The West Gate Tunnel Project will deliver a vital alternative to the West Gate Bridge, providing a much needed second river crossing, quicker and safer journeys, and remove thousands of trucks from residential streets.

The project will link the West Gate Freeway at Yarraville to the Port of Melbourne and CityLink at the Docklands via twin tunnels beneath Yarraville and an elevated Footscray Road.

The elevated road includes 300 piles of variable height. The piles have been precast in multiple segments, close to the site. Vertical post-tensioning bars assembly together all the segments of each pile.

This construction method of piles is more and more common but requires an impeccable preparation, both in terms of method statement and products definition. Each detail is fundamental for the success of the installation.

Dextra supplied Freyssinet with more than 1,000 tons of Freyssibar+ systems, grade 930/1080 MPa, with nominal diameters of 72mm and 55mm, and 7,500 anchorages for vertical permanent application.

With a close cooperation between DEXTRA, Freyssinet back-office (Technical Department and Freyssinet products company) and the job site staff (Freyssinet Major Project and Freyssinet Australia), the post-tensioning system has been perfectly adapted to the needs of the project.

The bar diameters, steel grade and the design of the anchorages have been validated through qualification tests according to Australian Standards, demonstrating the performance of the system.

This bar system can be used for post tensioning, prestressed ground anchors and any application involving temporary or permanent tie-rods, lifting, suspension, prestressed splices, etc.

Major project construction started in January 2018.