1. Construction Projects at Active EO Depots Dennis Nothdurft
Parari 2019

2. Outline Complexity – scope of EO depot construction Risk Controls
Lessons Learned

3. Complexity Why does construction adversely affect EO depot operations?
Explosives Storehouses sited to meet Inter Magazine Distance (IMD) requirements
Workshops sited to meet Process Building Distance (PBD) requirements
Defence Legal advised previous DEOP101 Risk Waiver policies did not meet Defence’s WHS obligations
DEOP101 now requires that construction workers must be protected by Inhabited Building Distances (IBD)
risk is commensurate with that in occupied office buildings on Defence sites

4. Complexity
Example: Construction of new ECB at 30 m from the front of an ECB with 45,000 kg HD 1.1 licence
Blast overpressure from 45,000 kg HD 1.1 incident at 790m IBD: 3.6 kPa
Some temporary hearing loss
1 ‘lethal fragment’ per 56 sqm
Blast overpressure from 45,000 kg HD 1.1 incident at 30m IMD: 793 kPa
Unsurvivable
Must reduce NEQ, but where does it go?
IMD
IBD

5. Complexity Why does construction adversely affect EO depot operations?
construction of new EO buildings is at IMD or PBD → much less than IBD!
must demonstrate that risk to construction and EO workers is reduced SFARP
if EO holdings and Quantity-Distances cannot be reduced to provide protection, then alternative risk treatment strategies are required to reduce risk SFARP.
unique Safety Cases / Operating Plans for each affected depot

6. EO Depot Construction Activities
Depots not undergoing construction
Jennings
Wholesale storage
‘shock absorber’ for Myambat
Direct Deliveries for large scale activities
Container storage for imports
Williamtown
Minor retail storage for RAAF Williamtown
Limited capacity
Singleton
Small magazine-style depot
Albatross
Minor retail storage for HMAS Albatross

7. EO Depot Construction Activities
EO Logistics Reform Program (EOLRP)
Complete as at Nov 2019
Fort Direction
Cerberus
Twofold Bay
Underway as at Nov 2019
Amberley (handover late 2019)
Townsville (handover late 2019)
Edinburgh
Darwin
Mangalore
Stirling
Myambat
Yet to Commence
Point Wilson

8. EO Depot Construction Activities
EO Logistics Reform Program
19 Earth Covered Buildings
5 Ammunition Process Facilities
9 Administration Buildings
10 Light Frangible Buildings
5 Non-Explosive Stores
Plus 3 traverses and 5 other facilities
commenced January 2018
expected completion FY20/21
Other significant construction projects:
Orchard Hills Asbestos Remediation (underway)
Darwin ECB Membrane Repairs (underway)
Stirling Wharf Redevelopment and Extension (underway)
Pt Wilson Wharf Redevelopment (about to commence)
Roadworks and utilities at multiple sites

9. Risk Treatment Strategies
EO handling restrictions in specified buildings during construction hours
Amended working hours (fatigue must be considered)
Removal or disposal of ‘higher risk’ EO (life-expired, safety restrictions)
Use of direct deliveries from Jennings & Myambat to support major activities
Small Quantity Facility licensing of EO workshops
Access and traffic controls
Assign specific roles to buildings
Daily NEQ printouts at all depots
Licensing Temporary holding areas for EO
Prioritisation of certain projects to provide storage capacity for EO imports

10. EO Depot Myambat Construction proposed in three separate phases
Guardhouse
Light Frangible Buildings
Phase 3:
Multiple Earth Covered Buildings
Phase 1/2 originally planned to be complete prior to commencement of Phase 3
Phase 1/2 not yet handed over, Phase 3 commenced in April
Fewer storage alternatives
Increased vehicle traffic and concurrent activity

11. EO Depot Myambat Current Depot Operating Plan
ARW and AIF workshops closed due to traffic flow and SAA LFB construction
Operate APB workshop on afternoon/night shift
EO restowed internally due to demolition of Building 23
1.1 EO and EO restowed internally to reduce risk to Stage 3 construction
Access prohibited to most ECBs during construction hours
Disposals performed after construction hours
Majority of Stage 1 & 2 construction is complete, but unavailable awaiting handover
Lightning Protection System to be upgraded after completion of EOLRP

12. EO Depot Myambat

13. EO Depot Stirling Construction HMAS Stirling Upgrade Project
Non-Ex Store (practically complete)
Administration Building
Ammunition Process Facility
Wharf Remediation & Extension
HMAS Stirling Upgrade Project
Security systems
Utilities
Roadworks

14. EO Depot Stirling

15. EO Depot Stirling Current Depot Operating Plan
Temporary workshop in operation during APF construction
Completion of NE Store enables:
significant increase in NEQ capacity
removal of access prohibitions on most ESHs
transporting maritime EO to Stirling to reduce risk in east coast depots
Limit road transport for EO that may to deteriorate from road transport exposure
Construction is suspended during major shipping activities and wholesale deliveries
Now approaching its fourth year of operating under construction conditions

16. EO Depot Amberley

17. EO Depot Darwin

18. EO Depot Orchard Hills

19. EO Depot Point Wilson

20. Lessons Learned (2017)
Early consultation with ADF customers and construction contractors essential
Uncertainty in construction site boundaries during planning
Limited understanding by each party of risks posed by each other
Differences in terminology and lingo
Must understand depot operating requirements
‘Whole of depot’ perspective required vs ‘licensing by building’
Security requirements are open to different interpretations
Must be able to demonstrate reduced risk
Numerous other non-EO WHS risks to manage

21. Lessons Learned Safety cases involve some level of QD non-compliance
Seek to limit consequences of incidents
Blast overpressure thresholds
Considering building orientation, EO design features
ADF unit behaviours dictated by operating requirements
Historical artefacts and UXO discoveries
Increased requirement for parking of EO laden vehicles
Enables on-time delivery to / collection from ADF during periods where access to EO buildings is prohibited
Increased risk of ELL breaches – forward planning required
Licence limits reduced
Stockholdings increasing due to large EO importations
COMSARM has no predictive NEQ management
Accelerate EO disposals where possible
Completion of early stage construction is essential to safely support later stages

22. Lessons Learned Managing unexpected external challenges
Isolating items with ‘no handling’ restrictions
Management of life expiry
Large EO importations
Changes in HCC of current EO
Changes to construction scope and schedule
Changes to ADF operating requirements
Safety Case amendments and stakeholder engagement
Less flexibility in depot operations eg, for short notice demands
Reduced access to ESHs and EO to implement changes to demands

23. Notable Challenges Reliance on administrative controls Incidents:
increases operating complexity
increases the risk of human error => INCIDENTS!
Incidents:
Licensing errors due to administrative workload
Licence breaches due to slimmer ‘NEQ margins’ and split shifts
Controlled / Prohibited Article breaches
Less manoeuvring space inside ESHs due to stock increases – handling errors
Refuelling of heavy construction equipment in ESAs
Utilities works are ‘moving’ work sites
Issues with access control and contractor management
High volume of Work Permits and monitoring effort

24. Notable Challenges - responses
Daily and Weekly meetings between Depot Management and Construction Site Managers to communicate current and planned activities for both parties
Additional external assurance activities to confirm Safety Case implementation
Improved supervision and planning
Improved tools for proactively managing NEQ
Sharing lessons learned between depots and stakeholders
Priority disposal of time-expired EO by Thales and Defence
High volume of EO deliveries while construction restrictions continue…

25. Service Delivery to Defence
“During this difficult period there was an extremely positive ANAO result, minimal if any complaints from end users and the Contract Authority was very pleased with the level of support provided by Thales – not only to the construction effort but also on maintaining service delivery and safety standards at the same time.”
Michael Walker
Director Logistics - Explosive Ordnance

26. Future Construction Programs
Completion of current projects, plus…
Townsville APF Refurbishment
Myambat Lightning Protection Upgrades
Orchard Hills Redevelopment – commencing FY21/22
APF, Administration, ECBs
GW Maintenance Facility
More ECBs in Darwin, Mangalore, Edinburgh, Twofold Bay

27. Summary
Construction will deliver a far more robust EO storage and distribution network
Meet ADF requirements for EO while maintaining safe depot operations
Keep construction teams, Thales staff and our neighbours safe
Support Defence to complete EOLRP on time and on budget
Work together to strike the right balance of objectives

28. Questions?