Bridges

As part of the West Gate Tunnel Project, Wurundjeri Way is being extended to create a city bypass, enhancing connectivity and alleviating congestion in Melbourne. A critical component of this extension is the construction of an elevated 1.6-kilometre viaduct spanning Dudley Street and Moonee Ponds Creek, featuring a unique elevated 4-way intersection where it connects to the viaduct connecting Dynon Road with the West Gate Tunnel.

The design of this elevated intersection presents complex challenges, particularly due to its proximity to the rail corridor and the need for curved high-performance level barriers at the intersection corners. The complex road geometry, sight distance requirements, and the constraints imposed by tight radii and extremely short barrier segments adjacent to expansion joints posed significant risks in design and construction.

To overcome this, a collaborative effort between the design and construction teams was essential. Innovative solutions were developed, focusing on the unique reinforcement required for the barriers within the limited available structural depth. This involved the implementation of bespoke 3D reinforced precast panels and meticulous detailing of reinforcement layouts, minimising on-site construction efforts as far as practical.

This paper provides a comprehensive overview of the design and construction complexities encountered during the design, detailing and construction of the elevated intersection on the Wurundjeri Way extension. It explores the valuable lessons learned, the innovative solutions adopted, and the pivotal role of close collaborations and continuous iterations in achieving project success.

The findings and insights from this project contribute to the advancement of best practices in designing and constructing complex structures within constrained brownfield sites. By prioritising constructability and implementing innovative solutions, the project demonstrates the possibility of achieving efficient and robust outcomes even within challenging constraints.