Archives: Case Studies

Water Corporation Drainage Works at Bayswater Station Rail Viaduct

The Morley to Ellenbrook Line project is part of a staged initiative targeting improvement and integration of transport options in Perth's north-eastern corridor. The project aims to deliver approximately 21km of rail infrastructure and ancillary works to support operational passenger rail between Bayswater and Ellenbrook. It includes design and delivery of five stations including intermodal bus and rail, with parking and associated roadworks at Morley, Noranda, Malaga, Whiteman Park and Ellenbrook stations, and ancillary works at the Bayswater Station.

FSC's Role

 FSC Civils was engaged to perform water corporation drainage works as part of the Baywater Rail Viaduct project.

Key Challenges

• Delays in start due to Design Issues and Scope Changes
• Pending APRA approvals and Dewatering for Open Drain Works
• No crane access for lifting pipes and shoring boxes underneath the bridge
• Little Room to work underneath the bridge.
• Retaining soil with Old Pit connection while excavating

Outcomes

Despite pending approval delays from APRA, FSC successfully delivered the project within the designated timeline.

To address dewatering challenges, dewatering pumps were deployed effectively.

Restricted access conditions prevented the use of a crane beneath the bridge; however, FSC adapted by utilizing a 49T excavator to lift shoring boxes and pipes, ensuring the job was completed.

Connecting new pipes while retaining soil around the old pipe connections posed a significant challenge, but FSC managed this by excavating in layers and installing the new pipes in stages, preventing soil collapse.

Overall, despite numerous obstacles, the project was a success and delivered on schedule as per the project timeline.”

Scope of works

• Bulk & detailed earthworks
• Removal of HDPE Pipes
• Preparation of Limestone Bases
• Installation of 1500mm drainage
• Stormwater Connections
• Insitu structural concrete pits
• Open channel drainage
• Rock pitching
• Dewatering
• Installation of bypass over pump
• Retention basin construction
• Access tracks & pavement construction
• Demolition works
• General civil work

AIR7000 RAAF Base Pearce

CPB Contractors were engaged by the Department of Defence to construct ten discrete work zones across the airfield. These works included strengthening and widening taxiways, extending existing taxiways and runways, and completing the redevelopment of the existing aircraft rinse facility at RAAF Pearce in Bullsbrook.

FSC's Role

FSC was engaged as a subcontractor to execute earthworks and FRP scopes within a live airfield environment. The work involved navigating and preserving critical in-ground infrastructure essential for ongoing airport operations.

Scope of works

• Installation & commissioning of Drainage Pit & Pipe
• Installation & commissioning of 2 SPEL Puraceptor Tanks
• FRP for reinforced concrete slabs
• Installation of electrical & communications infrastructure
• Construction of Rinse Building

Splendid Park Floodlighting Upgrade

The City of Wanneroo secured federal funds to carry out floodlighting upgrades to both ovals at Splendid Park, Yanchep. The project is to design and construct 100 Lux lighting upgrades to replace the current 50 Lux sports floodlighting. The upgrade will be funded by a combination of the Department of Local Government, Sport & Cultural Industries Club Night Lights Program, and also through the Federal Government’s Local Roads and Community Infrastructure Program.

FSC's Role

Head contractor engaged by the City of Wanneroo to perform and project manage the floodlighting upgrade project at Splendid Park.

FSC was responsible for the implementation of the project using its own accredited management system which included management of a number of specialist subcontractors.

Scope of works

• Design and construction of the lighting and lighting system including implementation of HSEQ and traffic management plans.
• Management of specialist electrical subcontractors.
• Supply, install and commission floodlighting system including all configuration trenching, piling works with 8m excavations, directional drilling, conduits, cabling, pits, ladders, distribution boards, & luminaries.
• All finishing works and training of maintenance workers on new electrical systems.

Metronet – Thornlie Cockburn Link and Yanchep Rail Extension

METRONET’s Thornlie-Cockburn Link is Perth’s first east-west rail connection, servicing the communities between the Mandurah and Armadale lines. The Thornlie-Cockburn Link is being built within existing rail corridors requiring a number of changes along the alignment including: - Relocating the freight lines to the northern half of the corridor to make room for the passenger lines in the southern half. - Replacing the Cameron Street-Elliot Place pedestrian level crossing with a footbridge over the rail for safer access. - Modifying the Ranford Road and Karel Avenue road bridges to accommodate the extra set of track and meet safety standards.

FSC's Role

Major subcontractor engaged by NEWest Alliance to construct:

• Nowergup Traction Power Substation
• Beckenham Traction Power Substation
• PSP & street lighting package

Scope of works

• Supply, Installation and Commissioning for the augmentation of the Nowergup 132kV/25kV traction substation and new return current cables to existing neutral section.
• Supply, Installation and Commissioning for the augmentation of the Beckenham 132kV/25kV traction substation and new return current cables to existing neutral section.
• Supply, Installation and Commissioning of Ranford Rd PSP & Street lighting package

ROM 4 – Roy Hill Minesite

Roy Hill expanded its operations with a new Run of Mine (ROM) located to the east of Marble Bar Road in the vicinity of the Ginbata airport location, currently named ROM 4. The ROM 4 Project is a 40.5Mtpa facility which is planned to deliver first ore by January 2023 and to be in service until 2032.

FSC's Role

FSC was responsible for the complete installation of formwork, reo and concrete for the work including all foundations, footings, plinths, slabs including reinforcement steel, concrete, formwork, embedment, cast-in plates, hold down bolts and cages for Package 1 which included the following structures,

• Crushing station foundation and slab,  
• Intermediate module footings  
• Driving sump 

Scope of works

• Laying waterproof membranes if required,  
• Placement of blinding concrete,  
• Tying reinforcement,
• Set structural bolts  
• Formwork
• Pouring of structural concrete,  
• Vibrating, levelling, finishing, and curing to all concrete,  
• Stripping and removal from site of all formworks after use,  
• Finishes / patches to all surfaces if required,  
• Protection of exposed threads of holding down points, 
• All construction joints (baking rod & sealant)

Port Debottlenecking Project

The Port Debottlenecking Project was developed to expand and debottleneck BHP’s Western Australia Iron Ore’s port capacity by developing an infrastructure and operating solution which would reliably and sustainably deliver a growth pathway to iron ore production capacity of 330Mtpa. The Project is located at Nelson Point within the Port Hedland Inner Harbour. The scope of the Project includes construction and installation of a new car dumper (including associated rail and materials handling upgrades), installation of a new product stacker (including new conveyor routes) and stockyard row, construction of a new freshwater recovery plant, upgrades to existing ship loaders, upgrades to existing lump rescreening plant and construction of a new sample station.

FSC's Role

FSC provided skilled labour to deliver the SMPE&I scope of works. 

Scope of works

Our team of skilled riggers, welders, fitters, electricians and carpenters assisted with the delivery of construction and installation of a new car dumper, installation of a new product stacker and stockyard row, upgrades to existing lump rescreening plant and construction of a new sample station.

Metronet – Morley Ellenbrook Line

The Morley to Ellenbrook Line project is part of a staged initiative targeting improvement and integration of transport options in Perth’s north-eastern corridor. The project aims to deliver approximately 21km of rail infrastructure and ancillary works to support operational passenger rail between Bayswater and Ellenbrook. It includes design and delivery of five stations including intermodal bus and rail, with parking and associated roadworks at Morley, Noranda, Malaga, Whiteman Park and Ellenbrook stations, and ancillary works at the Bayswater Station.

FSC's Role

Major subcontractor engaged by MELconnx to construct the following key elements of the works: 

• Beechboro Road bridge over rail (Bridge 1)
• Whiteman Park dual viaduct structure (Bridge 2)
• Whiteman Park dual underpass structures (Bridge 3)
• Bayswater Station viaduct structure (Bridge 4)

Scope of works

• Construction of all structural foundations, reinforced concrete walls, skirt beams, shear keys and diaphragms etc for the abutments, wing walls, bridge piers and footings, bridge walls and deflection walls.
• Construction of pier columns, and pier headstock.
• All formwork, reinforcing steel, concrete, precast installation & associated works.
• Installation of all bridge parapets, balustrades, transition barriers, concrete barriers etc.
• All associated temporary works (including associated design). 
• Construction of Water Corp open drain
• Detailed earthworks and drainage installation

Metronet – Byford Rail Extension

The Armadale Line is being extended approximately 8km south to a new ground-level station in Byford, supporting one of the fastest growing areas in Australia. Armadale Station is being rebuilt as an elevated station with three nearby busy level crossings removed and replaced with elevated rail. Other level crossings between Armadale and Byford are also being removed with alternative treatments to improve traffic flow and ease road congestion.

FSC's Role

FSC Civils is responsible for delivering complex construction works for the viaduct, showcasing our capability in handling large-scale infrastructure projects.” to “Major subcontractor engaged by METConnx to deliver complex construction works for the viaduct, showcasing our capability in handling large-scale infrastructure projects.

Key elements included:

• 1.5 km long Armadale Station viaduct
• Station Concourse Package
• PSP Bridge

Scope of works

Precast Installation:

• Installation of precast elements, including columns, headstocks, planks, and beams.
• Execution of complex temporary works to ensure stability and safety during installation, demonstrating our proficiency in managing intricate engineering challenges.

In Situ Concrete Works:

• Construction of in situ columns, beam stitches, plank stitches, derailment kerbs, and track slabs.
• Precise grouting of structures, ensuring structural integrity and longevity.

Earthing and Bonding:

• Comprehensive execution of earthing and bonding works across the viaduct, critical for operational safety and compliance with electrical standards.

RAAF Base Pearce & Gingin

Civcon were engaged by the Department of Defence to deliver critical infrastructure upgrades at RAAF Base Pearce and RAAF Base Gingin, including the construction of a new sensor equipment building at RAAF Gingin and a state-of-the-art airfield systems building and tower at RAAF Pearce.

FSC's Role

FSC was engaged as subcontractor to deliver a variety of insitu concrete services. This Defence Project presented unique challenges, particularly operating within a live air base environment. FSC’s expertise and commitment to safety ensured a successful delivery, meeting stringent Defence standards and contributing to the operational enhancements of these vital facilities.

Scope of works

• Reinforced concrete floor slabs, 
• Driveways, 
• Footpaths
• Drainage solutions

Murdoch Drive Connection – Bridge Construction & Upgrades

The Australian Federal and State Government’s $100 million Murdoch Drive Connection project extended Murdoch Drive south from Farrington Road to provide connections to Roe Highway and Kwinana Freeway. 

FSC's Role

Major subcontractor engaged by MRIA, FSC was awarded the contract for the construction of three new bridges and construction of an extension to a fourth bridge. 

• Bridge construction over Kwinana Freeway (Br.1692)
• Roe Highway ramp bridge over Murdoch Drive (Br.1693)
• Murdoch Drive bridge construction over Farrington Road (Br.1694)
• Kwinana Freeway bridge widening over ARC rail (Br. 1332).
• Works involved interaction with live traffic and rail networks over the Kwinana Freeway, Farrington Road and live rail line (with two of the bridges spanning the live train network).

Scope of works

• Construction of substructure piers (footings, bridge piers and restraint blocks, bearing pads and bearings).
• Construction of abutments (MSE wall panels, wingwalls, footings) – in situ and cast in items.
• All temporary works.
• All reo, formwork and concrete pours.
• Installation of tee-roff beams (including temporary electrification screens).
• Bridge deck and approach slab construction (including supply and installation of all expansion joint components.
• Underbridge lighting installation (excluding electrical works).