Mount Ousley Redundant Pipe Injection

New South Wales

Value: $250,000

As part of the $400 million Mount Ousley Interchange project, several pipes were identified as redundant by Transport NSW and required cementitious structural infill. These pipes, ranging from 55m to 270m, necessitated significant planning and support infrastructure. The intricate nature of this civil contracting task required a comprehensive approach to ensure success.

In any structural grouting project, grout placement is typically the easiest part of the infill methodology. However, the main challenges lie in effective planning and establishing contingencies to ensure continuous placement without forming air voids. This complexity was amplified in the Mount Ousley project due to the varying lengths and conditions of the redundant pipes.

Portolesi Structural, renowned for their expertise in civil contracting and structural grouting, was engaged to undertake this critical task. The team initiated an extensive process of consultation with the asset owner to ensure that all stakeholders were involved and informed of the risks and contingencies. This collaboration was essential for aligning the project's objectives and addressing any potential issues proactively.

The project began with detailed site assessments and the development of a robust plan that accounted for all variables, including the unique characteristics of each pipe. Advanced planning involved designing a custom infrastructure to support the grout placement process. This included creating access points and ensuring that the equipment could operate efficiently within the site's constraints.

During the execution phase, Portolesi Structural's civil contracting expertise was pivotal. The team employed a custom-designed, bespoke connection system to place grout from a single location on each defunct pipe. This innovative approach minimised disruption and ensured a seamless operation. The process was meticulously monitored to avoid air voids, a common issue in grouting projects that can compromise structural integrity.

Safety and quality assurance were paramount throughout the project. Portolesi Structural's robust quality systems and adherence to industry best practices ensured that the grout placement was performed to the highest standards. The team also implemented stringent safety protocols to protect workers and maintain the structural integrity of the surrounding infrastructure.

The successful completion of the grout placement from a single location on each pipe not only demonstrated Portolesi Structural's capability in civil contracting but also highlighted their innovative problem-solving skills. The project was completed on time and within budget, with all stakeholders satisfied with the outcome.

This case study underscores the importance of comprehensive planning, stakeholder collaboration, and technical expertise in civil contracting projects. Portolesi Structural's ability to navigate the complexities of the Mount Ousley Interchange project exemplifies their commitment to excellence and their pivotal role in advancing infrastructure development.