Projects

Projects

Projects

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.
Nepean River Footbridge
Location: 
Sydney NSW
Australia
Date: 
Jun 2017 to Jun 2018

Nepean River Footbridge

Description: 

The Nepean River Footbridge is a new bridge in Penrith, NSW that provides a safer crossing for pedestrians and cyclists over the Nepean River and improve connections to existing and future shared paths, including the Great River Walk. The main span is a 200m long steel truss that was prefabricated and tramsported to site. Each truss bay of 25m was assembled on site and incrementally launched across the river. Two temporary steel piers were erected in the river to provide support during the launching operations. Freyssinet Australia was contracted to provide design assistance on the launching methodology as well as performing the launching activities on site. Freyssinet also designed, supplied and installed 10 pot bearings, 4 for the truss and 6 for the approach span. The Nepean River Bridge has the longest main span of any shared path bridge in Australia. 

Key Aspects: 
Detailed launching sequence: truss position and geometry including deflection to determine clearances and required support heights, calculation of support reactions.
Detailed design, supply and installation of the launching system including: strand jacks at abutment to provide pulling force for launching, launching beams with lifting jacks (400T - 400mm stroke) on teflon sliding shoes, stainless steel sliding tracks on abutment and temporary piers, cradles on top of lifting jacks and fixed supports, guiding track inside workshop for rollers support, roller supports in workshop using 4 x 100T jacks each.
Proof testing of the truss supporting cradles (rubber/paint interface, structural stability of cradle and truss bottom chord).
Operation of the 9 x 25m launches including: survey control of support locations, launching truss using 2 x 50T strand jacks powered by a heavy lift pump, transfer of load to fixed supports, resetting of launch beams and changing of shimming arrangements.
Roads and Maritime Services (RMS)
Location: 
Harwood NSW
Australia
Date: 
Sep 2017 to Apr 2018

Bridge over Clarence River at Harwood Bearings and EJ Supply

Description: 

RMS planned to have a new bridge over the Clarence River at Harwood as part of Woolgoolga to Ballina Pacific Highway upgrade project. 

The new bridge has 36 piers with 23 on land and 13 over the river. It has 144 concrete girders weighing about 168 tonnes each. The span length is 41 metres and the clearance in the middle is 30 metres. 

The bridge is about 20 metres east of the existing bridge, 1.5 kilometres long and is four lanes wide crossing the Clarence River. 

Freyssinet Australia supplied 56 nos. 810x276 and 232 nos. 750x276 laminated elastomeric bearings with stainless steel attachment plates including 24 of sliding plate assemblies. 

With a different contract, Freyssinet Australia also supplied 44 linear metres of WP350 expansion joints to the same project. 

Key Aspects: 
Supply, logistics and quality management of overseas supplied products.
Transport for New South Wales
Location: 
Sydney NSW
Australia
Date: 
Jan 2014 to Sep 2017

North West Rail Link - Stay Cables, Post-tensioning Works & Bearings

Description: 

North West Rail Link is a railway link in Sydney which would connect Epping, The Hills Centre and Rouse Hill. The rail link will reduce the congestion along the route and provide direct rail services to the Northwest Business Park, Macquarie Park, St Leonards, Chatswood, the North Sydney district and the Central Business District (CBD). The project is a 23km route with 6 stations. 

Key Aspects: 
Freyssinet has performed the erection of the superstructure using span by span segmental erection on falsework.: * 1 406 m viaduct * 42 spans (374 segments)
Freyssinet also supply and erect the 32 stay cables, each cable is composed of 127 strands.
Design, supply and installation of 476 units pot bearings as per Australian standards. FPC brought the following added value to the project: * Product design, technical and sales assistance by FPC Asia * Production and quality control by FPC Romania and FPC Italy * Test in Isolab
Design specification: bearings with temporary stoppers, RMS requirement (PTFE bonded to the piston), very high vertical loads (up to 79000 kN, 7 tons bearings). Mock-up tests. Special corrosion protection for Australian market (SYS1NO), adaptation plates with Nelson studs, recessed circular cast-in plate for larger bearings.
Port of Melbourne Corporation
Location: 
Melbourne VIC
Australia
Date: 
Apr 2016 to Mar 2017

ICCP Steel Pile Corrosion Protection Program, Melbourne

Description: 
Spanning seven separate sites within the Port of Melbourne area, this design and construct project was undertaken for the Port of Melbourne Corporation (PoM). It was part of their program to minimise accelerated low water corrosion (ALWC) of steel piles that form part of wharves and piers.
 
ALWC is a type of microbial induced corrosion of submerged steel elements in marine and brackish water environments. ALWC can result in local rapid loss of steel cross section that can impact the structural strength of steel sheet piling, circular steel piles and other steel substructure elements.
 
The project involved the design, installation and commissioning of an impressed current cathodic protection (ICCP) system to each of the seven sites.
Key Aspects: 
The ICCP system designed, installed and commissioned by Freyssinet included 312 anodes and references, 425m of underwater continuity bar, over 1.5km of cable tray, 35km of cable and pile wrapping of 225 tubular steel piles.
The design was tailored to meet the specific requirements of both the client and the tenants of each site.
Work was carried out in close proximity to live shipping so the safety procedures for working around ships were carefully planned and closely monitored throughout.
Access to the work locations presented a number of challenges in terms of providing a safe and efficient access system for the workers. Access arrangements were designed to suit site conditions and included pontoons with handrails and guardrails, boats with scaffold arrangements and also a gangway and scaffold towers to access the water.
Roads and Maritime Services
Location: 
Sydney NSW
Australia
Date: 
Nov 2016 to Dec 2016

Cobbadah Creek Bridge 1R15

Description: 

The project consisted of external strengthening of the bridge over Cobbadah Creek, Northwest NSW (1 hour and 20 minutes north of Tamworth). 

The bridge is constructed on a skew with 4 spans, end spans of 12.5 metres and internal spans of 16.5 metres. The bridge was suffering from cracking in the beams, deck and abutments. Each face of both beams had the 1R15 system installed. 

Freyssinet Australia's role included the supply of steel deviators, strand and 1R15 anchors as well as the installation and stressing of the 1R15 system. Freyssinet conducted all tensioning site work excluding deviator installation, coring, beam thickening and access. Freyssinet installed the 1R15 system using 48 anchors; 24 active and 24 passive. 28 deviators were fabricated locally and installed along the length of the beams (completed by RMS) to create parabolic profile once the strands were installed. 24 galvanized, greased, sheathed strands, each 56 metres long, were installed along the length of the bridge and stressed using 25 ton AJ150 jacks. 

Key Aspects: 
The 1R15 system was an alternative solution proposed to RMS to eliminate major road works which would have involved closure of one direction of traffic at a time, even during night hours.
Work was conducted over a creek fed by a natural spring and inhabited by a threatened species so care had to be taken to reduce contaminants on site.
Anchors, deviators and strands were installed by hand from an erected scaffold under the structure, not impeding traffic flow.
Lendlease / Darling Harbour Live
Location: 
Sydney NSW
Australia
Date: 
Jun 2015 to Dec 2016

ICC Heavy Lift

Description: 

The Sydney ICC (International Convention Centre) heavy lift was completed for Lendlease for the Darling Harbour Live consortium's upgrade of the Darling Harbour Convention and Exhibition Centre Precinct. 

The full project encompasses a 2.5 Billion Dollar upgrade to the area including construction of new exhibition halls, convention centre, theatre and public realm replacing the existing convention and exhibition facilities. 

Judged as Australia's Best Infrastructure Project in 2017, the ICC Sydney is the biggest combined exhibition, convention and entertainment precinct in Australia, and was successfully delivered on budget, ahead of schedule. 

Key Aspects: 
Freyssinet was contracted to perform a heavy lift on the exhibition halls steel truss roof. The roof was a 3000T steel truss structure that was designed by Robert Bird Group, fabricated by Hyundai Steel and assembled on site by DME Engineering.
The roof has a 102m clear span and is 140m wide. The original plan was to lift the full roof in one, however on client request the lift was split into two independent lifts (1200T and 1800T).
Roads & Maritime Services - NSW Government
Location: 
Sydney NSW
Australia
Consultant: 
SMEC
Date: 
Jul 2013 to Dec 2014

Fern St Launch Bridge - Gerringong

Description: 

Design and construction of a 347m incrementally launched concrete bridge along the Princess Highway West of Gerringong and spanning over the existing South Coast railway crossing. This bridge was always identified as a key area of risks for the project and the launch bridge solution provided many benefits: - Reduction of environmental impact of the adjacent protected wetlands. - No need for road closure nor rail closure. - Elimination of many high-risk work activities. - More aesthetic pleasing structure: longer spans, slender structure. - Significant reduction of maintenance requirements.

 

Key Aspects: 
Technical assistance with launch design and methods.
Supply of specialized material and equipment (78 tons launch nose, 1000 tons launching jacks).
Installation of 150 tons post-tensioning strands.
Launching operations.
Design, supply and installation of 16 units stainless launch-over Pot Bearings.
Erection and dismantling of cast yard, temporary pier and launch nose.
Supply and installation of WP250 Expansion Joints.
Watpac Construction Pty Ltd
Location: 
Sydney NSW
Australia
Consultant: 
Bonar Bucalina / Matt Harding
Date: 
Mar 2011 to Jun 2013

One Central Park Residential Development

Description: 

First Stage of the development consists of two residential towers of 116m and 64.5m high, the tallest tower matching the height of the neighbouring UTS Tower. There is a common retail and recreational podium and garden and above these 593 apartments across the two towers in a mix of studio, 1, 2 and 3-bedroom apartments. Dramatically extending from the taller tower is a monumental cantilever housing a panoramic terrace and a theatrical public artwork: an innovative system of fixed and motorized mirrored panels known as a ‘heliostat’. The heliostat will capture sunlight and reflect it down onto the landscaped terraces, extending the central parkland at the heart of the new precinct into this very green building.

Key Aspects: 
The project consists of 5 levels of podium (Retail) 34 floors in the East Tower, 17 floors in the West Tower, 8 floors in Block 5a, 20 floors Block 5b and 29 floors Block 5c. The space covers 145,000 m2.
There are 5 basement areas cover 35,000 m2.
This project required a full time Supervisor as work was underway on multiple workfaces at the same time, with over 1000t of post-tensioning installed for the project.
Freyssinet received a letter of commendation from Watpac in relation to our safety on the site.
Government of South Australia
Location: 
Adelaide SA
Australia
Consultant: 
GHD
Date: 
Jan 2011 to Mar 2013

South Road Superway

Description: 

The South Road Superway is a 4.8 kilometre non-stop corridor, comprising of a 2.8 kilometre elevated viaduct structure, from the Port River Expressway to Regency Road located in the northern suburbs of Adelaide, SA. The viaduct structure consists of a dedicated dual carriageway constructed by the precast balanced cantilever method with cantilever and continuity PT tendons. Precast segments were erected by either Launching Gantry, Lifting Frames, or on Falsework using mobile crane.

Key Aspects: 
Construction methods engineering.
Supply of precasting machines, straddle carrier and gantry cranes.
Supply of launching gantry and lifting frames (2no).
Supply, installation and post-tensioning of continuity and cantilever tendons.
Supply of movement joints and bridge bearing.
VicRoads
Location: 
Melbourne VIC
Australia
Consultant: 
SKM Consulting Engineers
Date: 
Jan 2009 to Dec 2010

West Gate Bridge Strengthening

Description: 

Westgate Bridge is the largest bridge in Melbourne. The main span over the Yarra river is 336m long and made of a cable stayed steel box girder whereas the approaches are made of prestressed concrete multicell box girder. Western viaduct consists of 10 spans at 67m each and the Eastern Viaduct consists of 13 spans at 67m each. The traffic loading is to be increased by converting the outer shoulders into typical traffic lanes. Accordingly, the entire bridge is to be strengthened to enhance its structural capacity. The Western viaduct has already been partly strengthened in 2002. Strengthening is made of carbon fiber strips outside of the box girder, and additional external prestressing inside the box girder.

 

Key Aspects: 
Installation of external prestressing tendons in both Eastern and Western viaducts with 300 tons of strands in both viaducts.
Tendons are made of bare strands injected with cement grout in HDPE ducting.
Deviators and end blocks are made of cast-in situ reinforced concrete blocks stressed to the webs with 50 mm diameter Freyssibars.
The jacking of the bridge to relocate the deck at the abutment.
Willoughby City Council
Location: 
Willoughby NSW
Australia
Date: 
Feb 2007 to Nov 2010

Willoughby Incinerator Refurbishment

Description: 

This building was completed in 1934 and designed by Walter Burley Griffin of Griffin and Nicholls. It was closed in 1967 and transformed for commercial use in 1979 until the building was damaged in fire in 1996. In 2006, Willoughby Council was given a grant to refurbish the heritage listed building. The original building was a sandstone and reinforced concrete building containing a one-unit reverberatory incinerator and sewage dump.

Key Aspects: 
Initial Concrete Testing and Investigation, traditional concrete repair, installation of cathodic protection system, demolition of the chimney and reconstruction, bulk excavation, construction of lift shaft and tunnel.
The Cathodic protection was installed to the concrete slabs, gables and the reconstructed chimney.
Removal of spalled concreted through hydrodemolition, ensuring continuity of the steel and shotcreting.
Bulk excavation works involved bracing of the Sandstone wall and testing and classification of the soil.
Demolition and reconstruction of the chimney incorporated provision access to the chimney and inspection, original profile matching and matching the original height of the chimney.
Additional challenges included State heritage significance, environmental constraints and community relations.
Department of Transport, Energy and Infrastructure - SA
Location: 
Bakewell SA
Australia
Consultant: 
McConnell Dowell Constructors
Date: 
Apr 2007 to Jul 2007

Bakewell Underpass Bridge Launching

Description: 

The Bakewell Bridge Adelaide provides access via Henley Beach Road between the western suburbs and the City and is an important part of the metropolitan Adelaide arterial road network west of the City. The 80-year-old Bakewell Bridge was nearing the end of its structural life and with its poor safety record was becoming increasingly costly to maintain and repair. This project involved the replacement of the existing overbridge on Henley Beach Road, passing over James Condon Drive and the railway tracks in Mile End, with an Underpass.  Freyssinet lifted and launched the 3200-tonne railway bridge built offline on a temporary headstock 33.0 metres to its final position on the permanent abutment.

Key Aspects: 
Initial lift used 20 No. 200 tonne jacks to strip the formwork and install the temporary slide bearings on the headstock.
A duct cast into the end beams and a dead-end cast on the opposite side of the railway tracks allowed 12 No. 15.2mm diameter strands to pass through each end beam.
The railway tracks were cut and excavated allowing the Freyssinet team to launch the bridge into position.
The bridge was launched into position in just over five of the eight hours allowed for the operation.
Once the bridge was in the final position, the bridge was lifted, and the slide bearings were removed and the permanent bearings were installed.
Key to the project was minimal disruption to the railway network.
Baulderstone
Location: 
Glebe NSW
Australia
Consultant: 
RMS
Date: 
Jan 1992 to Dec 1995

Anzac Bridge

Description: 

The Anzac Bridge, replacing the Glebe Island Bridge, represented the newest landmark bridge in Australia at time of erection and is now a major feature on the Sydney skyline. Located in the Pyrmont area of Sydney this 350m central span, cable stayed bridge links Victoria Road with Pyrmont, Ultimo and the Sydney CBD. It is the longest bridge in Australia to use the cable stayed structural form when it was constructed. Freyssinet were selected to undertake the supply and installation of various new engineering technologies required to complete the construction of this landmark bridge.

Key Aspects: 
Stay cables to the main deck
Post-tensioning to the main deck and approach viaducts
Rock anchors
All heavy lifts utilised Freyssinet’s L180 centre hole heavy lift jacks specifically adapted for failsafe lifting of such structures. The system was used 25 times throughout the project varying in weight from 100 to 300 tonnes. Each jack has a safe working capacity of 180 tonnes and is powered by a purpose built electric hydraulic pump unit which can independently control up to 4 jacks at once so that lifting and lowering can be carried with a high degree of accuracy and speed.
The form traveller used to construct the overwater deck segments was 30m long and 32m wide and weighed 280 tonnes