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Capability Statement

Capability Statement

Leading supplier of Corrugated Metal Pipes and Bolted, Corrugated-Plate Structures

Overview

Roundel designs, manufactures, and supplies corrugated metal pipes and bolted, corrugated steel structures principally used for drainage culverts, underpasses, stockpile and personnel tunnels. Our business comprises of three related areas:
  • Corrugated metal pipes (CMP) including:
  • Z600 galvanised steel
  • HPL PE-coated Z600 steel
  • Aluminium
  • Bolted, multi-plate structures
  • Bolted, deep-corrugated plate structures.

Design

Design for the above structures is either carried out in-house or by local, independent, structural engineers. Both structural and hydraulic designs can be accommodated. Designs utilize the following standards:
  • AS / NZS 2041.1:2011 – Buried corrugated metal structures – Design methods.
  • AS / NZS 2041.2:2011 – Buried corrugated metal structures – Installation.
  • AS / NZS 2041.4:2010 – Buried corrugated metal structures – Helically formed sinusoidal pipes.
  • AS / NZS 2041.6:2010 – Buried corrugated metal structures – Bolted plate structures
  • AS 5100.2 – 2004 – Bridge design – Design loads.

Designs use both ring-compression theory and limit states design. For large-span structures Finite Element Analysis (FEA) is also used where required.

Stilcor CMP culverts:

Our fixed culvert pipe mills have the following manufacturing capabilities:

Corrugation profiles:

68 x 13mm, 75 x 25mm, 125 x 25mm.

Materials:

G250 Z600 hot-dip galvanized, HPL PE-coated Z600 galvanized, and aluminium.

Material thicknesses:

1.6mm to 3.5mm.

Diameters:

300mm to 3,600mm standard, 3,600mm+ subject to design (all in continuous increments).

Production capacity:

20 tonnes per day per mill – average.

In addition to the standard Z600 galvanised and aluminium materials, we offer the new HPL PE-coated steel which sets a new standard for helical culvert durability, even in aggressive conditions. Tested locally, and fully meeting the requirements of AS / NZS 2041.4:2010 Section 2.2.1 (d), the coated steel offers a 100-year life with exceptional abrasion and chemical resistance.

The product has been approved by Main Roads WA (MRWA), Transport and Main Roads QLD (TMR), the Australian Rail Track Corporation (ARTC) and Rio Tinto. Further details, material samples, and full test results are available on request.

Completed On-Site Projects

Projects successfully completed on site in recent years, with zero safety incidents, include:

  • The Tanami Road upgrade for Main Roads WA (ongoing, HPL PE-coated culverts).
  • Maride Salt – 850tonnes of HPL PE-coated culverts (2024).
  • South 32, Eastern Leases – Groote Eylandt, 900tonnes (2022).
  • Bravus (Adani) Carmichael Rail, QLD – 9,000 tonnes (2020-2021).
  • Rio Tinto Gudai-Darri Rail, WA – 4,200 tonnes of HPL PE-coated culverts (2019-2020).
  • Toowoomba Second Range Crossing, TMR. HPL PE-coated culverts.
  • Roy Hill Rail – 4,100 tonnes (Oct 2013 – April 2014).
  • FMGs’ Solomon Mine, Firetail & Rail Spur (Nov 2011 – Apr 2012) – 4,600 tonnes.
  • The Lang Hancock Railway and Mesa A for Rio Tinto (2009) – 1,450 tonnes

B200 Bolted, Corrugated Plate Structures

We offer a full range of bolted, corrugated plate arches in all geometric shapes including pipe arches, elliptical, underpasses, high and low-profile arches, using the 200 x 55mm corrugation. These are manufactured at our Townsville QLD facility. Material thickness ranges from 3.0mm to 8.0mm.

Deep, Corrugated-Plate Structures: B381 and Ultra-Cor:

We offer the 381mm x 140mm corrugation profile as per AS2041.6 Section 7, the strongest profile in the Standard. The profile caters for structures with spans up to and exceeding 18m and the loads imposed by high fills and heavy live loads, such as the haul trucks used in mining operations.

Stilcor CMP culverts:

For the largest spans, which can exceed 30m, we offer the Ultra-Cor profile manufactured by AIL of Canada. With a corrugation profile of 500mm x 237mm, the largest available, Ultra-Cor can be considered as a cost-effective, direct alternative to pre-cast concrete arches and concrete beam bridges. The photo below is of Shamal Bridge in Dubai, UAE which features the world’s largest span of a buried, steel bridge – 33.40m

Ultra-Cor
Offers considerable savings in terms of constructed costs, with far quicker installation and lower disruption to local road users. AIL offer a comprehensive design package including geotechnical advice

QA, OH&S and the Environment

Roundel is proudly certified to ISO 9001 (Quality Management), ISO 45001 (Occupational Health & Safety), and ISO 14001 (Environmental Management) for the design, manufacture, and supply of Corrugated Metal Pipes (CMP) and Bolted, Corrugated Metal Structures (BCMS).

We are committed to the highest standards of Quality Assurance, Environmental Sustainability, and Workplace Safety. Our ISO Triple Certification is a testament to our dedication to industry-leading practices, strict compliance, and the delivery of exceptional products and services, with a strong focus on safety and environmental responsibility. To support this, we operate a fully integrated document management system through Lucidity Software, ensuring efficient, transparent, and streamlined processes across all operations.
We would welcome your inquiries, and of having the opportunity of supporting you in the success of your next project.