Western Sydney continues to transform with momentum as CPB Contractors, in a joint venture with United Infrastructure, progresses construction on the Sydney Metro – Western Sydney Airport Surface, Civil and Alignment Works (SCAW) project.
With 90 percent of the project's precast segments now manufactured, delivery of the 3.2-kilometre elevated viaduct is set to progress at speed.
Produced at a specialised precast facility, CPB Contractors Project Director Vishal Khosla explains that the team is leveraging advanced design and construction techniques to enhance accuracy and consistency.
"We are using match casting to ensure each segment aligns perfectly. This approach ensures the viaduct's structural integrity and resilience," explains Vishal.
The match casting process involves creating the first segment with temporary moulds and casting subsequent segments against it, achieving a flawless, interlocking interface.
Each segment measures approximately 10 meters in width, 2.4 meters in height, and up to 3.2 meters in length, weighing between 45 and 65 tonnes each.
Specialised installation and transportation equipment are being used to assemble precast elements into an elevated viaduct between Orchard Hills and the new Bradfield Station. The segments are delivered to the site and installed using the Underslung Temporary Beam or Gantry. This method allows for precise alignment and installation and reduces the need for extensive scaffolding or temporary supports.
CPB Contractors’ construction of this 3.5km elevated viaduct is a key component of the Sydney Metro SCAW project. Once complete, it will connect Orchard Hills to Luddenham and pass through several important areas, including Blaxland Creek, Patons Lane, and the Warragamba pipeline.
In a joint venture with United Infrastructure, a consortium of Western Sydney-based companies including Burton Contractors, JK Williams and Mulgoa Quarries, CPB Contractors’ delivery of Sydney Metro’s SCAW project includes:
- 3.5 kilometres of elevated viaduct at Orchard Hills and Luddenham
- 6.7 kilometres of earthworks for track formation
- A 190 metre long rail bridge over the new M12 motorway
- A 20 metre long rail bridge within the airport
- Temporary and permanent access roads
- Bulk earthworks for the stabling and maintenance facility site