Our scope of work included the on-site production of 8,000 tonnes of Z600 Stilcor CSP culverts, with diameters ranging from 600mm to 2,700mm. To meet the project’s requirements, three pipe mills operated simultaneously on-site, servicing all sections of the works. Although originally scheduled for completion within 10–12 months, the project was successfully accelerated and completed in just six months, with zero safety incidents.
The project is believed to have been the largest single on-site culvert installation project undertaken in Australia, with our teams consistently achieving production rates of more than 150 tonnes of CSP culverts per day. This exceptional output enabled the project to be delivered efficiently while maintaining the highest standards of quality, safety, and performance.
The steel materials were imported on dedicated vessels, with each shipment carrying between 3,000 and 3,500 tonnes directly to the Port of Townsville. All culverts were manufactured in accordance with AS/NZS 2041.4 standards, ensuring compliance with stringent Australian and New Zealand quality and performance requirements.
The successful delivery of this project increased Roundel’s total on-site culvert manufacturing volume to more than 40,000 tonnes, a milestone that reflects an unmatched level of experience and capability within the industry.
Roundel also designed and manufactured the CHPP Stockpile Reclaim and Escape Tunnels for the project using its B200 bolted corrugated steel arches, which were manufactured in Townsville. As the only Australian company offering both the design and manufacture of corrugated metal pipes and bolted corrugated steel structures, Roundel provides nationally recognised expertise and end-to-end delivery capabilities across Australia.
