Burwood’s North Station crossover cavern as part of Sydney Metro’s Central Tunnelling Package, is designed to facilitate train movements between tracks, ensuring maintenance can be performed with minimal disruption to service. This cavern, approximately 145 meters long, 14 meters high, and 24 meters wide, was meticulously excavated using two road headers.

Kelko Construction’s scope of work for this project included the following: Formwork installation, reinforcement placement, and concrete pouring (FRP) for key tunnel structures:

Plenum Structure: Construction of crossover walls, a suspended slab with an upstand wall at Burwood North Station.

Crossover Cavern Headwall Eyelets: Completion of two headwall eyelets.

Nozzle Headwalls: Construction of two nozzle headwalls.

The 6.5-meter-high crossover cavern walls were constructed using the DOKA Framax Xlife Wall Formwork system, with conventional formwork methods utilised in the bespoke Y-junction areas. The 400mm thick plenum suspended slab was built using a combination of DOKA’s custom-designed SL-1 traveling formwork and AT-PAC Table and conventional decking formwork systems.

This intricate construction was carried out concurrently with the tunnelling operations of the broader project, ensuring minimal disruption and no impact on the project’s critical path.