Black Hill Intersection

Overview:

This project involved the duplication of John Renshaw Drive and Construction of a Signalled Intersection to the new Black Hill Industrial Estate.

The project was delivered under a Works Authorisation Deed (WAD) between TfNSW and Blackhill Industrial Pty Ltd.  KCE were engaged by Blackhill Industrial Pty Ltd as Principal Contractor to undertake the construct only contract.

Scope of work:

• Duplication of the existing John Renshaw Drive involving the widening of the existing road from a single lane in either direction to a dual carriageway for 1.5km including a signalised intersection.
• Management of the works involved guiding traffic through the 1.5km work area over a 60 week construction period. John Renshaw Drive at the location of the works is a high traffic volume road (10,000 vehicles per day) with an existing speed limit of 80-100km/hr.
• Construction works involved bulk earthworks, lime stabilised subgrades, heavily bound base course, stormwater pit and pipe network, kerb and gutter, box culverts, cast in-situ retaining wall and integrated F Type barriers, street lighting, guardrails, overhead power augmentation, deep lift asphalt pavement and wearing courses.
• It also involved the construction of a 1200 dia pipe sleeve to cater for future expansion of the water network. This work was alongside and in close proximity to Hunter Water’s Chichester Trunk Gravity Main (CTGM) which is a major piece of water infrastructure. A strategy of de-pressurisation and round the clock construction was formulated with Hunter Water and implemented to ensure continued supply, minimise disruption and eliminate some safety risks. A bridge structure was then constructed over this portion of the works for permanent access to the development. There were stringent requirements for undertaking this portion of works involving vibration monitoring, deflection testing and working during the de-pressurisation period.

Highlights and challenges:

• Management of substantial creek flows and difficult ground conditions for substantial culvert extension with excellent environmental outcomes.
• Cooperation with Hunter Water to resolve continuity concerns around feeding supply reservoirs during CTGM works.
• Positive working relationship with TfNSW and Independent Verifier to overcome issues and optimise outcomes.
• Complex management of traffic and staging for John Renshaw Drive being main thoroughfare between M1 and Hunter Expressway
• Complex management and procurement of quarried materials during industry shortage caused by prolonged wet weather and competition with other large TfNSW infrastructure projects occurring concurrently.