The performance of the works
82 Lucas commenced work in the performance of the Contract in April 2011.
83 Initially, Lucas had proposed establishing its Work Camp at about the midway point of the access road and working with two work fronts: one moving to the north-east and the other moving to the south-west. However, when mobilising, Lucas changed its approach as it realised that until the road had been at least partially constructed, it could not move equipment to the site of the proposed Main Camp. It established its Work Camp instead at Ponton Creek (about one-third of the way along the proposed road alignment) and worked with a single work front, that is, moving to the north-east.
84 One of Lucas' first activities was carrying out repairs to two crossings over Ponton Creek on the Kurnalpi-Pinjin road. The repairs were necessary in order that it could obtain access to the site (the crossings not being within the footprint of its Scope of Work). The repairs were carried out between 19 and 24 April 2011. They gave rise to one of Lucas' claims in the proceedings.
85 Apart from the Ponton Creek crossings repair works, all of Lucas' activities until 3 May 2011 were directed towards mobilisation. Those mobilisation activities also continued for some time after 3 May 2011.
86 Between 3 May 2011 and 10 May 2011, Lucas' work activity on the road was, with one presently immaterial exception, directed to clearing and grubbing part of the road alignment. On 11 May 2011, Lucas commenced working on the sub-grade. Although Lucas carried out a few hours of work on the sub-base on 16 May 2011, it did not commence work in earnest on the sub-base until 29 May 2011.
87 On 16 May 2011, issues arose concerning the compliance with the technical specification of the material which Lucas intended to use, or had used, for the sub-base.
88 On 16 May 2011, Knight Piésold issued a Particle Size Distribution (PSD) report which showed that the PSD curve for material excavated from cut areas (including V-drains) from Chainages 174 to 179 did not comply with the specification for sub-base material contained in cl 8.6.2 in the Scope of Work. On the same day, Mr Hentschke sent Technical Query (TQ#16) to Lycopodium. He attached a copy of the Knight Piésold PSD report and said:
Tender Schedule 4, items 9-15, indicated that approximately 240,000 m3 of sub-base material (75%) would be available "from cut areas (including v-drains) along right of way, haul from 0km up to and including 2km to fill the areas along right of way, moisture condition & compact as sub-base", and the balance of sub-base material, approximately 80,000 m3 would come from borrow pits en route.
From initial testing carried out by KP over the first 5kms of v drain material, the PSD Curve for this material does not meet the specified grading for sub-base, namely the material is too fine.
…
We require advice from Lycopodium as to whether or not, the out of grade sub-base material, will be approved for use, provided the specified compaction can be achieved.
89 Knight Piésold responded to TQ#16 on or about 24 May 2011. It did so verbally to Lucas personnel and then confirmed the position in a report to Lycopodium on the same day. Knight Piésold noted that it was expected that a significant portion of the material extracted from the V-drains along the road alignment would not require "modification" before being used for the sub-base. However, it remarked that, in those areas in which the V-drains contained lesser quality material, that material would be combined with more suitable material from other locations as and when required. In relation to Chainages 174 to 179 (in which the material from the V-drains had been found to be non-compliant), Knight Piésold recommended that some trial sections be established using different blends of material (some from the V-drains and some from borrow pits). The Knight Piésold letter said:
The results from the trial areas will give an indication of what will be required to achieve a sub-base material, it will also give an indication of the amount of material that will be required from each borrow to achieve this.
90 On 24 May 2011, Mr McGregor from Lycopodium provided Mr Hentschke with a copy of Knight Piésold's recommendation, describing it as the response to TQ#16.
91 Mr Hentschke said, and I accept, that he understood when he received this letter that it indicated that Lycopodium required some mixing of the material intended for the formation of the sub-base if the material excavated from the cut areas and V-drains was non-compliant with the Technical Specifications, and that that was so even if it involved increased costs.
92 On 30 May 2011, Mr Hentschke asked Mr Haworth at Lycopodium to issue a site instruction for "the blending work required on subbase construction between Chainages 178-175".
93 Mr McGregor from Lycopodium responded on 24 June 2011 with Site Instruction LE-005 (SI-LE-005). Mr McGregor's covering email said:
Please find attached the site instruction that relates to the blending of the sub-base material with the borrow pit material.
Could you please sign and return on receipt.
94 Mr Hentschke did sign and return SI-LE-005 to Lycopodium on 25 June 2011. I indicate now that I do not attach any significance to the evidence of Mr Hentschke that in hindsight he should not have signed the document.
95 Both the terms of SI-LE-005 and Mr Hentschke's signature assumed some significance in relation to Lucas' claim. Accordingly, I set out the terms of SI-LE-005. It is evident that it made use of a template form for site instructions. The italicised passages indicate those parts of the form which were added to the template by either Mr McGregor or Mr Hentschke.
To: Lucas Earthmovers (Contractor)
This instruction is issued under category (a) below.
(a) Attend to the following matters in relation to your Contract/Works
(the completion date and contract price are not altered as a result of this instruction)
(b) Submit a quotation by 24/6/11 for carrying out the following work
(c) Carry out the following work on a time and material basis and submit your claim
(d) Carry out the following work at your Contract Schedule of Rates
(e) Carry out the following work at your quoted price; S.I. No. _____
FULL DESCRIPTION OF WORK TO BE PERFORMED
Recommendation to mix materials from borrow pit with in situ material from the drains.
Lucas Earthmovers are hereby requested to mix materials from the nominated borrow pits and the in situ material excavated from the drainage channels to construct the sub-base layer as per the attached Knight Piesold site instruction.
Please note the following:
1. The operation of mixing and blending is at the Contractors expense as per the attached extract from the Site Access Road scope of works.
2. In the Contract schedule of remuneration, in the lump sum section, there are nominated line items 10-15 that allows for 80,250m3 of imported material from borrow pits to be used in the construction of the sub-base layer.
Note 1 The site instruction number is to be quoted on all related time, material and plant hire sheets, and on all invoices. Only one claim can be made under each site instruction number.
Note 2 For time and material work (category c) the Contractor must have timesheets signed daily by Lycopodium Minerals and is required to submit weekly summaries for individual SIs for Lycopodium Mineral's approval.
Note 3 Total final costs must be submitted within 7 days of completion of the work included herein.
Signed By: [Mr Hentschke] Signed By: [Mr McGregor]
for and on behalf of: [Lucas] for and on behalf of [Lycopodium]
Title: Project Manager Title: Project Engineer
Date: 25/6/11 Date: 22/6/11
(The Emphasis by underlining and bolding of subpara (a) were added to the template form)
Mr Hentschke added in his handwriting "VO#5" at the top of SI-LE-005 but it is not clear whether he did that before sending it back to Mr McGregor.
96 As can be seen, by SI-LE-005 Mr McGregor requested Lucas to mix materials from the nominated borrow pits with the material excavated from the V-drains to construct the sub-base layer, in the manner suggested by Knight Piésold on 24 May 2011. He also emphasised, by the underlining of subpara (a) and by the first note, that the costs of mixing and blending the material were to be borne by Lucas. It is apparent that Mr McGregor considered that this was appropriate given that the Contract Schedule of Remuneration contemplated that some 80,250 m3 of imported material from borrow pits would be used in the construction of the sub-base layer.
97 In his evidence, Mr Hentschke said that the content of subpara (b) of the instruction had created some doubt in his mind as to whether the instruction was of the subpara (a) type. However, I consider that, read as a whole, it is apparent that SI-LE-005 was issued under subpara (a), and that Mr McGregor's underlining and bolding of that subparagraph made that plain.
98 AGA attached significance to the acceptance by Lucas, indicated by Mr Hentschke's signature, that the mixing and blending operation required by SI-LE-005 was to be carried out at Lucas' expense.
99 The issues arising from the circumstance that the V-drain material did not comply with the Technical Specification for sub-base material in cl 8.6.2 of the Scope of Work continued after 25 June 2011, resulting in Lycopodium issuing further site instructions as well as giving verbal directions. Ultimately, the material in the V-drains along about 80% of the length of the access road did not meet the specification. In addition, some of the material sourced from borrow pits for the wearing course proved to be unsuitable.
100 On 30 August 2011, Lycopodium issued SI-LE-016 concerning the road between Chainages 160 and 164.5. This site instruction stated (relevantly):
Test results for material sourced from the borrow pit at Chainage 163 [have] failed the material specification for both wearing course and sub-base grading as its clay content exceeds the maximum limits.
This material has been placed as a 225mm layer along the alignment between Chainages 160.0 and 164.5.
The Contractor is hereby instructed to scarify the top of the wearing course between these chainages and place 75mm of material, sourced from the borrow pits at Chainage 170 or 145, as a capping layer.
Material from the borrow pit at Chainage 170 shall be exhausted prior to utilising material from the borrow pit at Chainage 145.
101 Mr Matthews said, and I accept, that Lucas had laid the 225 mm of wearing course because of a verbal instruction from Lycopodium personnel. That instruction had been given when it was found that the wearing course initially laid was too slippery, having a high clay content. It is not clear when Lucas laid the additional wearing course.
102 Lucas signed and returned SI-LE-016 on 31 August 2011.
103 On 9 September 2011, Lycopodium issued two Site Instructions, SI-LE-020 and SI-LE-021, both dated 8 September 2011. SI-LE-020 provided (relevantly):
Wearing Course Material Chainage 152.0 to 160.0
Due to a shortage of suitable wearing course material, the Contractor is hereby instructed to place material won from Borrow Pit 159 as a 225mm layer between Chainage 152+000 and 160+000. This is to consist of a 150mm layer above the General Fill plus a 75mm depth of "tyning" into the layer below.
This material has a higher plasticity and therefore it is to be capped with 125mm of material from Borrow Pit 146, consisting of a 75mm layer above the 'base wearing course' plus a 50mm depth of "tyning" into the layer below. This material is to suitably compacted to wearing course specification.
104 SI-LE-021 provided (relevantly):
Wearing Course Material Chainage 133.0 to 152.0
Material from Borrow Pit at Chainage 140 is likely to return high clay content and will therefore not be suitable to be used as wearing course layer.
Therefore the Contractor is hereby instructed to place this material as a 225mm layer consisting of [a] 150mm layer above the General Fill plus a 75mm depth of "tyning" into the layer below. This layer is to be capped with 125mm of material from Borrow Pit at Chainage 146, consisting of a 75mm layer above the 'base wearing course' plus a 50mm depth of "tyning" into the layer below. This material is to be suitably compacted to wearing course specification.
Following a review of material quantities, and taking into account current site activities, this Instruction is relevant to the chainages listed below and the material from Borrow Pit 140 and 146 is be utilised in the following manner.
• Ch. 151 to 152 150mm + 75mm ("tyned") material from Borrow Pit 140, capped with 75mm (+ 50mm tyned") material from Borrow Pit 146,
• Ch. 146 to 147 150mm + 75mm ("tyned") material from Borrow Pit 140, capped with 75mm + 50mm ("tyned") material from Borrow Pit 146
• Ch. 133 to 145 150mm + 75mm ("tyned") material from Borrow Pit 140, capped with 75mm + 50mm ("tyned") material from Borrow Pit 146
105 As can be seen, each of SI-LE-16, SI-LE-20 and SI -LE-21 required Lucas to adopt a method of road construction which differed from that required by the Contract. Lucas did not sign either SI-LE-20 or SI-LE-21. It did, however, comply with the instructions contained in each of these site instructions.
106 Each of the site instructions issued on 30 August and 8 September 2011 indicated that it was under category (a) in the template for site instructions, and stated that it did not have the effect of altering the contract price or completion date.
107 On 16 September 2011, Lucas introduced a night shift for the haulage of material from borrow pits to the location on the road alignment at which it was to be spread and compacted. One of Lucas' claims in the proceedings concerned the additional cost of performing work at night.
108 In [47] of the ASC, Lucas alleges that Mr Stuchbury from Lycopodium issued a verbal direction on 11 October 2011 and/or 27 October 2011 that:
(a) in respect of the 70 km of access road then constructed by Lucas between Chainages 106 and 178, it add a further 75 mm layer of sub-base material from borrow pits to the existing 150 mm thick sub-base layer formed from the material excavated from cut areas (including V-drains) along the right of way. This would increase the thickness of the sub-base layer from 150 mm to 225 mm, so that the road would have a profile depicted as follows:
(b) in respect of the balance of the access road not then constructed, it source material from borrow pits to construct a single 250 mm thick wearing course layer where the material excavated from cut areas (including the V-drains) along the right of way was not suitable for use in constructing the sub-base.
109 However, Lucas did not lead evidence to support the allegation that a direction to this effect had been given on 11 October 2011 although there was evidence of a non-specific kind about verbal instructions given by Lycopodium personnel.
110 Nevertheless, by October 2011, it was apparent that the material in the V-drains along the sections of the road still to be constructed which would be suitable for use as the sub-base would be much less than the amounts indicated in Sch 4 to Sch A2 in the Contract (which showed the derivation of the lump sum price for the road construction activity). This led to discussions between the parties. Eventually, agreement was reached that the method of road construction should be modified.
111 The construction methodology was discussed at a meeting on 27 October 2011 between Ben Lucas, Mr Matthews and Mr Doyle from Lucas and Messrs Stuchbury, Ruggiero and Walker from Lycopodium. Three options were identified:
(a) Option 1 - In those areas in which material from the right of way including the V-drains was suitable as sub-base material without blending, the pavement design was to remain as a 150 mm sub-base and 150 mm wearing course as per the technical specification in the Contract;
(b) Option 2 - In those areas in which the material from the right of way including the V-drains was not suitable as sub-base material without blending, the pavement design would be altered to consist of a 250 mm wearing course only (ie, no sub-base would be constructed); and
(c) Option 3 - In those partially completed areas at which the level of material was already up to the 150 mm sub-base level, testing would be conducted and appropriate directions would be issued by Lycopodium on a case-by-case basis.
112 In a second meeting on 2 November 2011, it was agreed that Options 1 and 2 would be applied between Chainages -9.5 to 0, Chainages 0 to 60 and Chainages 190 to 214. A decision as to the areas to which Option 3 would be applied was deferred pending the receipt of test information.
113 Subsequently, Mr Matthews (Lucas) and Mr Stuchbury (Lycopodium) conferred and reached agreement as to the locations at which the different methodologies were to be applied.
114 In effect, in relation to those sections of the road still to be constructed in which the material in the V-drains was not suitable as sub-base without blending, Lucas was to place a single 250 mm layer of wearing course using material obtained from borrow pits, instead of the two separate layers of 150 mm sub-base and 150 mm wearing course.
115 On 8 December 2011, Lucas submitted a request for a variation pursuant to cl 29.2 of the Contract in respect of Site Instructions LE-016, LE-020 and LE-021 on the basis that its compliance with those instructions had involved it hauling material for distances exceeding those contained in Sch 4 to Sch 2 in the Contract. It claimed a total amount of $41,418 (exclusive of GST). None of this amount comprised time-related costs.
116 Another meeting occurred between Ben and David Lucas, and Messrs Matthews, Maiolo and Doyle from Lucas with Mr Massoudi (AGA) and Messrs Stuchbury, Walker, George and Beveridge (Lycopodium) on 19 December 2011. At this meeting, the Lucas representatives presented a written request for a variation order (VO#42) reflecting the difference between the volumes of in situ and borrow pit material contained in Sch 4 to Sch 2 in the Contract and the actual and anticipated volume needed to construct the road, in addition to amounts for the increased haulage distances involved. It claimed payment of these amounts at rates said to have been specified in Items 40-43 of the Schedule of Rates attached to its Tender of 31 January 2011, but which appear to be those specified in Items 9-38 in that Schedule. In addition, Lucas claimed $4,297,671.93 (plus GST) by way of Preliminaries. Lucas withdrew this request during the meeting on 19 December as part of the discussions directed to the resolution of the issues.
117 In a letter bearing the date 22 December 2011 addressed to Mr Stuchbury, Mr Matthews recorded the agreement reached at this meeting as (relevantly):
1. …
2. All in situ materials from side drains as per line items 40 & 41 will be paid as a lump sum. These items will be paid at a pro rata rate against the total km of these items of work that have been completed at the date of the claim or forecast for the estimated claim.
3. In areas where the in situ sub base material from side drains does not meet specification payment will be made for an additional 75mm of sub base imported from borrow pits as required.
4. Extra payment for material will be made for the additional volumes to sheet areas that were considered dangerous in wet conditions (approximately Chainage 166 to 160 at nominally 150mm in lieu of 75mm).
5. From Chainage 60 to Chainage -9.5 an assessment of the road alignment will be made by [Knight Piésold] and either 150mm or 250mm of wearing course will be installed from borrow pits. In the case where 150mm of wearing course is installed there will be no requirement for extra material. In the instance of 250mm of material laid. Lucas will be paid for only 75mm of imported material for savings made installing in one layer.
6. The above methodology as mentioned in point 5 [can] be ignored if Lucas continue with the 2 layer construction of 75mm imported material (paid against line item 42 of the progress claim schedules) mixed into the non conforming in situ material and capped with 150mm of wearing course.
7. Payment will be made in the next progress claim for all insitu side drain material that was deducted from previous claims.
118 It was not suggested that Mr Matthews' letter was inaccurate in its recording of the matters agreed. In particular, when Lycopodium responded (at the prompting of Lucas) on 16 July 2012 to the Lucas letter of 22 December, it did not suggest that Mr Matthews had misstated the position.
119 It seemed to be common ground that the road-making after 19 December 2011 was carried out in accordance with the revised methodology.
120 By Contract Variations 8 and 9 (CV-8 and CV-9) issued on 8 March and 17 April 2012 respectively, Lycopodium allowed Lucas variation claims of $1,580,272.24 and $49,605.83 respectively. This was a total of $1,629,878.07.
121 The substantive parts of CV-8 and 9 were as follows:
CV-8
THE CONTRACT SHALL BE VARIED TO THE EXTENT SET OUT BELOW:
Item Description Value
1 Adjustments to Remuneration Schedule 4 Items 10.0 to 15.0. $808,386.12
Win from borrow, load, haul from 0km up to and including 6km, place, spread, moisture condition and compact as sub base
2 New items added to Remuneration Schedule 4 Item 15A to 15H. $836,955.04
Win from borrow, load, haul from 6km up to and including 14km, place, spread, moisture condition and compact as sub base
3 Adjustments to Remuneration Schedule 4 Items 16 to 28.0. $(527,921.01)
Win from borrow, load, haul from 0km up to and including 13km, place, spread, moisture condition and compact as wearing course
4 New items added to Remuneration Schedule 4 Item 28A to 28G. $340,436.76
Win from borrow, load, haul from 13km up to and including 20km, place, spread, moisture condition and compact as wearing course
5 Adjustments to Remuneration Schedule 4 Items 51 to 60.0. $122,415.33
Win from borrow, load, haul from 0km up to and including 10km, place, spread, moisture condition and compact as wearing course
Refer to the attached spreadsheet for specific details on each line item
TOTAL: $1,580,272.24
Original Contract Price
Previous Contract Variation (No.001 to 006 (incl))
Amount of this Variation
$35,016,992.60
$168,448.75
$1,580,272.24
Varied Contract Price $36,765,713.59