Project Overview:
The Elizabeth Drive Watermains are part of a key package of major infrastructure upgrades within the WSAGA (Western Sydney Aerotropolis Growth Area) to support the new Western Sydney International Airport and surrounding development
Project Description:
Quickway were engaged under Sydney Water’s NEC4 Engineering and Construction Contract to deliver this key package as part of the WSAGA (Western Sydney Aerotropolis Growth Area) Pipeline to the new International Western Sydney Airport. Quickway self-perform circa 70% of the works, including trenching and pipeline construction, valve installation, insertion of carrier pipe through bores, and hydro testing (flushing) of pipelines. The scope of works included the construction of the following:
- 2km of OD 813 SCL (Steel Cement Lined) pipeline along the busy Elizabeth Drive.
- The work included the installation of SCL pressure main along with numerous complex valve assemblies (Hydrants/Stop valves) and tie-ins to DN 1000 HDPE pipelines that was constructed using HDD bore methodology.
- The works also included DN 450 DICL main and a road crossing across Elizabeth Drive using open trench excavation methodology, with concrete encasement.
- Construction of several maintenance holes, hydrant valve pits, and scour pits.
- Installation of large diameter (DN750) Gate Valves and Hydrant Valves
- Potholing to identify services and prove proposed alignment of pipeline.
- Temporary Works Design and/or Geotech sign-off for deep excavations
- Steel welding, full-time Weld Inspector and 100% NDD weld testing
- Installation of pipe through HDD bore and subsequent grouting of the bore annulus.
- Installation of Cathodic Protection (with Test Points and Anodes) to protect the steel pipeline.
- Pressure Testing and commissioning of the whole pipeline.
- Reinstatement and restoration following completion of the works.
Key Challenges/Highlights:
- Quickway provided the full-time resources required to meet a tight program, and with experience/skillsets to manage a large diameter steel pipeline project.
- Challenging design and sections of the work was in water charged ground. Even though, this was environmentally sensitive the project got delivered with zero environmental incidents.
- We provided alternative design solutions for road crossing methodology to ensure a safer construction method was used by collaborating with TfNSW.
- Excellent safety record and no LTI’s on the project.
- Internal welding of steel pipes under confined space conditions. All confined space parameters had to be addressed for this high-risk work to ensure the safety of all personnel on site.
- Deep excavation in difficult terrain. The combination of shoring boxes and benching was used to install this pipe to the large depths. The length of the pipe made it difficult to use conventional shoring boxes.
- The project was completed within schedule/program.
- The entire pipeline network successfully passed compliance testing defect-free, at first attempt, and handed over to our client. The project is part of the Western Sydney Aerotropolis Growth Area.
- Working adjacent to live traffic with a short construction window per shift while working outside of normal work hours. Program was critical and had to be closely managed to ensure deadline was met and intensive planning required.
- Worked collaboratively worked with Sydney Water WRDT to ensure the project was delivered successfully, and to the satisfaction of the Client.