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Windsor Road,
M2 Upgrade - Baulkham Hills, NSW

Project featuring the RECo TerraPlus® System

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Project Details

The Hills M2 upgrade started in January 2011 and was completed in August 2013. The M2 upgrade involved building an extra lane in each direction between Windsor Road, Baulkham Hills and Lane Cove Road to improve traffic flow and reduce congestion for motorists.

The Upgrade Delivered

  • New west facing Windsor Road on and off ramps (opened July 2012)
  • Additional eastbound lane from Windsor Road to Pennant Hills Road
  • Additional eastbound lane from Pennant Hills Rd through M2 Tunnel to Lane Cove Road
  • New Christie Road eastbound on ramp (opened January 2013)
  • New Herring Road westbound off ramp (opened January 2013)
  • Additional westbound lane from Beecroft Road to Pennant Hills Road
  • Widened road between Lane Cove Road and Beecroft Road to reinstate the 3.5 metre traffic lanes and 2.5 metre breakdown shoulder for cyclists
  • Norfolk Tunnel widened in both directions.

Benefits of the Upgrade

  • Reduced congestion during morning and afternoon peak periods.
  • New access points to Sydney's growing residential and business centres.
  • Restoration of a 100km/h speed limit along the motorway from Lane Cove Road to Beecroft Roads.
  • New entry/exit points to create opportunities for additional public transport services and facilities.
  • Increased capacity to accommodate planned future residential and business growth.

Windsor Road, M2 Upgrade - Baulkham Hills, NSW

Features of the Upgrade

  • New west facing Windsor Road on and off ramps.
  • Additional eastbound lane from Windsor Road to Pennant Hills Road.
  • Additional eastbound lane from Pennant Hills Road, through the Norfolk Tunnel, to Lane Cove Road.
  • New Christie Road westbound off ramp.
  • New Herring Road westbound off ramp.
  • Widened westbound lanes from Lane Cove Road to Beecroft Road.
  • Additional westbound lane from Beecroft Road to Pennant Hills Road.

Interesting Facts

  • Approximately 150 staff members and 600 field staff were engaged on the project.
  • 106 girders installed to widen or lengthen bridges on or over the motorway.
  • 60,000 tonnes of rock excavated and 5,200 rock bolts installed as part of the Norfolk Tunnel widening work.
  • 6.8 kilometres of noise walls relocated.
  • 3.5 kilometres of temporary noise walls were installed.
  • Over 22 kilometres of cable installed for the Intelligent Transport System.
  • 50 major sign structures relocated.
  • Over 48,000 square metres of concrete pavement laid.
  • Seven hectares of bushland revegetated.

General Information

Retaining Solutions works involved installation of approx 5No reinforced soil walls including piled bridge abutments, approach ramps and road widening applications utilising the RECo TerraPlusĀ® System laid back at 1:50 (2%). Scope of works included installation of: TerraPlusĀ® panels; REHas soil reinforcements (45mm & 50mm wide); 90-degree corners; sand/cement mix surrounding drainage pits; spreading & compaction of the imported RSW backfill (38,000m3 crushed sandstone) used within the reinforced fill zone; 3000m3 of H/2 zone backfill in addition to 1350m3 of heel drains & 2,000linm of strip drains at soil nailing/shotcrete interfaces.

Another key feature of this project was that Retaining Solutions designed and constructed both internal and external panel propping systems due to elevated construction of walls over existing T-Wall structures built back when the M2 was originally constructed. Other features which are paramount to civil construction were that of plant/people interaction of the ground. Safety was the highest priority to ensure all workers were separated from plant movements in this tight corridor.At all times there was panel placement and backfill operations occurring concurrently.

The materials handling of the imported RSW backfill was handled very professionally / efficiently by both LEICON foremen and RSOLN operators.

The works were carried out to a very tight construction programme on time, within budget and most importantly satisfying LEICON & RTA strict OHS guidelines. Retaining Solutions produces with every wall complete, full quality documentation e.g Inspection & Test Plans, Daily Quality Verification Checklists in addition to detailed daily site diaries detailing operations and overall checks carried out over the duration of the wall construction from levelling pad placement to finishing panel installation. Again Retaining Solutions skilled operators secured approx 2 years of wet-hire for zero swing excavators and our entire suite of tracked bobcats from T190 through to T870 (Attachments include forks/sweeper/profiler).


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Project Specs

  • Application - Piled Bridge Abutments, Approach Ramps & Road Widening
  • Product - RECo TerraPlus® System
  • Finish - Plain Grey
  • Area - 7000m2
  • Max. Height - 11.0m
  • Length - 1350m
  • Loadings - 25kPa & Crash Barriers
  • Design life - 100 years
  • Owner - RMS
  • Client - Leighton Contractors Pty Ltd

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