Barangaroo Sydney is a once in a lifetime urban transformation of Sydney's spectacular harbour foreshore. With a combination of residential, commercial, park land, a new casino and train station, the development represents the largest waterside project currently under construction worldwide.

Completion is expected in 2024 once the Metro station is slated to finish. More than 50 percent of Barangaroo will be dedicated public space encompassing a continuous Sydney Harbour promenade, expansive parklands, plazas and coves.

Barangaroo is expected to contribute more than $2 billion a year to the NSW economy. Visit barangaroo.com for Barangaroo specific information.

Online Concrete Cutting Services joined the construction team as a preferred subcontractor in 2012 and will continue as a preferred subcontractor until completion.

We have been engaged to perform extensive concrete sawing and drilling works, including deep road sawing, perimeter exclusion zone (PEZ) drilling works, large scale wire sawing, track sawing, GPR scanning, service locating, as well as BROKK remote controlled demolition works.

Due to the high-profile nature of the site, the compliance standards are greater than ever encountered, forcing all parties to perform at their optimum level.

Among some of the many concrete sawing and drilling works performed at Barangaroo, Online Concrete Cutting Services played an integral part in the removal of some large sections of the foreshore boardwalk as part of the urbanisation and reshaping of this area. The removal of the boardwalk utilised almost all facets of our services from a combination of large-scale wall sawing and wire sawing to core drilling, bursting, splitting, as well as BROKK robotic demolition. With significant focus on the Barangaroo project not only locally but also on an international stage, strict environmental controls were adopted especially where works were completed alongside as well as above the pristine waters of Darling Harbour.

Online Concrete Cutting Services were also tasked with the job of removing large sections of the concrete caissons that form the main water seal between Sydney harbour and the land on which Barangaroo has been built. To facilitate removal, a coffer dam was built on the water side of the wall to stop water ingress. The cutting and removal of the concrete caisson wall sections was performed over the course of one weekend using two wire saws working simultaneously to create a 4 metre by 2 metre opening. The opening is now used as the main water intake for the cooling towers.

Sydney Metro Northwest representing the first stage of Sydney Metro, Australia’s biggest public transport project and a priority infrastructure investment for the NSW Government. Sydney Metro Northwest opened to customers on 26 May 2019.

Project value of $8.3 billion which included the delivery of:

• The first fully automated metro rail system in Australia using driverless train technology
• 8 new train stations at Cherrybrook, Castle Hill, Showground Road, Norwest, Bella Vista, Kellyville, Rouse Hill and Cudgegong Road as well as upgrading 5 existing stations
• An underground section route comprising 15.5km of two track railway in a twin tunnel configuration between Epping and Bella Vista
• A 7.5km section of above ground route from Bella Vista to the Tallawong stabling facility, comprising a combination of Skytrain viaduct and embankment

Online Concrete Cutting Services, as the preferred sawing and drilling subcontractor, was engaged on an ongoing basis from initial early works to post commissioning works.

All facets of concrete sawing and drilling were undertaken with multiple crews active onsite throughout the project. Concrete cutting works included large scale wire sawing of the tunnel opening, track sawing to depths in excess of 1000mm, countless number of road sawing metres, core holes, hand sawing and ring sawing.

Wire Sawing on NRT project - As part of the construction of the underground sections of the NRT project, the tunnels were lined with concrete rings as they were being formed by the Tunnel Boring machines. To align these concrete rings with the tunnel openings, the concrete ring sections extending beyond the tunnel opening needed to be removed. Large scale wire sawing was required due to the sheer size of these concrete rings, being 250mm thick and over 6 metre in diameter. Depending on access, the concrete rings were removed in sections, with some being removed in only 3 sections resulting in over 20 metres of continuous feed diamond wire running at a time.

Track sawing on NRT project - To facilitate the construction of the various stations, several large concrete slabs in excess of 1 metre thick were installed to support 500 tonne cranes. Nearing station completion these slabs needed to be removed using two of our Pentruder track saws operating simultaneously cutting through the 1000mm deep heavily reinforced concrete used for the crane slabs.

Representing a key piece of infrastructure for the Wagga Wagga high productivity freight route, the Eunony Bridge upgrade provides enhanced access to the Bomen Industrial Park and connections to the Olympic Highway. The original bridge which opened in 1975 had become too narrow and load limited to cater for the increased truck size and daily traffic flow. The main support structure of the bridge was assessed by council to be in excellent condition, whom elected to retain everything from the head stock down and rebuild a new stronger and wider deck.

The bridge reconstruction was able to be completed within 6 months, with 40,000 work-hours being contributed to the $10.6M bridge widening and strengthening project. The new bridge is capable of taking loads up to 160 tonnes and has a life expectancy of 100 years.

With the Eunony Bridge being over the Murrumbidgee River and vital to many local farmers for irrigation, environmental control posed a significant challenge as nothing was allowed to fall into the river. A nappy system was implemented and hung under the bridge to catch slurry and other waste. A 450-tonne crawler crane was established on the southern bridge approach to lift the deck planks out one at a time as they were cut and drilled free.

With the crane often being at maximum reach and each plank weighing approximately 30 tonnes the cutting and drilling had to be precise to ensure the planks were completely separated and able to be lifted without resistance to the crane.

Online Concrete Cutting Services had to stitch drill across every 2nd head stock, completing 70 core holes per span, 115mm in diameter 750mm deep through the heavily reinforced extremely hard river gravel concrete. At the completion of the stich drilling the opposite end of the planks were cut free using our deep cutting road saw to cut across the bridge deck on top of the head stock to a depth of 750mm, a depth that is beyond the capability of the largest road saw on the market. To facilitate this cutting the road saw needed to be modified to reach full depth. After the centre planks were released and removed the edge planks including attached footpath had to be cut free. This was performed using two wall saws operating simultaneously cutting 20 metre lengths at a depth of 1000mm, again near the limits of wall sawing cutting depths.

The project required us to be on site for 4 months with a staff of 3 to 4 operators working 7 days a week to complete our deconstructions works whilst at the same time other contractors were working quickly behind us on the reconstruction in order to reinstate this vital transport link within the strict timeframe set by council.

CBA Bank - Martin Place, Sydney CBD. Works performed at the Commonwealth Bank building at Martin Place. This job involved the widening of the existing central atrium as well as all levels leading to the atrium. Two new circular glass lifts providing access to the new rooftop were also installed. The sawing and drilling works performed included core drilling (prevent overcutting), road sawing, ring sawing and wire sawing. Amazingly all works were performed during continuous bank operation. Silent sawing and drilling methods were adopted to facilitate works. Multiple crews worked six days a week for three months to complete the project within the strict time frame.

Victoria Cross Station - North Sydney. Remote controlled robotic crushing & breaking (BROKK) utilised for the removal of concrete wall panels across thirteen levels. The delicate nature of this project demonstrated the versatility and finesse provided by the BROKK demolition robots which were able to manoeuvre around the tight work area and operate without disturbing the surrounding occupants. The demolition robots outperformed traditional excavators which were restricted due to noise and weight limitations.

Shell House - Sydney CBD. Likely the largest heritage listed building left standing whilst entire internal structure was removed. Works involved cutting floors flush to the external walls for entire floor removal. Concrete cutting involved the performance of significant road sawing and track sawing metres to achieve the desired outcome.

Waterloo Station - Sydney. Angled deep core hole drilling to pin sheet piled walls using multiple auto-feed drill rigs were in operation on a continuous basis. The use of auto-feed drill rigs resulted in significant productivity gains whilst keeping labour resources to a minimum. With multiple operators using 3 to 4 auto-feeds, operators were able to achieve on average productivity in the range of 3 times standard drilling rates.