Rail
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Project One | Introduction
Morley Ellenbrook Rail Extension – METRONET
Permacast supplied the structural precast package for Perth’s first elevated rail structures at Whiteman Park and Bayswater, part of the Morley–Ellenbrook Line, METRONET’s landmark public transport project.
We provided constructability advice, cost-effective precast solutions, and complex lift planning, ensuring seamless coordination with MELconnx. With high-volume production and 120,000 m² of secure storage, we delivered just-in-time components, reducing site risk and disruption. The project featured road-over-rail and underpass structures, complex bridgeworks, and Australia’s first ballast box spreader for 21 km of track ballast.
Project One | Overview
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Client
MELconnx
Location
Bayswater to Ellenbrook, WA
Duration
2023
Cost
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Project Specifications
- 444 precast structural elements, including:
- 40 Prestressed/Post-Tensioned L-Beams (Whiteman Park Viaduct)
- 50 Prestressed Box Beams (Bayswater Viaduct)
- 35 Headstocks (Bayswater Viaduct)
- 319 Precast Planks (Bayswater Viaduct)
- Dual-crane beam lifts involving complex rigging, detailed lift plans, and multi-team coordination
- Fabrication at Permacast’s Cardup facility, with integrated QA/QC procedures
- Early-stage constructability reviews, reinforcement modelling, and clash detection
- Off-site storage and delivery sequencing supported by 120,000m² of secure, compacted hardstand
Project Details
- Designed for elevated rail infrastructure, Whiteman Park Viaduct L-Beams required exceptional engineering precision and rigorous production control, exceeding typical precast bridge complexity.
- Advanced 3D modelling and clash detection resolved constructability challenges and sequencing in the highly congested reinforcement design.
- Post-tensioning ducts were precisely installed within dense reinforcement zones, ensuring accurate placement and seamless integration.
- Large volumes of cast-in components were installed within tight tolerances to meet strict design specifications.
- Extensive temporary works were engineered to safely support fabrication, lifting, and handling of long-span elements.
Project Two | Introduction
Forrestfield Airport Link
The Forrestfield Airport project is a major infrastructure initiative involving 3,325 tonnes of reinforcement, thousands of reinforcement cages, station components, and noise and retaining walls. Permacast has applied precision manufacturing, innovative handling methods, and strict safety practices to meet the client’s rigorous specifications and accelerated timelines efficiently.
Project Two | Overview
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Client
SI-NRWJV
Location
Forrestfield Airport
Duration
2017 – 2020
Cost
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Project Specifications
- Total of 3,325 tonnes of processed reinforcement
- Type One: 8,700 rings, six reinforcement cages per ring, totaling 52,200 reinforcement cages at 350 kilograms each
- Type Two: 215 rings, six reinforcement cages per ring, totaling 1,290 reinforcement cages at 1,200 kilograms each
- Fabrication tolerances: plus zero / minus five millimetres
- Airport Station: four beams, 26 tonnes each
- Tunnel liners: 20,500 reinforcement cages
- Belmont Station: 65 deck planks
- Bayswater: 220 noise and retaining walls
- 18,000 units of Monoblock rail sleepers
Project Details
- Fully welded reinforcement cages manufactured to stringent specifications in accordance with AS1554.3.
- Production capacity of up to 36 rings per day, equivalent to 216 reinforcement cages daily.
- A process-driven project requiring precise time management where every minute counts.
- Permacast managed all transport and logistics in-house, coordinating approximately 900 B-double truckloads.
- Custom transport stillages designed and manufactured to maintain shape and dimensions during transit.
- Storage capacity for over 600 rings, allowing production up to three months ahead of casting to minimize client and project risk.
- Unique manufacturing and handling methods developed to achieve outstanding safety and efficiency outcomes.
- First-time adaptation of Permacast’s specialist in-house reinforcement manufacturing methods for an external client.
- Accelerated setup implemented to meet tight deadlines.
Testimonials
Our collaborative efforts have contributed to the success of significant projects, including major infrastructure initiatives such as the New Perth Stadium and the Gateway WA project.