The Hills M2 Motorway upgrade is a $500 Million project comprising widening of the existing motorway between Baulkham Hills and North Ryde. The structural works comprised significant retrofitting of the existing bridge structures as well as widening the existing Norfolk Tunnel. Demolition of several structures was also required as part of the project.

Our infrastructure team was responsible for the development of the temporary works to enable the complex retrofit works to be constructed. Work packages included:

  • Hanging formwork structures
  • Acoustic and containment structures for tunnel widening works
  • Temporary access bridges
  • Climbing formwork systems
  • Bridge demolition methodology
  • General structure demolition methodology
  • Tower crane installations
  • Walkway brackets and temporary stability systems for precast Super Tee girder installation

Project Value:
$500 million
Sectors:
Road

Client:
Leightons
Robert Bird Group Services:
Temporary Works
Structural Engineering
Demolition Advice

Key technical challenges

  • The primary tower structure consists of a composite slab and beam structure. Due to the long beam spans and thin slab, extensive analysis for footfall vibration was required to ensure the structure achieved code requirements and client expectations.
  • Working with the existing structure and developing design solutions that strengthened rather than demolished.
  • Extensive co-ordination with the mechanical engineer to develop a strategy that minimised beam penetrations and beam notches.
  • Differential shortening analysis with consideration of mega truss, steel structure, concrete structure and existing structural elements

Environmental performance

  • 5 Star Greenstar
  • 5 Star NABERs Energy and 4 Star NABERs Water ratings.

Hanging Formwork

RBG’s construction engineering team designed several formwork structures that were suspended from the underside of existing bridge structures, to enable bridge alteration works to be constructed above live traffic. The formwork structures utilised a combination of proprietary systems and bespoke elements to complete the works.

Bridge Demolition Methodology

Our Construction Engineering Team developed the methodology for demolition of a four-span cast in situ post tensioned bridge that spanned across the M2 Motorway. The bridge was demolished using excavators with the pulverising attachments. Due to the presence of stressed steel tendons, a sequence for demolition was developed to ensure that the bridge structure remained stable at all times during the demolition process. The bridge was safely and successfully demolished within the shutdown period, with no disruption to traffic outside the shutdown period.

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