Project Description

The Caulfield to Dandenong Level Crossing Removal project involved the removal of nine level crossings on Melbourne’s busiest railway line via conversion of the existing at grade track to an elevated structure. Robert Bird Group undertook the design of over 75 separate temporary and enabling works packages including retaining walls, custom formwork, reinforcement jigs, noise walls, concrete runway beams and slabs for heavy plant (piling rigs and cranes), existing service verifications, access stairs and platforms, SPMT transport, and staged construction of station canopies. Enabling works also included delineation fences and hoardings, stormwater drain diversions, pedestrian crossings, and utility protection works.

Project Challenges

• Finite element analysis of modular steel formwork for the bridge piers was required due to an unusual, curved shape. This allowed Robert Bird Group to deliver an efficient design to the client.
• Design of 160m long concrete reinforced beam on variable ground that could only deflect 2mm at any point due to supporting 2 no. 230 tonne moving gantry cranes.
• Staged erection design and analysis for five new railway stations. Robert Bird Group assessed the permanent steelwork for lifting and installation in a “modular” system as well as designing temporary works to ensure that no part of the structure was overstressed during construction.
• Civil and structural design of a 400m long embankment either side of the existing railway line including new temporary concrete bridges across critical services to support 100 tonne piling rigs and cranes.

Added Value

To optimise the project, we designed fibre-reinforced concrete boxes that allowed for the excavation of new pile caps without the need for steel reinforcement. This solution enhanced productivity for the client and reduced costs compared to traditional methods like sheet piling and contiguous piles.