{"id":25091,"date":"2022-08-16T15:35:50","date_gmt":"2022-08-16T05:35:50","guid":{"rendered":"https:\/\/www.infrabuild.com\/?post_type=case_study&#038;p=25091"},"modified":"2022-08-16T15:35:52","modified_gmt":"2022-08-16T05:35:52","slug":"sydney-gateway-external-challenges-no-deterrent-for-projects-success","status":"publish","type":"case_study","link":"https:\/\/www.infrabuild.com\/case-studies\/sydney-gateway-external-challenges-no-deterrent-for-projects-success\/","title":{"rendered":"Sydney Gateway: External challenges no deterrent for project\u2019s success"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\"><em>Large-scale infrastructure projects inevitably have their challenges and complications. COVID and a La Nina weather pattern, which saw the highest ever recorded rainfall totals on the Australian East Coast, have challenged the Sydney Gateway project in ways no one foresaw.<\/em><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">InfraBuild Reinforcing\u2019s Steve Niven, Peter Markuse and Dave Drevon have taken time to reflect on key lessons stemming from the business\u2019s involvement on the Sydney Gateway project to date. The team also explores what the project means for the InfraBuild business in terms of product supply, manufacturing capacity, and the benefits we\u2019ve been able to offer customer John Holland and Seymour Whyte.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cThe project commenced in November 2020 \u2013 and to date, we\u2019ve supplied around 1,400 tonnes of bar and 2,000 tonnes of prefab. So, we\u2019re probably around 15 percent into the job. It\u2019s a 15,000-tonne job so we\u2019re still very early days\u201d, explains Project Manager Steve Niven.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Sales Manager for Infrastructure and Major Projects Peter Markuse says the preplanning by the Reinforcing team has been a significant factor in keeping the project on target.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cWe recently received a big rap from the customer because we spent a lot of time preplanning. We&#8217;ve been working with them from the start due to the volume of the piling cages that were involved.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cWe said we\u2019d like to start delivering early, so we started delivering two to three months earlier. That kept the program up and has been a significant factor for us, particularly with the unpredictable weather.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cBeing in front has been a real benefit, and a real key learning for infrastructure jobs going forward. When we talk to customers on new jobs, we talk to them now about how we can start supplying earlier and discuss how they can find some room for that, to maintain the program. That\u2019s important and has been a major lesson,\u201d explains Peter.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">NSW Regional Prefab Manager Dave Drevon has taken a lead role in the preplanning stages on the Sydney Gateway project. Major prework meetings were held early on to ensure the project started on time with minimal issues, says Dave.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"4000\" height=\"2668\" src=\"https:\/\/www.infrabuild.com\/wp-content\/uploads\/sites\/8\/2022\/08\/Qantas-Drive-flyover.jpg\" alt=\"\" class=\"wp-image-25093\" srcset=\"https:\/\/www.infrabuild.com\/wp-content\/uploads\/sites\/8\/2022\/08\/Qantas-Drive-flyover.jpg 4000w, https:\/\/www.infrabuild.com\/wp-content\/uploads\/sites\/8\/2022\/08\/Qantas-Drive-flyover-1280x854.jpg 1280w, https:\/\/www.infrabuild.com\/wp-content\/uploads\/sites\/8\/2022\/08\/Qantas-Drive-flyover-720x480.jpg 720w, https:\/\/www.infrabuild.com\/wp-content\/uploads\/sites\/8\/2022\/08\/Qantas-Drive-flyover-768x512.jpg 768w, https:\/\/www.infrabuild.com\/wp-content\/uploads\/sites\/8\/2022\/08\/Qantas-Drive-flyover-1536x1025.jpg 1536w, https:\/\/www.infrabuild.com\/wp-content\/uploads\/sites\/8\/2022\/08\/Qantas-Drive-flyover-150x100.jpg 150w\" sizes=\"auto, (max-width: 4000px) 100vw, 4000px\" \/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">Challenging site constraints<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">A major road connection, the Sydney Gateway will provide a toll-free link between the domestic and international airport terminals, reducing travel times by up to 40 minutes during the morning peak for motorists travelling from Parramatta to Sydney Airport. A major link in Sydney\u2019s motorway network, the NSW State Government says the Sydney Gateway project will improve traffic flow and divert trucks from local streets around Mascot.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Construction of the Sydney Gateway is a joint venture between John Holland and Seymour Whyte involving the delivery of two sections. First, the International Terminal and Qantas Drive connection, which links Sydney\u2019s motorway network to the International Airport Terminal and Qantas Drive. Secondly, the Domestic Airport Terminals access, which will create an arterial road connection and overpass to Sydney Airport&#8217;s Domestic Terminals.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The Sydney Gateway construction team are working in a highly constrained and confined live traffic environment, delivering a total of 5.1 kilometres of arterial road, around 3 -kilometre active transport link and 19 bridges and viaducts. The project is due for completion in December 2024. <\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Product supply from InfraBuild Reinforcing includes reinforcing bar and prefab, pile cages, reidbar, mesh, and accessories such as Ancon products, sonic tubes and related steel reinforcing products. The team at InfraBuild Reinforcing\u2019s St Marys site is manufacturing the lion\u2019s share of the total supply with our Villawood site providing additional support. <\/p>\n\n\n\n<p class=\"wp-block-paragraph\">In total InfraBuild Reinforcing is supplying 1,800 tonnes of piling cages to be used in 15 of the new bridges and viaducts. <\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Dave explains that prior to the project commencement, cage redesigns were required to allow for sonic tube installation. Sonitec tubes are designed to be encased in the piling cages and foundations to allow for future testing of the concrete integrity by ultrasonic waves, while the pile cages were constructed to a single design as opposed to seven.<\/p>\n\n\n\n<blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\"><p>\u201cAnother constraint on pile cages was plane headroom, which meant limitations on cage lengths,\u201d Dave says. \u201cAnd site constraints also meant product deliveries were required between 12am and 1am, so we had to prioritise pre-booking loads for out of hours deliveries for piling and prefab.\u201d<\/p><cite>Dave Drevon, InfraBuild Reinforcing Prefabrication Manager<\/cite><\/blockquote>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1920\" height=\"1281\" src=\"https:\/\/www.infrabuild.com\/wp-content\/uploads\/sites\/8\/2022\/08\/C1-Workers-with-rio-1-1920x1281.jpg\" alt=\"\" class=\"wp-image-25094\" srcset=\"https:\/\/www.infrabuild.com\/wp-content\/uploads\/sites\/8\/2022\/08\/C1-Workers-with-rio-1-1920x1281.jpg 1920w, https:\/\/www.infrabuild.com\/wp-content\/uploads\/sites\/8\/2022\/08\/C1-Workers-with-rio-1-1280x854.jpg 1280w, https:\/\/www.infrabuild.com\/wp-content\/uploads\/sites\/8\/2022\/08\/C1-Workers-with-rio-1-720x480.jpg 720w, https:\/\/www.infrabuild.com\/wp-content\/uploads\/sites\/8\/2022\/08\/C1-Workers-with-rio-1-768x512.jpg 768w, https:\/\/www.infrabuild.com\/wp-content\/uploads\/sites\/8\/2022\/08\/C1-Workers-with-rio-1-1536x1025.jpg 1536w, https:\/\/www.infrabuild.com\/wp-content\/uploads\/sites\/8\/2022\/08\/C1-Workers-with-rio-1-150x100.jpg 150w, https:\/\/www.infrabuild.com\/wp-content\/uploads\/sites\/8\/2022\/08\/C1-Workers-with-rio-1.jpg 2048w\" sizes=\"auto, (max-width: 1920px) 100vw, 1920px\" \/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">Capabilities and communication<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Regular meetings, both for the customer and the InfraBuild team, have been critical to the success of the project\u2019s supply and delivery. \u201cIt&#8217;s all about being pre-emptive,\u201d Steve Niven explains. \u201cBy regularly catching up we get an understanding of what&#8217;s coming up in the next three weeks. It&#8217;s about constant communication, and that&#8217;s the key.\u201d&nbsp;<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Dave elaborates, \u201cthe meetings are a way of managing multiple fronts and keeping up with the project\u2019s program. Aligning customer expectations with our business capabilities is always important.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cThere have been many challenges where large volumes of steel were required at the same time in different sections of the project. We work continuously with the Sydney Gateway project teams to manage supply and keep on top of supply schedules to ensure pour dates aren\u2019t missed.\u201d<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cWe work in so closely with the customer that we practically all become part of one team,\u201d says Peter. \u201cSteve has long standing relationships built over quite a number of years and there\u2019s a lot of trust. These relationships are as important as the financial component. The relationship and the experience are incredibly important.\u201d<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Reinforcing has brought a suite of capabilities to the Sydney Gateway project:<\/p>\n\n\n\n<ul class=\"wp-block-list\"><li>an experienced team, with two full time detailers dedicated to the project;<\/li><li>prework and ongoing weekly meetings with site engineers to review the program;<\/li><li>technical expertise, 5D modelling for headstocks, piling cages, sonic tube installation, inclinometer, and production capability on detailed workshop drawings and mechanically coupled tension piles.<\/li><\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Responsive Reinforcing team stays ahead<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">There\u2019s a stark difference between large scale infrastructure projects like Sydney Gateway and building construction. And there\u2019s a sense that the InfraBuild Reinforcing team is enjoying the process on Sydney Gateway.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cA big difference is the time on these types of projects. There\u2019s a lot more planning,\u201d says Steve. \u201cIt all comes down to planning and being responsive to the customers timetable.\u201d<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">There\u2019s a sense of pride for the whole Reinforcing team working on the project.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cIt\u2019s been extremely satisfying working with a long-standing customer on projects that are building the future of Sydney,\u201d says InfraBuild Reinforcing\u2019s NSW Regional Manager Grant Rennett.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">In his role as prefab manager, Dave says there\u2019s also great satisfaction in knowing he was part of the redesign stages, ensuring close collaboration with customer and supplier to deliver the schedule on time and with minimal issues.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cWe\u2019ve got an extensive Reinforcing team involved on the project, led by the regional manager, sales manager, and prefab manager who collectively have decades of work experience on large-scale major infrastructure projects.\u201d<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">It was the team\u2019s negotiations prior to the project commencement, backed by a project manager and admin team who stay on top of the day to day requirements, which have ensured the project started well explains Dave.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">And judging by the progress so far, the Sydney Gateway project is shaping up nicely.<\/p>\n","protected":false},"author":43,"featured_media":25092,"menu_order":0,"template":"","meta":{"_acf_changed":false,"_members_access_role":[],"_members_access_error":""},"tags":[],"business_division":[111],"case_study_sector":[121],"case_study_solution":[124,129],"class_list":["post-25091","case_study","type-case_study","status-publish","has-post-thumbnail","hentry","business_division-reinforcing","case_study_sector-civil","case_study_solution-prefabrication","case_study_solution-project-management"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v28.2 (Yoast SEO v28.2) - 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