2019 Innovation Name: Richmond River Bridge: Pre-cast Headstocks
Awards: 2nd Most Innovative Property, Construction & Transport Company
This innovation represents the first time in Australia that a bridge of this width (4-lanes) has been constructed with a single precast headstock. While pre-casting has been used before, this has only been achieved, for smaller and less complex headstocks. Up until now, integrated headstocks of this size, have been cast on site, at height. The industry hasn’t previously been able to develop a precast headstock strong and durable enough to be reliably manufactured off-site, and stable enough to transport to its final location; yet light enough to be safely lifted into position.
To achieve a light, yet strong product, we designed the headstock in the shape of a tub, with relatively thin walls. While the thin walls made the headstock light, which was important so that we could transport and lift it, they also made the tub more prone to cracking during transportation and lifting into the final position. Therefore, our team had to develop a whole new, never-before used process for bridge construction. The processes used in the past were inappropriate for handling this innovative product. The development of the headstock tub as a precast component of the bridge sets the standard for future bridge projects in Australia.