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Concrete In Australia : June 2013
48 Concrete in Australia Vol 39 No 2 Design and construction of Werribee Aqueduct Dr Kabir Patoary-- Principal Structural Engineer, Bridges, GHD Dr Tahmina Hossain -- Structural Engineer, Bridges, GHD Graeme Joynson -- Principal Structural Engineer, Bridges, GHD 1.0 INTRODUCTION e impressive $20 million Werribee Aqueduct project has provided a critical upgrade to Melbourne s sewerage infrastructure and ensured that Melbourne Water can continue to transfer up to 60% of Melbourne s sewage to the Western Treatment Plant. Located in Melbourne s west, the Werribee Aqueduct project has replaced the final section of Melbourne s original open channel sewer constructed in 1891. e project was delivered by the Pipelines Alliance, a partnership between Fulton Hogan, Jaydo Construction, GHD and Melbourne Water. e project was awarded the Civil Contractors Federation (CCF) Earth Award 2010 and Engineers Australia Victorian Division Engineering Excellence Award 2011. e new aqueduct, which neighbours the original heritage- listed brick aqueduct and Melbourne s high pressure gas pipeline, consists of a 70 m long section spanning the Werribee River. e aqueduct is made of incrementally launched post- tensioned concrete and has a 5.3 m square external cross- section incorporating an internal 4.7 m diameter High Density Polyethylene (HDPE) lined circular pipe. It is supported by three piers consisting of precast segments and is connected to the rest of the replacement works on ground via an articulated expansion joint. Designed with the local community in mind, the aqueduct will also serve as a bicycle pedestrian bridge to help connect existing and planned shared paths, parks and residential developments in the area. Working at a height of 15 m above the river bed created a unique set of Occupational Health & Safety (OHS) constraints that challenged the designers and the construction team. is paper summarises a number of innovative techniques adopted by the design and construction team to overcome the constraints on this challenging infrastructure project. 2.0 PROJECT OBJECTIVES AND REQUIREMENTS e Werribee River aqueduct transfers about 60% of Melbourne s sewage to the Western Treatment Plant along the Western Trunk Sewer (WTS). e original aqueduct was an open channel brick arch bridge and was built in the 1890s. In the 1960s, that aqueduct was replaced by a cast insitu concrete box section supported by six precast, prestressed T-beams. e aqueduct was designed as a temporary structure and has exceeded its planned service life. As part of a major five year program of works to improve Melbourne s sewerage and drainage systems, Melbourne Water decided to construct a new aqueduct, remove the existing concrete aqueduct and retaining the original heritage-listed brick aqueduct. e new aqueduct also provides a pedestrian and bicycle crossing to connect existing and planned shared paths, parks and residential developments in the area. 3.0 DESIGN CONCEPT e new aqueduct is a post-tensioned concrete box girder with internal grouted tendons. e potential for cracking and leakage was minimised by maintaining compression in the concrete at all stages of loading. Launched incrementally from the east and located 13 m upstream of the original brick aqueduct across the Werribee River, the new aqueduct consists The technical design drawing for the Werribee Aquaduct. Inground section Inground section