concrete slab, tree root pruning, and the installation of a root barrier to prevent further root growth beneath the floor slabs in the basement car park. To clear the blocked stormwater pipe, tree root coring was recommended, or alternatively the replacement of the blocked section of pipe.

Tree roots Euston Rd Alexandria

Roots were blocking an in-ground stormwater pipe.

Tree roots lifting concrete slab

Two trees roots in excavation outside the storeroom wedged between two concrete slabs, lifting the top slab.

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