The $407 million Southern Expressway Duplication project transformed the one-way reversible expressway into an 18.5km multi-lane, two-way expressway between Bedford Park and Old Noarlunga.

The project was completed in 2014. Ten existing road bridges over the expressway were extended and widened to cross the wider carriageway.

Project Value:
AUD$407 million
Year Completed:
RBG Client:
Baulderstone Pty Ltd

Primary Contractor:
BAJV – Joint Venture Baulderstone & Abi Group
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

Robert Bird Group provided construction engineering services for the road bridge extensions. Works packages included:

  • Temporary support of existing bridges to allow for abutment demolition and construction of a new central pier and additional span
  • Temporary sheet piling for excavation of the wider carriageway and construction of new bridge abutments
  • Temporary bridge girder restraint for widening and extension of existing bridges
  • Temporary long span steel trusses to support existing services during the bridge widening process
  • Site inspections

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