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Concrete In Australia : December 2008
NATIONAL PRECASTER NUMBER 50 • NOVEMBER 2008 Lorne Pier reconstruction project relies on precast The Lorne Pier is a fantastic community and tourism asset for Lorne and a feature of Victoria’s Great Ocean Road. First constructed in 1878 in response to the need for a safe place for ships to dock, it has been reconstructed several times since then. In response to a 2005 government tender to replace the existing 1960’s concrete pier, McConnell Dowell, with architects EDAW and engineer Maunsell, developed an innovative engineering method using hollow precast concrete piers to construct the new structure. The new Pier is the same length (196 metres) and width as the old pier but now features a superb platform on the end, with generous space for the large numbers of people who visit the pier for recreational fishing and sight-seeing. The team’s winning solution included the use of the existing concrete as a work platform during construction, enabling access for a 30 tonne excavator fitted with rock coring equipment, and a 50 tonne crawler crane to install the tubular precast piles and erect the superstructure. Construction of the new pier was a massive project, requiring the installation of sixty four new concrete piles and the erection of more than 1,300 square metres of timber for the deck and fishing platform. An estimated 30,000 work-hours were needed to construct the new Pier. In lieu of drilling a socket into the rock and pouring/pumping concrete in-situ into tubular steel formwork, McConnell Dowell developed an alternative piling strategy using precast concrete piles produced by Hollow Core Concrete, these being cast using super workable high flow concrete. The piles included a cast-in 80 mm PVC grouting tube and 100 mm steel shoe at the base with a two-metre freeboard allowance for pile casing cut-off after pile installation. Each pile was cast into its socket using 50MPa underwater grout. The precasting process ensured improved control over concrete placement and vibration in the pile, removed the logistics and time constraints for curing involved in cast in-situ concrete, and minimised the environmental risk associated with pouring concrete in a marine environment. The precaster also provided an alternative precast beam to headstock connection detail which was incorporated into the final solution. The revised detail allowed for more tolerance in the installation of the beams and meant that the position of cast-in ferrule connections were not critical. The connection detail for the beam incorporated a temporary headstock frame which served as an access walkway to provide for safe installation of the beams and provided a simpler pin-to-bracket connection. Four headstock frames were fabricated to allow work on subsequent pile bents to be continued while stitch pours were curing to the required release strength. The edge beams were cast against timber form liners with many of the beams being cast to irregular curved faces requiring a high level of skill to achieve the required tolerances with recesses being cast within the beams to facilitate concealed light boxes. Work on the new pier, including demolition of the old pier, took only 12 months to complete. The quality of the work was recognised in a Master Builders Awards 2008 Award for Excellence. It also won an IEAUST Victorian Engineering Excellence Award. The new Lorne pier has since become a major attraction along the Great Ocean Road. Lorne Pier Reconstruction Project Location: Client: Design team: Head contractor: Lorne, Victoria Great Ocean Road Coast Committee and the Department of Sustainability and Environment Maunsell and EDAW McConnell Dowell Precast manufacturer: Hollow Core Concrete 36 Concrete in Australia Vol 34 No 4