Byford Rail Extension – METRONET

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Introduction

The Byford Rail Extension is a flagship METRONET project extending the Armadale Line 8km south, providing a vital public transport link for Perth’s growing south-eastern suburbs. This $846 million investment improves commuter access, reduces congestion, and supports urban growth. Permacast supplied the structural precast package for the Armadale Viaduct and Wungong Rail Bridge, working closely with METCONNX to optimize constructability, reinforcement, and sequencing, simplifying on-site construction and reducing program risks. Co-located at Permacast’s facility, the client benefited from seamless communication and fast decision-making. To meet tight deadlines, Permacast scaled production, extended work hours, and prefabricated elements concurrently, using secure storage for just-in-time deliveries. The project included WA’s heaviest beam and a custom pier-to-pile connection system developed with the client.

Client

METCONNX

Location

Armadale to Byford, WA

Duration

2024

Cost

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Project Specifications

  • 830 precast elements manufactured under tight tolerances, including:
  • 77 Piers
  • 94 Headstocks
  • 107 Prestressed Box Beams
  • 20 Prestressed Station Beams
  • 532 Precast Planks
  • 13,327m³ of high-performance concrete
  • 6,296 tonnes of reinforcement steel
  • 9-month production and delivery program
  • 120,000m² of sealed hardstand storage and laydown area, supporting flexible delivery sequencing
  • Night-time deliveries (2am–5am) to minimise traffic disruption, coordinated with site operations

Project Details

  • This project marked Permacast highest-ever volume of structural precast elements and included some of the most complex components we’ve delivered to date.
  • Industry-first pier-to-pile connection detail, developed in collaboration with METCONNX and achieved through custom Permacast mould design, allowing faster installation and increased on-site tolerances
  • Manufactured and delivered WA’s heaviest precast beam, a 240-tonne, 45-metre-long prestressed unit, using a Permacast designed and third-party certified transport cradle, 24-axle haulage, and dual-crane lift planning with engineered rigging.
  •  We had an industry-first high-flow concrete mix designed and approved by PTA within three months, the first of its kind approved for bridge beams and planks in WA. It enabled full coverage through congested reinforcement, resolving a key constructability challenge.