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.

MELconnx

Bayswater to Ellenbrook, WA

2023

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• 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

• 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.