The North West Rail Link elevated viaduct is part of the Sydney Metro Northwest rail line between Kellyville and Rouse Hill. The 4km ‘skytrain’ consisted of 124 spans with a 270m long stay cable bridge constructed over Windsor Road at Rouse Hill. The skytrain runs parallel with Windsor Road and was constructed using a combination of overhead gantry (ISJV), under slung gantry (VSL) and false work.

Freyssinet was contracted for the design, supply and install of 476 pot bearings (205t). Freyssinet Products Company (FPC) Asia was consulted for design, technical and sales assistance. FPC Romania and FPC Italy coordinated production and quality control with bearings testing conducted by ISOLAB.

  • General Contractor
    Salini Impregilo Joint Venture
  • Customer/Owner:
    Transport for NSW
  • Engineer
    SMEC Australia Pty Ltd
  • Freyssinet Subsidiary
    Freyssinet Products Company Asia
  • Works period
    January 2014 - September 2017

Freyssinet Scope

Details of the design and supply of the pot bearings include:

  • Total of 476 pot bearings
  • Total bearing weight was 205 ton with largest individual bearings weighing 6.9 ton (1.8m x 1.8m) on the stay cable bridge.
  • Some bearings included temporary locking device (designed by Technical Department) to accommodate the erection methodology
  • Due to their size, the larger bearing on stay cable bridge incorporated an innovative recessed circular hollow masonry plate to optimise edge clearance issues.
  • Requirements to be met for Australian market: special corrosion protection system (SYS1NO), PTFE bonded to the piston.

Installation of pot bearings was also conducted by Freyssinet:

  • Bottom mortar pad constructed in advance of the superstructure erection.
  • Top mortar pad integrated with the erection cycle to determine timing of grouting.

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