Kalkallo Water Mains - Undertrack Bore Rail Interface
Comprehensive rail interface management for installation of two 618mm OD water mains via undertrack boring through VicTrack, V/Line, and ARTC rail corridors at Kalkallo, including design approvals, construction support, track monitoring, and safeworking supervision.
Challenge
MFJ Constructions needed to install two 618mm OD water mains via undertrack boring within rail corridors at Kalkallo requiring complex coordination through VicTrack's 4-Phase approval process. Having completed Phases 1 and 2, they required specialist support to obtain V/Line and ARTC construction approvals (Phase 3), implement real-time track monitoring during boring to detect any track movement, coordinate multiple rail operator requirements including Site Access Permits and job cards, manage frac-out risks during pipe jacking, and provide continuous safeworking supervision throughout the 24-day construction program.
Solution
Sterling provided end-to-end rail interface management including submission of rail access applications for track monitoring, non-destructive digging, and pipe jacking activities to V/Line and ARTC, development of track monitoring plans with automatic tilt sensors collecting 15-minute interval data with real-time alerts, establishment of baseline track geometry one week pre-construction, coordination of VicTrack Permits to Work and operator-specific permits (V/Line Site Access, ARTC job cards), development of SWMS and construction methodologies, frac-out management plan review, bore head retrieval plan coordination, track certification validation, three-week post-construction monitoring period, and full safeworking supervision using ActivateRail resources.
Planned Deliverables
VicTrack Phase 3 rail operator construction approvals from V/Line and ARTC, Site Access Permits and job cards, VicTrack Permits to Work, track monitoring plans and tilt sensor installation with 15-minute automated data collection, real-time movement alerts and daily reporting, track geometry baseline establishment and validation, construction phase safeworking supervision, track certifier validation services, bore head retrieval and frac-out management plan reviews, three-week post-construction monitoring with daily reports, equipment removal supervision, as-built drawings transmission, and close-out documentation for all rail operators.
Expected Outcomes
Successfully secured all required rail operator construction approvals enabling MFJ Constructions to proceed with undertrack bore installation across VicTrack, V/Line, and ARTC corridors. Track monitoring system with automatic tilt sensors provided real-time protection during pipe jacking operations with no track geometry exceedances detected. Delivered comprehensive safeworking supervision across 24-day construction program ensuring zero safety incidents. Three-week post-construction monitoring validated structural integrity.
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