Precast concrete everywhere

The most obvious usage of precast concrete on the West Gate Tunnel Project is the tunnels themselves.

Each of the 3-lane tunnels requiring 2500 precast concrete segments to line the interior.

West Gate Tunnel Project photo

But the massive viaduct running above Footscray Road also requires tonnes of precast concrete.

Piers to hold up the two carriageways.

Then there is the bridge deck itself.

Assembled using a giant mobile gantry.

From shorter sections of precast concrete.

Enter LS Precast

In a paddock outside Benalla is a yard filled with massive pieces of precast concrete.

Google Maps

Cranes everywhere.

Each massive piece of precast concrete was created inside an bigger sheds.

Then stacked up outside.

Google Maps

Hundreds of tunnel lining segments waiting to make the trip to Melbourne.

Multiple times a day, A-double semi trailers departs the yard.

On the 200 kilometre, two and a half hour drive down the Hume Highway to Melbourne.

There they thread their way through the western suburbs to West Gate Tunnel work site.

The precast concrete elements that make up the elevated viaduct above Footscray Road are also manufactured at Benalla.

But since these elements are much larger.

West Gate Tunnel Project photo

They need to be transported by specialised low loader trucks.

West Gate Tunnel Project photo

To spread their extreme weight across the road surface.

West Gate Tunnel Project photo

What about trains

Benalla is on a railway line, and so is Melbourne – so why not transport all of these pieces of precast concrete by train? Well, that is exactly what the government said would happen.

New Benalla manufacturing facility to create hundreds of jobs for rural and regional Victorians
1 Feb 2018

Victoria’s largest precast concrete manufacturing facility will be built in Benalla to supply major Victorian infrastructure projects, create 400 jobs and provide a massive boost to the local economy.

The $60 million facility will be operated by local businesses and will supply precast concrete for major projects including the West Gate Tunnel Project.

The facility will be capable of producing up to 1,500 tonnes of concrete product per day at peak capacity.

Benalla’s access to road and rail infrastructure means the facility is well placed to supply future Victorian and interstate projects, creating ongoing economic benefits to Benalla and surrounding communities.

To limit the number of trucks on local roads, the precast concrete segments for the West Gate Tunnel Project will be transported to Melbourne by freight train.

A new 700m rail siding will be built along the existing rail line in Benalla to provide a direct link between the precast facility and Melbourne.

The West Gate Tunnel Project will provide an estimated $11 billion boost to the Victorian economy, creating 6000 new jobs.

Construction of the Benalla precast facility is due to commence in March 2018, and it will be fully operational from October 2018.

With a railway siding constructed right into the casting plant at Benalla.

New Rail Siding For Benalla Precast Concrete Facility
25 September 2018

Work has started on a huge rail siding to service the new precast concrete facility being built in Benalla.

Minister for Roads Luke Donnellan joined Member for Northern Victoria Jaclyn Symes to visit the worksite today, that will soon start producing precast concrete for the Andrews Labor Government’s West Gate Tunnel.

A new 700 metre siding will be created from the existing rail line to provide direct access to the precast facility.

New rail track will also be built – connected to the nearby freight line – so the concrete segments can be loaded directly from the precast facility on to freight trains and transported to Melbourne.

About 20 metre of new track has been laid and the existing train line is being upgraded ahead of the commissioning of the new siding in late 2018.

Construction is well underway on a new $60 million precast concrete facility in Benalla in readiness for concrete production.

The facility will initially provide over 65,000 concrete products for the massive West Gate Tunnel Project.

Excavators are currently levelling the site and the steel frames are going up for the three large sheds to be built on the site.

The precast facility will include a concrete batching plant, the large sheds for precast concrete production, offices, precast product storage, maintenance areas, a precast rail siding and 300 car parking spaces for workers.

The precast facility will be the largest of its kind in Victoria, capable of producing over 1,500 tonnes of concrete product per day at peak capacity.

The precast facility will create 400 jobs and will help ensure regional communities can benefit from the many opportunities created by the state’s booming infrastructure sector.

Quotes attributable to Minister for Roads and Road Safety Luke Donnellan

“It’s fantastic to see the progress being made on this, the largest precast concrete facility of its kind in Victoria.”

“Building the new rail siding means that we can get concrete products from Benalla to Melbourne via the existing rail network, avoiding heavy vehicle traffic and associated road impacts.”

Quotes attributable to Member for Northern Victoria Jaclyn Symes

“This is a massive investment in Benalla and we are already seeing jobs being created for local people with construction well underway.”

“This facility nearly didn’t happen due to the Liberal and National parties’ opposition to the project, I’m proud that my home town of Benalla and people throughout the north east share in the benefits of the Andrews Labor Government’s West Gate Tunnel.”

But by October 2020 their messaging had changed.

By having the concrete segment facility in Benalla, it ensured that regional Victoria benefited from our state’s infrastructure boom – creating jobs and providing a boost to the local economy.

The facility is supplying a variety of precast concrete products for the West Gate Tunnel Project and was selected due to its proximity to local quarries, its production capability and the easy access to Melbourne via transport networks . These products come in a range of sizes, shapes and weights.

A number of precast segments are not suitable to transport by freight train and will be delivered to West Gate Tunnel work sites by truck, using approved truck routes. The project team is exploring which precast segments are suitable to transport to Melbourne via rail. We’ll keep you updated through these channels as things progress.

The rail siding is clearly visible in the aerial view on Google Maps.

Google Maps

But as fas as I know, the rail siding at the Benalla precast yard has never been used by trains, and none of the precast segements have been transported by rail – however the cement used to make the segments did get moved by rail to Benalla station.

Footnote: some videos

Building the concrete precast facility at Benalla.

And flying over the completed yard.

Test fitting tunnel lining segments.

Delivering precast segments to the West Gate Tunnel work site.

Assembling the bridge columns.

And an animation showing how the bridge builder above Footscray Road works.

Footnote: other recent projects

The concrete segments for the Metro Tunnel were cast at a yard at Ravenhall, only 30 kilometres from their final destination.

While the precast concrete for the ‘Skyrail’ bridges were initially cast 50 kilometres away at Pakenham, and are now cast 70 kilometres away at Kilmore.

Post retrieved by 35.215.163.46 using

The post Precast concrete from Benalla with love appeared first on Waking up in Geelong.

On the downstream side is the original 1936 bridge, with art deco-styled decorative parapets, pillars, and light fittings.

And beside it a far more utilitarian concrete bridge completed in 1992.

In the beginning

Lynch’s Bridge was an early crossing place on the Maribyrnong River for those headed west of Melbourne, with owner of the neighbouring Pioneer Hotel, Michael Lynch, operating a punt on the site from 1849. A competing crossing was operated by Joseph Raleigh at Maribyrnong, which replaced his punt with a bridge in 1858.

SLV photo IAN20/12/66/4

And so in 1863 Michael Lynch petitioned the government for permission to replace his punt with a pontoon bridge, provided he was granted a half acre of land on the eastern bank of the river for the abutments and approaches.

Members of the Essendon and Flemington Council not in favour of private bridges, and the matter was debated, with one local resident questioning the motives of Lynch.

In September 1864 a motion was passed to prohibit Lynch from building a bridge, but it soon rescinded, with the new bridge in use for Melbourne Cup Day 1864.

‘Flemington Racecourse from the Footscray side of Salt Water River, Victoria ‘ by J Ryan

Local residents found the toll gate a nuisance, but Lynch talked up his bridge, telling Western District sheep and cattle owners they only needed to pay a single toll if headed to the sheep and cattle yards on the opposite bank.

As a result in 1866 the Essendon and Flemington Council proposed purchasing Mr Lynch’s bridge, as did the Footscray Council in 1867. However it took until in 1882 for the bridge to be brought under public ownership, the Footscray Council abolished the toll and requesting the Commissioner of Public Works pay the reminder of the loan.

A replacement bridge

However that was not the end of the saga – in October 1901 Lynch’s Bridge was closed by the Public Works Department due to it falling into disrepair, and a Mr J. Byers erected a pontoon bridge beside it to carry traffic to Flemington Racecourse, for a “small toll” of one penny. The debate as to who should fund the cost of a new bridge continued in the months that followed, with a tender finally awarded in December 1902 – eighteen months since the bridge was closed.

MMBW plan 781

The new bridge opened without ceremony in May 1903, after contractors finished their work and left it open for traffic, with members of the Flemington and Kensington Council holding an official opening a few days later, without the involvement of the Footscray Council who also funded it.

SLV photo H2151

The new bridge was built of timber, and had a lifting span in the middle, which sometimes caused delays to river traffic, and had high ongoing running costs.

Haven’t we been here before?

September 1929 was a familiar event – Lynch’s Bridge closed after being declared unsafe for traffic, reopening after temporary repairs were completed over a three week period.

The Footscray Council and the City of Melbourne then considered a number of options for a permanent crossing – a new five span reinforced concrete bridge for £38,750, a new three span steel bridge for £35,900, or extending the life for the existing bridge for five years for £2,250. The Footscray Council objected having to fund half the cost of a new bridge, delaying the start of construction, with an agreement finally reached in January 1936 for the Country Roads Board to pay half the cost of the project.

Opened in 1939, the new Lynch’s Bridge was built on a different angle to the timber bridge it replaced, allowing Ballarat Road to be realigned to meet Smithfield Road, eliminating a dangerous curve on the Footscray side. The Footscray Council suggested naming the new bridge ‘Gent’s Bridge’ after the Town Clerk of Footscray, but it came to nothing.

Traffic troubles

As Melbourne grew, the amount of traffic using Lynch’s Bridge grew – 43,000 vehicles per day using it in 1989, half the volume that used the West Gate Bridge. And the area became known as a blackspot for motor vehicle crashes, with the 1985-88 period seeing 79 separate incidents, including 16 head-on collisions, and nine deaths.

The Age, 23 November 1989

Leading in November 1989 to a coronial inquest being opened into a number of recent fatalities at the site.

Excessive speed was the main cause of car accidents on Lynch’s Bridge in Kensington, an inquest on three deaths on the bridge was told yesterday.

Sergeant Noel Osborne, of the accident Investigation section at Brunswick, said that despite measures to make the four-lane bridge safer, most vehicles approached it too fast. 

The deputy state coroner, Mr Graeme Johnstone, is holding joint inquests on Kevin John Lewis, 35, of Broadmeadows, and Emily Jane Stonehouse, 4, of Werribee, who were killed in an accident on 23 October 1988, and Matthew James Simmons, 25, of Box Hill, who died in an accident on 14 February this year.

Lynch’s Bridge crosses the Maribyrnong River near Flemington Racecourse. The approach from Footscray, on Ballarat Road, has three lanes that narrow to two before a sharp left-hand bend on to the bridge. The Smithfield Road approach, from Flemington, is two lanes.

Sergeant Osborne, asked by Mr Johnstone to suggest safety measures, said that even if the Ballarat Road approach was narrowed to one lane in an effort to slow traffic, he believed many drivers would still try to take the bend too fast. He said the answer was to duplicate the bridge.

“That in my mind is the answer. We certainly would not be having the head-ons as we are now. The number of people killed at this location has caused me great concern. It appears that not a great deal has been done.”

Mr John Connell, of the Roads Corporation, said speed cameras had shown that more than 70 per cent of vehicles approaching the bridge on Ballarat Road travelled faster than the 60 kmh speed limit. The fastest speed had been 139 kmh despite signs recommending 55 kmh.

Peter James McDonald, a truck driver from Maidstone who crosses Lynch’s Bridge regularly, said that at the time of the accident involving Mr Simmons, the camber of the road pulled vehicles to the right as they turned left on to the bridge from Ballarat Road. The inquiry is continuing

The inquest heard that duplication of the bridge had been proposed in 1975, with the cost in 1989 money estimated to be $3 million.

In his findings to the 1989 inquest, Coroner Graeme Johnstone noted that the 1938 bridge was not unsuitable for the volume and speed of traffic passing over it, recommending that the Ballarat Road approach to the bridge be restructured so that the three-to-two lane merge is further from the sharp bend onto the bridge, and that the VicRoads make duplication of the bridge a priority in their road improvement program.

As a result, a duplicate bridge on the upstream side of original bridge was completed in 1992, allowing the 1936 bridge to be dedicated to westbound traffic.

The duplication of Lynch’s Bridge and road approaches at Flemington was opened to traffic in April 1992 and has eliminated one of Melbourne’s worst accident blackspots. In accordance with a Coronial Inquiry recommendation to fast track the works, new technology for bridgeworks and roadworks construction was used. Road approaches over poor ground conditions utilised polystyrene as lightweight fill – a first for VicRoads and Australia. The method reduces road settlements to manageable levels and achieves cost savings over more conventional alternatives. The project was completed in June 1992 at a cost of $5.5million.

And finally – another upgrade

In August 2019 it was announced that Lynch’s Bridge would be upgraded as part of the Western Road Upgrade public–private partnership.

A National Trust-listed bridge which was once the main gateway to Melbourne’s west will be upgraded this week as part of the Victorian Government’s Suburban Roads Upgrade.

Member for Footscray Katie Hall today announced the start of important work to rehabilitate the Ballarat Road Bridge, under the $1.8 billion Western Roads Upgrade.

The crossings over the Maribyrnong River are steeped in history, with the outbound Lynch’s Bridge built in 1936 and heritage listed for its “historical and technical significance” by the National Trust in 2005. Millions of Victorians and visitors would have crossed this bridge in some form.

Lynch’s Bridge also holds technical engineering significance, as one of the first steel and concrete crossings designed so the reinforced concrete deck works together with the steel beams.

The historic five-span bridge sits alongside its more modern counterpart known as the Smithfield Bridge, which was built in 1990.

The 108-metre bridges will undergo work to strengthen them for the future for up to 45,000 vehicles which travel over them every day.

It is anticipated they’ll be used by up to 50,000 cars and trucks daily by 2031.

The art-deco style of Lynch’s Bridge will be preserved as safety barriers are upgraded on both bridges, and footpaths and drainage will also be improved.

There will be some lane closures in place as this work is underway to ensure road crews can work safely and quickly.

Work included.

– removed old barriers and replaced them with new safety barriers
– installed cathodic corrosion protection to protect the metal bridge supports from rust and deterioration
– resurfaced the road on the bridges and on approach to the bridges
– removed features no longer needed such as broken lights.

You had to look close to see the changes.

Major Roads Project Victoria photo

But the big new crash barriers are easy to see when driving past.

But one thing that is obvious is the focus on motor vehicles, not active transport.

The bridge has enough space for a grass median strip!

Yet pedestrians are forced into a narrow footpath.

And cyclists are given a narrow strip of asphalt, centimetres from passing vehicles.

Pretty crap upgrade, isn’t it?

Footnote: water under the bridge

When I visited Lynch’s Bridge in December 2020, I noticed these new looking steel additions to the piers of the 1992 bridge.

My initial thought was strengthening work linked to the Western Road Upgrade project, but turns out I was wrong – it’s actually linked to the West Gate “Tunnel” Project.

West Gate Tunnel Project photo

A post on their Facebook page dated 11 November 2021 mentioning the work.

West Gate Tunnel Project crews have started working on modifications to streamline the piers on the Smithfield Road Bridge.
These works will help during high flows in Maribyrnong River and mitigate flooding once our new Maribyrnong River bridge is built. Gaps between the columns will be filled with concrete to create a wall type pier with rounding at both ends.

The works required to compensate for new piers in the Maribyrnong River at Footscray.

West Gate Tunnel Project photo

Forming part of the elevated roadway between Footscray Road and the actual West Gate “Tunnel”.

West Gate Tunnel Project photo

And the work at Lynch’s Bridge seems to have flown under the radar – the only other mention of it I could find was a single line in the West Gate Tunnel Project “Final Report for Submission to the Minister for Planning” for March 2019 to August 2019.

Flood mitigation works completed at Smithfield Bridge

I wonder what difference these works made to the October 2022 Maribyrnong River flood?

Post retrieved by 35.215.163.46 using

The post A history of Lynch’s Bridge at Footscray appeared first on Waking up in Geelong.