Robert Bird Group performed a number of commissions for the Gateway Bridge Upgrade project:

  • Provided technical construction advice for load testing fabricated items and connection of the
  • Alimak hoist rolling tie to pier jump form
  • Designed specialist formwork and concrete placement systems as well as systems and handling equipment for the precast yard which was established on site.
  • Bridge demolition methodoligies.
  • Stressing bed for precast deck units.
  • Temporary bespoke formwork systems to facilitiate the construction of road widening areas,

Project Value:
$2.12 billion
Year Completed:
Building Metrics:
1.6km long
6 Lane Bridge

Leighton Contractors + Abigroup JV
Robert Bird Group Services:
Construction Engineering

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.

Key technical challenges

RBG redesigned the steel plunge columns enabling complex bracing arrangements and programme hold-points to be removed, hence simplifying excavation and improving health and safety. The ground floor slab was redesigned for significant construction loads and to prop the basement wall whilst maintaining a large void to allow the core to rise.

RBG also checked all permanent works elements for the temporary loads induced by the innovative construction sequence. The construction method further reduced the ground movements, thereby minimising the risk to sensitive network rail facilities adjacent to the site.

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