WA’s historic Forrestfield-Airport Link rail project has won the $150 million-plus project value category at the 2023 WA Earth Awards, the civil construction industry’s annual awards for project excellence.
Now known as the Airport Line, the Forrestfield-Airport Link project involved two tunnel boring machines tunnelling for 8km -- the longest tunnels ever built in Western Australia.
The congestion-busting Leach Highway and Welshpool Road Interchange project won the $75-150 million category, while two other State Government Transport Portfolio projects took out the under $2 million and $5-10M categories respectively.
CCF WA CEO Andy Graham said the dominance of transport projects again this year -- with four out of the seven category winners -- underlined the importance of road, rail and harbour works to the state’s civil construction sector.
“Another hugely important sector for our industry is resources construction projects, and it was pleasing to see our member company Whittens win the $30-75 million category for works at Fortescue’s Iron Bridge project,” Mr Graham said.
“Rounding out the category winners were two projects delivered for other highly valued State Government clients -- Water Corporation and DevelopmentWA.
“We were thrilled to welcome State Government members of Parliament Hon David Michael MLA and Hon Pierre Yang MLA to the event, and to share in celebrating the winners with them.”
Another major transport project, the Mitchell Freeway Extension, was presented with the Judges’ Award.
The Earth Award category winners will now represent WA at the National Earth Awards, to be announced in Canberra on November 10.
The seven category winners and Judges Award winners are listed below with information about the projects. More information, and high-resolution images of the projects and award presentations, are available on request.
2023 WA Earth Awards Winners
Project Value more than $150 million: Webuild-NRW Joint Venture, Forrestfield-Airport Link
Now known as the Airport Line, the $1.86 billion project is the first new train line to be introduced into the Public Transport Authority network since 2007.
Construction involved two tunnel boring machines excavating directly under Perth Airport’s runways, from High Wycombe to Bayswater, reaching around 27m below ground at its deepest point. The TBMs each spent approximately 900 days underground, placing more than 9000 concrete tunnel lining rings that had been manufactured in a local facility.
The project also delivered three new stations, three emergency egress shafts, 12 cross passages, two dive structures, rail infrastructure and systems.
The project did not stop at all through the COVID pandemic. Webuild-NRW effectively managed the global supply chain issues, delivering the project within budget.
Project Value $75-150 million: Leach Welshpool Alliance, Leach Highway and Welshpool Road Interchange
This project addressed one of Perth’s most congested and dangerous intersections.
Main Roads WA’s delivery methodology involved a sole-source Alliance Development Agreement phase, which allowed the early involvement of constructor Georgiou Group, designer BG&E, and geotechnical consultant Golder & Associates. This resulted in a range of beneficial value outcomes, including earlier design enhancements – such as a more efficient and sustainable roundabout design for Welshpool Road, replacing the original signalised diamond.
Construction challenges and solutions included a non-traditional three-span post-tensioned bespoke tapered bridge over live rail. LWA created innovative temporary support systems across each stage of the bridge installation. LWA meticulously staged 32 traffic switches to ensure two lanes each way remained active on Leach Highway throughout construction.
Project Value $30-75 million: Whittens, Iron Bridge Project Earthworks and Concrete – Port, Concentrate Handling Facility & Concentrate Diversion Pond.
Whittens delivered the earthworks and concrete for the Concentrate Handling Facility and Concentrate Diversion Pond in Port Hedland – self-delivering over 320,000 cu. m of earthworks and 10,700 cu. m of concrete, and managing a multitude of specialist subcontractors.
Whittens overcame the challenges of completing critical works during the pandemic through detailed planning and efficient execution. During the tender process, the project team identified cost savings could be achieved through smarter scheduling, efficient methodologies and the use of alternative materials.
Whittens’ project team had a clear understanding of client Fortescue’s objectives, and maintained open communication with the client while creating a positive atmosphere. Through early identification of project risks, Whittens anticipated necessary actions and mitigation measures, reducing costs and avoiding disruptions.
Project Value $10-30 million: RJV, Princess Margaret Hospital Demolition & Remediation
This was one of the largest projects of its kind undertaken in an urban setting in WA. It was also one of the most high-risk, requiring significant asbestos removal, innovative solutions for managing the works close to residential areas, and the sensitive treatment of heritage elements.
With 56,000 tonnes of concrete and bricks to be removed from the site, as well as 15,000t of steel, many months of planning went into the careful management of the demolition process.
From the outset, minimising disruption to stakeholders and residents was identified as critical to the successful delivery of the project. Managing dust was a key concern and special care was taken to limit its spread using water mist cannons and scaffold containment sheeting.
To manage the extent of asbestos onsite, various innovative and advanced techniques and methods were employed.
Project Value $5-10 million: Ertech, Onslow Boating Precinct Stage 1A
This multi-stage upgrade to the boating facility and supporting infrastructure included the dredging of 45,000 cu.m of material to facilitate the construction of a rock wall revetment; two new boat ramps; and a floating pontoon holding jetty. Also included were a new stormwater drainage line, gross pollutant traps, sealed carpark and driveway, solar-powered street lighting, and associated road furniture.
Ertech’s alternative construction methodology involved a temporary earth bund, complete with dewatering systems, to protect the work area from the influence of tides. This allowed work to be performed up to 8m below high tide level, with 70 per cent of the dredging and rock revetment works able to be completed in dry conditions. The entire boat ramp construction was performed in the dry, hugely improving safety and efficiency.
Project Value $2-5 million: Rob Carr and Water Corporation, Belmont Park Optus Stadium DN500 Water Link
This project included the construction of a new water distribution main connecting to an existing DN500 water main located in the northern precinct of the Optus Stadium site; and micro-tunnelling under the PTA rail corridor and Graham Farmer Freeway to connect to a proposed DN400 water main located in the Belmont Park Development site.
The proposed pipe alignment extended across an area historically used as a landfill and a concrete batching site. Both controlled and uncontrolled fill were encountered across the site. The area was known to contain remnants of cinders and fly ash from the decommissioned East Perth Power station. This required onerous controls to manage the safety and environmental outputs. Rob Carr showcased exceptional expertise in managing a mix of ground conditions along the tunnel alignment.
Project Value up to $2 million: Enviro Infrastructure, Leighton Embankment Remediation
Enviro remediated a failing limestone embankment, which was causing debris fall and posing a risk to rail operations on the Fremantle Line. The embankment was cut almost 100 years ago in the early development period of Perth’s rail network, and years of weathering had caused sectional undermining and erosion to the limestone rock face.
Not only was the remediation footprint located within the structural clearance of the rail line and its high voltage Overhead Live Equipment, but a redundant 600mm asbestos water main was identified as running through the full extent of the 325m long remediation alignment. Despite extensive logistical and planning challenges, the project was delivered on time, on budget and with zero HSEQ incidents or quality non-conformances.
Judges Award: Mitchell Extension JV – Mitchell Freeway Extension
The extension of the Mitchell Freeway in Perth’s northern suburbs encompassed the 5.6km extension of the freeway, duplication of Wanneroo Road, new freeway access points at Lukin Drive, Butler Boulevard and Romeo Road, shared paths, underpasses, and a bridge over the Butler railway.
Sustainability was a priority focus, with the joint venture engineering innovative solutions to reduce the project’s carbon footprint. This included the first successful trial of EME2 sustainable asphalt for Main Roads WA, and sharing materials with METRONET’s Yanchep Rail Extension project to reduce waste.
Showcasing exceptional innovation and agility throughout the program, the JV employed cutting-edge techniques to optimise cost effectiveness for on-time delivery of a seamlessly executed project, with two major additions to the original scope.
