Heavy Haul Rail Culvert Renewal Program
Sterling delivered a comprehensive culvert renewal program for a major rail network operator, replacing six reinforced concrete box culverts across heavy-haul coal rail systems. The program involved coordinated track closures and innovative construction methodologies to maintain critical drainage infrastructure.
Challenge
A major rail network operator required renewal of six aging culverts across their heavy-haul coal rail network to maintain operational integrity. The sites required carefully coordinated track closures within tight windows to minimise disruption to coal haulage operations. One site presented additional complexity requiring complete turnout removal and reinstallation during an extended closure.
Solution
Sterling's Central Queensland team led delivery of all six culvert renewals with support from the Victoria team during shutdowns. Each site followed standard culvert installation methodology: track possession, rail/sleeper removal, excavation to 200mm below design level, subgrade proof rolling with DCP testing by RPEQ Geotechnical Engineer, Type 2.1 foundation compacted to 98% DDR, RCBC placement using 25T Frannas with Presstite and Sikaswell waterstops, stabilised sand backfill (12:1 dry mix), Damtec ballast matting, capping installation, and ballast reinstatement in 300mm layers. For the complex turnout site, specialised lifting equipment was deployed to clear the turnout cassette from the construction zone. Sterling proposed an innovative alternative using their own precast headwalls and wingwalls to reduce on-site time.
Deliverables
Complete removal and replacement of six RCBC structures across six sites with varying dimensions and lengths. Ancillary works including in-situ concrete aprons, headwalls, wingwalls, guideposts, handrails, and flood rock scour protection. 12-month defect liability period.
Outcome
Sterling successfully delivered all six culvert renewals within programmed closures, restoring critical drainage infrastructure across the heavy-haul coal rail network. The innovative precast headwall methodology was trialled to reduce construction time and improve safety.
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