Projects

Projects

Projects

Moonee Valley City Council
Location: 
Melbourne VIC
Australia
Consultant: 
Pitt & Sherry
Date: 
Jan 2020 to Jul 2020

Afton Street Footbridge Upgrade

Description: 
The original design and construction of the Afton Street Footbridge was carried out in the 80s, comprising of a cable-stayed main span of 70m and back span of 25m. The tower and main girders are steel and the existing decking, joists and handrails were timber.
 
The project, jointly funded by Moonee Valley City Council and Maribyrnong City Council, facilitated the upgrade of the footbrigde to include new steel beams, barriers and handrails, a new FRP deck, lighting and a comprehensive waterblast and coating.
 
The bridge is much loved by the local community, providing a vital link across the Maribyrnong River for pedestrians, cyclists, commuters and families. 
Key Aspects: 
Freyssinet, as principal contractor, undertook the project management along with the waterblasting and coating works, deck and handrail removal, deck installation and condition assessments. Freyssinet also managed the lighting upgrade, asphalting and installation of the new steel joists, barriers and handrails.
Access to the bridge was carefully planned to ensure public river traffic was never impacted. The access systems comprised of both scaffold and barge arrangements providing safe and efficient working platforms.
The existing timber handrails and decking were recycled, ensuring commitment to our company's waste minimisation strategy.
-
Location: 
- SA
Australia
Date: 
Jul 2019 to Jul 2020

Wind Turbine Foundation Repair

Description: 

Freyssinet were engaged to complete repair works to wind turbine foundations at a windfarm in South Australia.

Movement at the base of the wind turbines had been detected and the source of the movement was examined. Upon investigation it was determined that water ingress between the foundation and turbine interface had been exacerbating the movement and creating voids.

Freyssinet’s works involved stabilisation of the turbines through repairs to the foundations and prevention of future water ingress to the foundation-turbine interface.  

Key Aspects: 
Excavation of turbine foundation and removal of existing concrete collar
Coring of 1.5m holes into foundation and injection of epoxy resin
Epoxy crack injection of radial cracks in foundation
Concrete repairs to defective concrete caused by turbine movement
Coating of corroded steel turbine sections
Installation of structural plinth around turbine circumference to assist in bracing against further movement
Installation of waterproofing membrane between foundation and turbine
NSW Government - Transport for NSW
Location: 
Dubbo NSW
Australia
Consultant: 
BECA
Date: 
Dec 2018 to May 2020

LH Ford Bridge Rehabilitation, Dubbo, NSW

Description: 
The LH Ford Bridge is a 613m long reinforced bridge and is the only current high-level bridge
in Dubbo, NSW that remained opened during a 1:100-year ARI flood event. Completed in
1969, the structure has experienced a high level of degradation in 50 years of service life
including 300mm sag of the drop-in span and significant vertical deflection due to live loads.
The project required the construction of 2 new piers in the Macquarie River to support the
main span underneath the halving joints. 16 units of bearings were installed to connect the
new piers to the existing concrete structure with fabricated steel shear keys providing lateral
load capacity. External post tensioning has been installed in the land spans and the drop-in
span to account for the modified bridge support locations and strengthen the bridge to allow
for the increased traffic loads.
Key Aspects: 
Freyssinet Australia was selected by TfNSW as the head contractor for the project. All quality, safety and environmental aspects of the project were managed by Freyssinet site team to conform to TfNSW requirements. Major subcontractors were engaged for piling operations over water (including barges) and erection of a suspended scaffold requiring detour of wide vehicles. 6 units of reinforced concrete piles approx. 21m below water level were installed and capped with precast concrete skirts. Reinforced concrete piers of 12m high were constructed using a climbing formwork/falsework system supported from cast-in elements of the first pour and braced off the piles. Temporary pier bracing were installed and bridge jacking was undertaken during a night road closure to correct the load. Live traffic was permitted on the bridge during the day for bearing installation works. External post tensioning tendons were installed using a total of 600m individually stressed stay cable strands enclosed in HDPE ducts and waxed anchorage boxes. 300 holes were drilled through the concrete webs and girders without damage to the existing steel reinforcement.
BHP - Iron Ore
Location: 
Newman WA
Australia
Consultant: 
AECOM - Freyssinet
Date: 
Dec 2019 to Apr 2020

Marillana Bridge Bearing Replacement

Description: 
The project came with some unique issues and Freyssinet was contracted by BHP to initially
design access platforms around the piers that will be utilized as working platforms during
construction and as permanent platforms for asset inspections by BHP. Then, to design a
method for replacing the bearings and execution of the works. The existing bearings
prematurely needed replacement due to an increase in loading on the bridge and to comply
with new design standards. Freyssinet approached AECOM as consulting engineers to
analyze the structure and calculate the bearing loads. FPC designed and supplied the new
bearings with the calculations provided by AECOM. FITS, AECOM and Freyssinet worked
together to design a method for jacking the structure within the constraints of the client and
the geometry of the structure. With the increased axle loadings, the bearings required
additional fixings to resist the forces and extra bolted connections had to be created between
the bearings and bridge girders.
Key Aspects: 
Freyssinet scope of works included design, supply and installation of new access platforms and replacement of spherical bearings.
Freyssinet designed, delivered and executed the works within the time specified by BHP.
The timeline only allowed 7 days shutdown to jack the bridge by 30mm, remove the existing bearings, demolish the grout pads, replace the 32 new bearings at 7 piers and 2 abutments, recast grout pads under new bearings, cure grout and lower the bridge back to its position.
The bulk of the installation works was done outside the shutdown period. Freyssinet handed the completed bridge back to BHP 24 hours early.
BHP Billiton Iron Ore Pty Limited
Location: 
Perth WA
Australia
Date: 
May 2019 to Apr 2020

Low Level Bridge Replacement Program

Description: 

The Low Level Bridge Replacement Program consists of the replacement of seven (7) existing steel bridges on the BHP Newman Main Rail with new concrete culvert structures to ensure sustainable, safe operation of the railway and to consider future haul capacity expansion. 

Due to the clients operating requirements, each bridge has to be replaced within a twelve (12) hour shutdown window. Each new concrete bridge is constructed offline approximately 10 meters adjacent to the existing bridge. 

Freyssinet is engaged to lift and slide the existing bridge out of the rail alignment, and lift, slide and lower the new bridge into final position in the rail alignment with tight installation tolerances within a two (2) hour duration in order that the subsequent rail and finishing works could be completed on time. 

Key Aspects: 
The new concrete bridge culverts included 1 x 6 span, 1 x 5 span bridge and 5 x 4 span bridges, the largest weighing approx. 600T. Bridges are lifted with locking collar hydraulic jacks and slid using rollers and strand jacks.
Additional Freyssinet scope of works include design, fabrication, supply and installation of temporary works for both types of structures, and temporary post tensioning with Freyssibars.
The first bridge replacement (6 span) was completed on the 3rd of July 2019, with the 2nd one week later. The remaining bridges are scheduled within shutdowns over the next 6 months.
Port of Melbourne Operations Pty Ltd
Location: 
Melbourne VIC
Australia
Consultant: 
Freyssinet Australia Pty Ltd
Date: 
Sep 2019 to Mar 2020

D&C of ICCP for Webb Dock East

Description: 

As part of the Port of Melbourne’s ALWC (Accelerated Low Water Corrosion) protection program, Freyssinet were engaged to design, install, commission and monitor an ICCP (Impressed Current Cathodic Protection) system to protect the submerged sheet piles at Webb Dock East Berth 1.

This berth is used daily by ships transporting goods between Victoria and Tasmania and normal shipping operations were maintained throughout the works. 

Key Aspects: 
A bespoke access system was used to work within the narrow space between the wharf face and the berthed vessels.
Diving works included underwater welding and installation of all submerged ICCP components.
Additional protection to anodes subject to thrust was designed to ensure long term operation under harsh conditions.
The installation included sourcing the electrical supply from the adjacent wharf approximately 230m away. The current is then distributed from Transformer Rectifier Units (TRU) along the wharf within a PVC cable tray system to reduce the risk of corrosion and provide longevity.
Melbourne Central
Location: 
Melbourne VIC
Australia
Consultant: 
AECOM
Date: 
Jan 2020 to Feb 2020

Melbourne Central Column Truncation

Description: 
A new slab was casted in between two existing levels where there was enough headroom
to do so. This added a whole new level to the building overall. In the middle of this new slab
was a steel column that could be removed in the lower level. This column's only purpose was
to keep the glass roof supported.
Key Aspects: 
Freyssinet was asked to design a suitable jacking solution to safely carry the load of the entire column and lattice glass roof structure. Once the temporary jacking solution was designed, Freyssinet had to install and carefully jack the entire system, releasing the bottom hinge bearing. The bottom bearing was carefully cut from the bottom column section as it would be reused on the new slab. Furthermore the bottom column section was truncated leaving the roof and upper column section resting on the Freyssinet jacking system. The existing bearing was reattached to the top column section, grouted below and the entire assembly lowered.
Port of Melbourne Operations
Location: 
Melbourne VIC
Australia
Consultant: 
ARUP & AW Maritime
Date: 
Nov 2018 to Jan 2020

Appleton Dock Wharf, Pavement and Fire Rehabilitation

Description: 
Appleton Dock was constructed in the 1950s and consists of pre-cast concrete beam-slabs supported on timber piles and a cast in situ concrete relieving platform with an integral concrete sheet pile wall supported on precast concrete piles. The deck is overlayed with asphalt to provide a trafficable surface and the old sheds were demolished and removed, leaving a concrete floor. The terminals are currently used to handle break-bulk cargoes, dry bulk and containers.
 
Condition inspections and surveys of the wharf structure and terminal pavements identified the need for rehabilitation works to maintain acceptable levels of service. Freyssinet's works included rehabilitation of Appleton Dock Berths B, C, D & E above and below the wharf, including the installation of a new fire main, redundancy of the existing fire main, pavement repairs, timber pile repairs and concrete repair. 
Key Aspects: 
Freyssinet as Principal Contractor self-performed project management, delamination testing, concrete repair and encasement grouting works.
Other specialist activities included fire main removal and installation, asbestos removal, concrete demolition, sawcutting, concrete pouring, asphalting, diving, reinforcement welding and crane lifts.
Freyssinet undertook complex program optimisation to work safely and efficiently around daily live shipping and stevedoring activities.
The State of Victoria, through the Level Crossing Removal Authority
Location: 
Melbourne VIC
Australia
Consultant: 
Level Crossing Removal Project
Date: 
Aug 2019 to Dec 2019

Southern Program Alliance - Level Crossing Removal Project - Carrum Bridge

Description: 
The project is part of the Level Crossing Removal Program undertaken in Melbourne, Victoria.
It consists of two parallel railway bridges which are about 500 meters long each. The bridge
top structures are fully precast on both piers and spans. Piers are made in two parts, a
column and a crosshead, which are about 6 meters high in average. Piers are provided with 8
PT bars each, either diameter 58 mm or 75 mm. Span are made of 32 meters long U-trough
provided with 6 no. of 12C15 tendons. All precast elements were installed by cranage. Global
duration of the project was approximately 3 months.
Key Aspects: 
Freyssinet scope is as follow: - Supervision of installation of PT bars in the pile caps - Installation of precast piers - Dry packing and joint flooding between precast pier elements - Full PT operation on bars (installation, stressing and grouting) - Full PT operation on tendons in U-Trough (threading, stressing and grouting)
NSW Government - Transport for NSW
Location: 
Grafton NSW
Australia
Consultant: 
Aurecon
Date: 
Oct 2017 to Dec 2019

New Grafton Bridge - Additional Crossing of the Clarence River

Description: 
Grafton Bridge is located across the Clarence River in Grafton, New South Wales. After an
inspection in October 2008 it was found out that the bridge cannot withstand the increasing
volume of traffic. To improve traffic efficiency between existing Grafton and South Grafton,
Roads and Maritime Services (RMS) decided to deliver an additional crossing over Clarence
River. The parallel New Grafton Bridge located 70 meters east of the first bridge is composed
of two lanes and has been designed to increase up to four lanes depending on the traffic
demands. The new bridge is 525 meters long and is composed of 2 super-tee approach
spans, 2 end spans (box girder) and 5 mid-spans (box girder).
Key Aspects: 
Freyssinet involvement on this project includes erection of 176 nos. precast segments involving specialist and post-tensioning equipments, supply and installation of cantilever post-tensioning works and supply and installation of temporary and permanent bridge bearings and expansion joints. The scope of work also included supply of specialist equipment designed and fabricated for the project: lifting beams, pier bracket, stitch form and stitch beams, stressing platforms, jack handling frame, jacks for end spans erection on falsework, epoxy and o-rings and temporary PT and related hydraulic jacks and pumps. The bridge was opened to traffic on 12th of December, 2019.
Aqua Metro Services Pty Ltd
Location: 
Carrum Downs VIC
Australia
Date: 
Oct 2018 to May 2019

Sedimentation Tank Refurbishment, ETP Carrum Downs

Description: 

Secondary sedimentation tanks 17 & 18 at the Eastern Treatment Plant had experienced significant cement loss to the original uncoated concrete tank walls and all joint sealant had become defective.

Freyssinet identified the potential for asbestos in the original joint sealant and, prior to starting works, were able to optimise works to allow for the removal of the asbestos whilst maintaining program. The project involved life extension repairs, including concrete repair, coating, joint replacement and sealer.

Freyssinet Technical Services also carried out a condition assessment of steel structures providing the client with a comprehensive asset management plan.

Key Aspects: 
Removal of defective concrete via Ultra High Pressure (UHP) water jetting to the tank shell across 1,800m2.
Concrete repairs to tank shell and application of 1,800m2 Ultra High Build (UHB) epoxy to tank walls. Despite the UHB epoxy being applied in high temperatures, a good quality finish was maintained.
1.4km of joints were replaced.
2,400m2 of penetrative concrete sealer was applied.
Australia Square Tower Façade Remediation
Location: 
Sydney NSW
Australia
Consultant: 
ARUP
Date: 
Jun 2018 to Apr 2019

Australia Square Tower Façade Remediation

Description: 

Repair on building façade including joint sealant replacement (15,000lm), façade panel concrete repairs (4,000L), pressure washing and application of silane coating on panels (18,000m2) Installation of new panelized louvre windows on upper plant room (200m2) Access via Building Maintenance Unit and Swing Stages

S.A. Water
Location: 
Adelaide SA
Australia
Date: 
Jan 2018 to Jan 2019

Kangaroo Creek Dam Upgrade

Description: 

Kangaroo Creek Dam is situated on the Torrens River 17km North-East of Adelaide. The aim of the project is to increase the crest height of the ogee spillway in order to increase the total catchment capacity of the dam. 

Key Aspects: 
Design and supply of temporary platforms for drilling and stressing works and procurement of materials.
Drilling 216 mm - 311 mm diameter, 40 metres deep holes for 22 nos. of permanent strand anchors.
Fabrication, installation, grouting and stressing of anchors. Finishing of anchors after stressing results approval.
Installation of 150 rock bolts and 150 metres of consolidation grouting.
Completing the above works safely and complying to stringent specification.
Riverlee NBGS Pty Ltd
Location: 
Melbourne VIC
Australia
Consultant: 
Aurecon (Wharf) & Lovell Chen (Crane)
Date: 
Nov 2017 to Jan 2019

Wharf & Heritage Crane Rehabilitation at North Wharf, Melbourne

Description: 
North Wharf Berths 4 & 5 are located on the Yarra River, Melbourne, and were constructed over various time periods ranging from the 1930s to the 1950s.
 
Freyssinet were engaged to carry out refurbishment of both the wharf and heritage crane. 
 
Following the refurbishment by Freyssinet the site is now being transformed into a mixed-use development comprising of residential, hotel, retail and public park amenities. 
Key Aspects: 
Freyssinet as Principal Contractor self-performed project management, hydro-demolition, dry spray, encasement grouting and the demolition and replacement of the transition deck.
Other specialist activities included diving, reinforcement welding, fender replacement and asbestos removal.
The pile rehabilitation included 277 encasements and 16 spliced piles.
Freyssinet also carried out a horizontal move of the heritage crane and its refurbishment, including paint removal.
Other parts of the heritage crane refurbishment scope managed by Freyssinet included scaffolding, encapsulation, application of a new coating and glazier works.
Brisbane City Council
Location: 
Brisbane QLD
Australia
Date: 
Feb 2018 to Nov 2018

Rehabilitation Works at Schneider Road Bridge, Eagle Farm

Description: 

Schneider Road Bridge is located at Schneider Road, Eagle Farm, Brisbane, Queensland. It was designed by Cardno in 2006 and was built by a contractor on the same year. 

An inspection was carried out in 2013 by Cardno and discovered the defective pot bearings at the abutment. Another inspection was undertaken by AECOM and found the concrete spill-out a the northern abutment which has seriously weakend the articulation of the deck. 

With these defects found on the bridge, Brisbane City Council instructed the replacement of 40 units of bridge pot bearings and removal of concrete at the northern abutment to free up the articulation of the bridge. 

Key Aspects: 
Freyssinet initially planned to use a Synchronous Lifting System to jack the whole structure, one end at a time. However, upon inspection of the superstructure it was not possible to perform synchronized lifting due to the low standard of the bridges initial construction and out of plane deck units. For this reason, Freyssinet used the load transfer method using flat jacks to change-out bearings and concrete/mortar plinth under live open road conditions.
During the jacking of the structure, new lateral restraint system was installed for each abutment headstock. Once lifted, defective pot bearings were removed and replaced with new ones designed and manufactured by Freyssinet.
Central Highlands Water
Location: 
Daylesford VIC
Australia
Consultant: 
Stantec
Date: 
Jun 2018 to Oct 2018

Daylesford Low Level Basin Remediation

Description: 
The Daylesford Low Level Basin was constructed in 1966 and is part of the potable water delivery system for Daylesford, Victoria. The basin is constructed in ground with a reinforced concrete liner on the floor and sloping walls. An upgrade on the Basin was completed in 1996 including the installation of a steel clad roof. 
 
Ongoing issues with the basin’s water tightness through previously repaired concrete joints lead to the requirement for remediation. An HDPE liner was specified for installation on the concrete liner to improve water tightness. Inspections on the basin also identified defective coating and corrosion on roof members.
 
Freyssinet was engaged to complete the remediation on the structure including the installation of a new HDPE liner and roof refurbishment. 
Key Aspects: 
Installation of geofabric and HDPE liners over existing basin concrete liner.
Installation of access system to facilitate roofing works.
Roof sheeting removal and reinstatement including approximately 300 lineal metres of new purlins, 25 new bridging members, new roof cladding and ventilators.
Locally applied epoxy based steel coating system.
Disinfection of basin and hydrostatic testing following remediation works.