The $40 million Bolivia Hill Upgrade on the New England Highway involved constructing a 320-metre, 150-metre centre span, concrete balanced cantilever bridge utilising post-tensioned balanced cantilever technology and cast-in-situ concrete construction methods. The bridge improved road safety and enhanced road transport productivity, efficiency, and reliability of travel.
Engaged by GSRG, CaSE & Pike Design served as the Specialist Temporary Works (TW) Consultant, responsible for checking various TW equipment and installations, both new and existing, throughout the construction phase.
Using 3D modelling, CaSE & Pike modelled the pier segment reinforcement. In addition to resolving clashes, they optimised pour heights to increase production.
CaSE & Pike Design were directly involved in the initial above-ground works, commencing with dual pier blades 18 metres high, built using formwork lifted by a mobile crane. Subsequently, 12-metre-long, 8-metre-high pier heads were poured on the formwork supported on a platform cantilevering 6 metres outward from the blades.
The formwork created for the pier head combined off-the-shelf formwork with components from existing form-travellers, modified for dual-purpose use to minimise the number of crane lifts. CaSE & Pike Design checked, inspected, and certified this overall formwork and access system.
The form-travellers, re-used from a previous project, were adapted to suit the bridge gradient, comply with local Australian Standards, and improve productivity and safety through several innovations. Following pier head construction, the form-travellers were assembled on top of the pier head to commence balanced cantilever construction.
CaSE & Pike also completed designs for the closure pour, including sequencing, clamping, and formwork for both end span and mid-span closures, involving significant liaison with the permanent works designer.
