Flinders Street Viaducts: Melbourne CBD

One of the projects we are currently working on is the Flinders Street Viaduct.

The old viaduct was initially constructed in 1889 then duplicated in 1915. The four lines help to carry the City Circle, Burnley, Caulfield, and Northern loop  between Flinders Street Station and Southern Cross Station.

In the 1970s during the construction phase of the City Loop the four tracks of the old viaduct were upgraded for bidirectional use with the northern bridge carrying the City Circle and Burnley Loop tracks and the southern bridge carrying the Caulfield and Northern Loop tracks. The overall length of the viaduct measures approximately 760m with individual spans ranging from 10m to 24m.The northern bridge consists of 45 spans from the brick abutment beside the car park of the Grand Hotel to the Flinders Street Station vaults at Banana Alley. The southern bridge comprises 44 spans as it does not pass over Span 1 or Pier 2 and sits on original ground adjacent to the Grand Hotel at the corner of Flinders St & Spencer St.

This work involves refurbishing the 270m long section both underside and topside within the rail corridor between spans 1-16. Over 12000 square meters of steel.

Flinders Street Viaduct Flinders Street Viaduct Flinders Street Viaduct

McElligotts have been able to achieve treatment of 216lm of topside girders in just 50hrs! including full containment, hazardous coating removal, and a 3 coat protective system applied. Just 8 occupations will see the topside completely refurbished.

Works on the underside is just as complex dealing with numerous stakeholders, detailed pedestrian and traffic management including works over tram and busways.

McElligotts are achieving fantastic results supported by our accredited management systems, enabling these high risk works to be undertaken on one of Melbourne’s busiest thoroughfares without impact to the nearby public or environment.

Achieving a remarkable finish we are able to give new life to this iconic structure and help make it a feature of the area for many years to come.

We’re proud to have been contracted by Metro Trains Melbourne to remediate this significant Melbourne structure.

Flinders Street Viaduct Works

Flinders Street Viaduct Upgrade

Port Lonsdale Lighthouse

McElligotts were recently engaged by the Victorian Ports Corporation Melbourne (VPCM) to undertake remedial works on the heritage listed Point Lonsdale Lighthouse.

The Point Lonsdale Lighthouse is located in Point Lonsdale, Victoria and is operated by the Victorian Channels Authority. The Lighthouse stands on the eastern end of the Bellarine Peninsula, on the western side of the entrance to Port Phillip from Bass Strait, overlooking one of the ten most treacherous navigable passages in the world, the “rip”.

First lit in 1902, the Point Lonsdale Lighthouse plays an important part in Victoria’s history, having helped keep sailors safe for many years.

The design is quintessential of late nineteenth century Victorian lighthouses, consisting of a cylindrical concrete tower atop an octagonal prism signal station and observation room. The structure is made from reinforced concrete and surmounted by a lantern, which was later replaced with an acetylene light and later again, an electrical light.

Now, the Point Lonsdale Lighthouse holds weekly tours where visitors can explore the inside of the building and learn the right history of the lighthouse, so it’s important that it remains safe for use and looks as good as new. As part of the remedial works, McElligotts will be carrying out steel refurbishment and re-coating the outer side of the lighthouse. We are honoured to have been chosen to work on this important historical building and cannot wait to get started.

Point Lonsdale lighthouse repairs

Wantirna Sewer Shaft

McElligotts was engaged by Melbourne Water to rehabilitate the Wantirna Sewer Shaft in March, 2017.

The scope of work included the rehabilitation of a 65m deep and 12m diameter sewer shaft. At McElligotts, the safety of our staff and clients is our top priority, so It was especially important for us to maintain a safe system of working as working within a live sewer can be dangerous for a number of reasons.

Our work on this project included:

  • Access, egress and rescue capability
  • Work platforms, safety lines and catch facilities
  • Cleaning of all internal surfaces in the shaft
  • Removal of all softened and acidified concrete from shaft walls and platforms
  • Rehabilitation and remediation of all concrete surfaces including rebuiliding
  • Application of a protective coating

McElligotts finished this project within a short six-month time frame, working around the clock to ensure the Wantira Sewer Shaft was restored as quickly as possible.

Black Hill Water Reservoir

McElligotts was engaged to remediate concrete seepage at the Black Hill Water Reservoir. Owned by the Hunter Water Corporation, the Black Hill Water Reservoir is an 86 million litre water reservoir, constructed in 1939. The structure was still in good overall condition, but had begun to show signs of seepage, with water escaping through deteriorated joint seals and cracks in the concrete slabs. Remedial concrete works were necessary to keep the water safe and the structure stable and protected. We completed the project between July and September 2017.

The project demanded a 20-year minimum design life and certification with the Australian standard AS/NZS 4020 for contact with potable water.Firstly, we applied a primer to the concrete surface and placed a flexible bonding tape to the 5,000 lineal metres of joints. To repair the cracks in the floor and toe slabs, Intercrete 4841 (cementitious-polymer protective coating) and Intercrete 4872 (waterproof reinforcing tape) were selected as the most suitable products within the project’s requirements.

We had a timeframe of 42 days for this project which had a floor area of 11,000m2 and short shutdown windows when we were able to apply the coating. When selecting the coating and application method, we needed to accommodate for the structural movement and stresses observed during the regular usage and maintenance of the site (up to 5mm vertical movement in the floor was observed in prior surveys).

Ultimately, we were able to meet the client’s requirements to schedule, and we’re pleased with the finished outcome. The Black Hill Water Reservoir will be well-protected from any structural stress and corrosion for decades to come.

West Gate Bridge Strengthening Project

Built in 1978, West Gate Bridge is an iconic structure that’s played a huge part in moving Melbourne for decades. After thirty years of operation, West Gate Bridge had daily traffic of 160,000 vehicles, compared to the 40,000 it was carrying per day after opening. McElligotts was sub-contracted by John Holland Construction for abrasive blasting and other remedial works.

Roles we performed included removing and containing red lead paint, abrasive blasting of the internal and external structures and creating profiles for strengthening steel and carbon fibre to be attached. At the time, this was one of the largest projects in the world incorporating carbon fibre. We enjoyed working on this project and overcoming the challenges it faced, including traffic and fast turnover requirements. At the height of this project, McElligotts had 100 workers per day on-site.

West Gate Bridge 2019-2021:

In February 2019, we were proud to have again been contracted by VicRoads to work on the West Gate Bridge, this time as part of their painting refurbishment project. We are still currently working on this project and are on track to have it completed in conjunction with the set deadline. The scope of work is somewhat similar to the original work we did on the bridge, only this time we are just focusing on restoring the painting and abrasive blasting rather than strengthening.

Our main task is to abrasive blast and paint 55,000 sqm of steel on the underside of the bridge, which included blasting the 9 platforms that are suspended 60m off the ground. In order to do this, the platforms are contained to a class 1 containment system and then abrasive blasted back to bare steel for inspection of the steel condition. In alignment with our sustainable values here at McElligotts, all waste material is vacuumed up and bagged at the bottom of the bridge. After this, the surface is then re-blasted and a 4-coat system is applied to the steel structure and signed off before the platforms can be traversed along the bridge.

Photo Gallery:

Here we see the underside view of the work platforms, (8) in total , that we work from to carry out the containment , abrasive blasting and recoating of the steel section underside . As work is completed the platforms are inched along from East to West across the massive steel spans of this bridge. A truly amazing project to be involved in .

West Gate Bridge Remediation

Eastern Treatment Plant Refurbishment

McElligotts performed remedial construction works during the Eastern Treatment Plant refurbishment between August 2011 and November 2013. During construction, major leaks had developed in concrete structures, requiring a strip of the existing coating and a relining. Our team lined over 5000m2 of concrete with Polibrid, using a reinforced coating system we’d developed using geo fabric. Geo fabric was pinned to the concrete to mitigate the potential for future coating failures.

From there, we applied intercrete bands to expansion joints, providing extra strength in the coating system to prevent water pressure leaking through the joints. Ultra-high pressure surface preparation was performed on the external concrete surfaces to ensure the correct surface profile was achieved. As the water treatment plant has some high foot traffic areas, we made sure that the coating selected was non-slip. This was a large project requiring many co-ordinated steps with 200 other contractors onsite working alongside us.

Refinery Maintenance

We conduct remedial maintenance programs at oil and gas refineries across Australia, putting together maintenance programs tailored to our client’s needs. Our team have worked on tanks, pipelines, walkways, vessels and exchangers, providing services that include:

  • Ultra-high pressure cleaning and surface preparation
  • Abrasive blasting and hand tool surface preparation
  • Robotic blasting
  • Relining
  • Scaffolding access
  • Protective coating application
  • Toxic paint removal
  • Remedial concrete works, including concrete injection and chemical bunding