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.

SI-NRWJV

Forrestfield Airport

2017 – 2020

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• 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

• 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.