As part of the Sydney Metro West Central Tunnelling Package, the Burwood North Station site crossover cavern is designed to facilitate train movements between tracks, ensuring maintenance can be performed with minimal disruption to service. This cavern, approximately 145 metres long, 13 metres high, and 25 metres wide, was meticulously excavated using two road headers.

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

• Plenum Structure – construction of crossover walls and a suspended slab with an upstand wall at the Burwood North Station site
• Crossover Cavern Headwall Eyelets – completion of two headwall eyelets
• Nozzle Headwalls – construction of two nozzle headwalls

The 6.5 metre high crossover 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.