MAJOR WATER INFRASTRUCTURE PROJECT

Tiltex 7B & 10B Anti Cracking GCCM was approved for a large scale Major Water Infrastructure Upgrade Project to protect steep soil excavation batters from washing out and weakening during a lengthy construction period. 

Tiltex 7B & 10B provided a watertight, concrete protection layer to the ground surface batter of the construction site whilst construction works continued. 

Tiltex 7B & 10B’s 5 metre wide by 20m long roll lengths were quickly deployed over the steep excavation batters by Tiltex Australia installation personnel providing a faster, more economic and durable alternative to shotcrete with no cost over runs and surplus shotcrete spill to remove.  

To ensure a successful project, Tiltex Australia provided our client with Construction Methodology, SWMS & inclusion of working at height & steep batters, ITP’s & QA/QC Procedures to ensure a quality engineering solution with detail, focus, safety and commercial advantages.  

ROYAL SYDNEY GOLF CLUB UPGRADE WITH TILTEX 12B & HDPE

The Royal Sydney Golf Club has extensively upgraded the golf course which included the design & construction of a large irrigation dam to aesthetically blend into the golf course landscape.

The lining system comprised of a SDV2300 structural drainage void material followed by a 2.0mm smooth HDPE liner, thermally welded and tested and included sealing terminations to concrete sump structures, hydrostatic relief valves and pipe inflow penetrations.

In addition to the extensive destructive & non-destructive testing of the 2.0mm smooth HDPE liner, an Arc conductive test survey was conducted over the 2.0mm HDPE liner to ensure no damage to the liner.

A protection overlay of our exclusive Tiltex 12B GCCM was placed over the 2.0mm HDPE liner to provide protection from exposure to the elements and protection from physical damage by feral animals, vandalism and fire.

JOHN HOLLAND AGAIN CHOOSES TILTEX B GCCM OVER 100MM CONCRETE

John Holland chose Tiltex 7B Anti Cracking GCCM over 100mm concrete to replace concrete dish drains as part of Sydney Water’s Advanced Water Recycling Centre (AWRC).   

3200m2 of Tiltex 7B was laid over batters and drains for an erosion control solution for the bioreactor project. Tiltex Basalt Fibre enhanced GCCM was the preferred product over other erosion control alternatives as it provides impermeability, is maintenance free and uses 86% less concrete than 100mm concrete. 

To ensure a successful project, Tiltex Australia provided our client with: 

• Construction Methodology 

• SWMS 

• ITP’s & QA/QC Procedures 

• Certified Lifting Equipment 

• Training and supervision - whilst we offer a full installation service, we supplied training and supervision for the John Holland team to install.  

Tiltex 7B’s 80MPa Compressive Strength, 16.1* Flexural Strength properties and 5m wide, 20m long rolls ensured a faster installation, saved costs and a reduced material requirement whilst obtaining a higher quality erosion control result. Faster installation was important as the batters were adjacent to access roads.

*After 7 days 

MINING PROJECT - PAPAU NEW GUINEA

Tiltex Australia recently designed and supplied 5700m2 of Tiltex B range as part of a large drainage project at a gold mine, 900 km from Port Moresby, Papua New Guinea.

Tiltex 10B GCCM was specified as an impermeable barrier to be placed over a 10 metre wide benched drain to control & convey rainwater & runoff flow across the bench to redirect flow from infiltration through fractured rock to potentially undermine the rock bench .

The site can endure 200mm of rainfall in one event and Tiltex B GCCM was an obvious choice where the placement of 5 metre wide Tiltex B rolls, overlapping with adhesive seaming of the sheet panels to the bench substrate and rock wall was a fast process.

Tiltex B GCCM cannot be over-hydrated which was an important consideration with the expected heavy rainfall conditions throughout the day & night.

Our Head of Installations at Tiltex Australia trained and supervised the installation by the Mining installation team. There was extreme heat and humidity in the tropical climate, as well has heavy rain, making the installation more challenging but the project was completed ahead of schedule.

Tiltex Australia’s CEO, Mark Curtis, inspected the installed Tiltex B GCCM some months after completion and found the product to be cured hard & performing as intended. Tiltex B GCCM will be considered for other projects on the mine for drainage channels and slopes where high erosion occurs.

Tiltex 12B chosen again at NSW Coal Mine

Tiltex 12B was again selected for further erosion control works at a major coal mine in NSW for protection of a channel & spillway for rain event flow into a storage facility.

A perimeter anchor trench secured the Tiltex 12B material into position at the crest, longitudinally down both sides of the drop structure and at the toe. Cement stabilised backfill material was placed into the anchor trench where Tiltex 12B transitions from unlined channel to Tiltex 12B lined channel to minimise scouring of backfill material.

Our exclusive Tiltex 12B GCCM is designed for ground surface protection in high flow channels & spillways to control erosion & costly maintenance to re-build scoured surfaces. It provides protection with 80MPa Compressive Strength & 16.1*MPa Flexural Strength.

Our Tiltex Australia installation team installed Tiltex 12B in less than 2 days and it was operational within 24 hours.

*after 7 days

MANGOOLA COAL MINE EROSION CONTROL PROJECT

Mangoola Coal Mine in Northern NSW required embankment erosion control protection for overpass bridge arch batter slope to stop scouring of rock material dropping onto the haul road and control of water conveyance to drainage points. 

2900m2 of Tiltex 9B were laid and sealed with our exclusive STAB41X adhesive to the concrete termination. 

 The site conditions were difficult with access issues and operational constraints but were managed well by our Tiltex installation team.  

Tiltex 9B Anti Cracking GCCM was specified over other erosion control alternatives, such as shotcrete, due to it’s fast installation, cost effective alternative and superior product performance (80MPa Compressive Strength and 16.1MPa* flexural strength) and our engineering & installation expertise to adhere to the very stringent mine site requirements. 

*after 7 days

TILTEX B AGAIN SPECIFIED FOR ARTC PROJECT

Tiltex 12B was recently specified for another rail infrastructure maintenance drainage and embankment project for ARTC.

Our exclusive Tiltex 12B 80 MPa Compressive Strength, Basalt Fibre reinforcement Anti Cracking GCCM was utilised in 4 applications.

• Cess Drains

• Spillways

• Embankment Erosion Control

• Remediating existing concrete drains with Tiltex 12B.

 Tiltex 12B was specified due its track record of performance with previous ARTC projects. For this project, Tiltex 12B removed the need for concrete trucks in the remote location and provided a product that was able to be installed quickly, so to as not affect rail operations and the environment surrounding the project.

 Our exclusive Stab 40 Adhesive was used to seal each of the seams of the 5m wide Tiltex 12B rolls, ensuring a high tensile strength seam bond at every overlapped seam.

 Tiltex Australia tailors Tiltex B installations and repairs to work with rail clients and contractors in order to have experienced personnel provide quality workmanship, safe work practises at cost effective pricing. 

Whether for smaller applications or large-scale projects, our Tiltex Basalt GCCM is a cost effective alternative to other erosion control materials and to concrete, shotcrete and their expensive specialist equipment.

Water Infiltration Barrier & Erosion Control Protection to a Reinforced Earth Wall - stage 1 & 2

Tiltex Australia’s installation team have just completed a major water infiltration barrier & erosion control to the ROM Wall Crusher A project at Ironbridge Mine, Pilbara WA. Our team installed Tiltex 12B Anti Cracking 80 MPa Compressive Strength GCCM over 50 metre+ long steep batters at 1V:1.6H, secured with our soil anchor grid system designed to endure 50m/sec winds.

Tiltex 12B GCCM was specified for covering slopes above the ROM Wall and its primary design is to inhibit water infiltration behind the metal facing wall panels and provide ground surface erosion protection of batter slopes. The project involved deploying the Tiltex 12B’s 5 metre wide x 20 metre long rolls longitudinally down the steep batters and seaming with our unique Tiltex B STAB 40 seaming system. Installing a soil anchor grid system at 2 metre grid pattern and perimeter soil anchors at 0.5 metre spacing. Over 4000sq m of Tiltex B were installed over Stages 1 & 2 of the project.

Hydrating Tiltex 12B GCCM on steep slopes is achievable with our exclusive Saturation Hydrator apparatus to provide an even distribution of water through Tiltex 12B’s matrix structure to ensure no unset cement and to initiate curing to 80 MPa Compressive Strength and 16.1 MPa* Flexural Strength properties. 

*7 days

TILTEX 10B RAIL EMBANKMENT RECONDITIONING PROJECT

Tiltex 10B GCCM was specified as the ground surface erosion control over the embankments and drains for ARTC’s Werris Creek Reconditioning Project. Safety, time management and a durable, low maintenance product were all critical elements of this project’s success. 

4,900m2 of Tiltex 10B was supplied, installed and hydrated on steep batters during the rail possession. Over 60 x 5-metre-wide panel widths of Tiltex 10B were deployed by Tiltex Australia site personnel requiring over 1,090 lineal metres of seam bonding. Our 5 metre wide rolls provided a 1/4 of the seaming requirements than other GCCM’s.

Tiltex Australia tasked 2 teams to deploy Tiltex 10B with 2 personnel per team allocated to man a day shift and a night shift to meet the clients rail possession deadline. The project was completed safely with no injury downtime & ahead of schedule.

moorebank flood diversion channel

tiltex B ANTI CRACKING GCCM replaced 100mm concrete

• Our client required a better solution for temporary and permanent erosion control of a main drainage channel during severe rain events over a large catchment area for a logistics infrastructure development project.

• Tiltex B Anti Cracking GCCM replaced 100mm concrete and was deployed longitudinally & equilaterally across the drainage channel where the channel curves. 

• Tiltex B Anti Cracking GCCM was 10 x faster to install than the previous used conventional FRP Concrete and the project was completed ahead of schedule.

• The project was tested a month after installation with the highest rainfall in 38 years. The product performed perfectly.

Cherbourg Waste Water Treatment Plant

tiltex was chosen over just HDPE liner to protect a community asset

• Tiltex was specified to line 30,948m2 HDPE lined waste water effluent ponds to protect the liner from nature’s elements, prolong the liner’s operational life and to protect a vital community asset from damage which would have major issues for the community if the effluent ponds were damaged. .

• Tiltex protects the HDPE liner against damage from UV degradation, wind up lift, temperature changes, animals, livestock and minimizes vandalism & fire damage.

• See below for our video highlighting to vastness of the project and how well Tiltex protected this area.

HAWAII pilot project for highway drain application to re-open road

In Hawaii, a pilot project was completed using Tiltex B for a highway roadside drainage system that was previously washed away due to a major landslide.

Due to it’s ease of application to existing road infrastructure and hot asphaltic road surfacing to Tiltex B, fast application time & 80 MPa compressive strength, Tiltex B Anti Cracking GCCM was found to be the most cost effective and quality choice to deliver a fast, strong drain application next to a major State Highway so that this road could open sooner than was planned.

Tiltex B installation had minimal traffic disruption with less equipment requirement at the roadside than with traditional concrete drain lining methods, which can add complexity and risk of safety and visibility hazards for vehicles and construction workers. It took approximately 3 days to lay, secure and harden 122 metres of roadside drain so that they were able to apply the asphalt for re-opening of the road.

State Rail Project

tiltex B anti-cracking gccm replaced 100mm concrete

TILTEX B ANTI CRACKING NOW SPECIFIED FOR government RAILWAY UPGRADE PROJECTS

• Tiltex B Anti Cracking GCCM is specified on a number of railway projects, working with major organisations such as John Holland and Laing O’Rourke.

• Tiltex B was specified due to its exclusive anti-cracking enhancement properties, ease of installation, sustainable material benefits and cost savings over traditional 100mm concrete which had previously been used.

• As rail erosion control maintenance needs to be done as quickly as possible to maintain rail service, Tiltex B Anti Cracking GCCM was chosen as it’s ease of installation means railway maintenance can occur quickly with minimal disruption to railway services.

• 100m2 of Tiltex 12B can be installed every 20 minutes, making it a much faster installation than using shotcrete & concrete. It is also a more cost effective alternative than traditional erosion control methods.

• Tiltex has a 50 year design life and a 30 year warranty* making it a long term erosion control and drainage solution.

Phillips 66 remediation

PASSADENA USA

tiltex b anti cracking gccm replaced rip rap & shotcrete

• Tiltex 12B was specified for remediation of fuel bunds for Phillips 66 refinery in Pasadena USA to replace aged and cracked bituminous and shotcrete seal.

• Installation was quick, ahead of schedule, with high end results improving the durability and safety around the fuel bunds.

 Tiltex 12B specified on TfNSW Drains & Channels

  Tiltex Australia has recently completed 2500m2 of GCCM drainage along a TfNSW carpark. Our exclusive Anti Cracking Tiltex 12B GCCM replaced FRP Concrete.

 Tiltex 12B 5 metre wide rolls were run equilaterally along the drain, making it fast to install by our Tiltex Australia installation team.

 Due to having the widest GCCM available in the market, Tiltex 12B was installed quickly with less seaming and wastage than other narrower GCCMs available. Our simple one-step seam solution without screws, also provided less complication adding to an efficient installation result.  

The measured velocity post installation is up to 7.41m/s. Tiltex provides international 3rd party durability testing & a 50-year design life backed by a 30 year warranty. 

 Tiltex B Anti Cracking GCCM has a Compressive Strength of 80MPa & a Flexural Strength of 16.1MPa* - one of the highest GCCM specifications available. 

 Tiltex B Anti Cracking GCCM is more environmentally friendly solution than FPR concrete as  lower emissions are produced at the point of manufacture, less plant and equipment is required when installing and Tiltex B has a faster construction schedule further reducing emissions when on site. 

queensland mining spillway application

tiltex b anti cracking gccm chosen over rock pitching

• Tiltex was chosen as a cost effective erosion control material over rock pitching at a Queensland mine site.

• Tiltex B was a much safer surface than previous rock pitching used with the benefit of strength from the 80MPa Compressive Strength properties and faster more cots effective installation times.

• Due to Covid-19, our Tiltex Australia engineers & installation team instructed our customer to install Tiltex B via specialised training and then on site video for direct installation guidance.

• The installation ran went smoothly, the project was completed ahead of schedule easily with great results, whilst maintaining safety practices.

  “The use of Tiltex product resulted in direct, measurable safety & risk management benefits for the project by introducing a new, cutting edge product to eliminate what was previously high risk, high labour intensive work on a 1:4 batter. Additional benefits from a time & cost perspective were also achieved.” Project Delivery Lead .

aecom capping PROJECT

tiltex was chosen over rip rap & shotcrete

• Aecom required a safe, cost effective and fast installation solution for their capping of asbestos and chemical protection to provide safety to their workers.

• Tiltex B Anti Cracking GCCM was specified over previously used shotcrete and rip rap due to its smooth, protective surface, environmental considerations and guarantee of impermeability.

  
  
  

Adelaide Estuary Project

tiltex b anti cracking gccm was chosen over quarry rock

• This river estuary in Adelaide is inhabited by Australia’s largest salt water crocodile population. Our client used to track load 38 tonnes of quarry rock, 90 minutes away from site, to cover 17.2m2 of river bank. It would take 3 truck loads a day to cover 51m2 after unloading and placing the rock. One truck load of Tiltex B can cover 1600m2 (12B) and up to 2300m2 (7B) to control river bank erosion.

• With Tiltex B, 1 roll is installed in less than 20 minutes making travel, cartage and installation times reduce by more than half and offering long term erosion control solution.

Tiltex’s Latest Project Videos

Tiltex 7B & 12B installed by our expert team for erosion control of a main drainage channel over a large catchment area for an infrastructure development project.

Tiltex 10 was used to cover 30,000m2 of effluent pond batter slopes to protect the HDPE liner from exposure to UV radiation, heat sensitivity, bush fires, feral animals, livestock & to minimise vandalism.

Tiltex 80MPa Compressive Strength Concrete In A Roll was used in a 28 acre residential development as a stormwater collection basin.