Ferrycarrig has been engaged by Fulton Hogan to deliver the Moorebank Intermodal Terminal Import-Export Terminal and the Precinct East Infrastructure works. The project involved potable water infrastructure, pressurised sewer infrastructure, fire water infrastructure, electrical infrastructure, Stormwater infrastructure and communications infrastructure. The project comprised the provision of all labor, key materials, and services necessary to carry out the construction of water and sewer pipework, and other utility works, also including site civil works, concrete works, and commissioning works.

The scope of work incuded:

• Water infrastructure: 1.5km of HDPE pipes installation, valves, hydrants, risers and above ground pipeworks, RPZ/backflow devices and water meters, live tapping bands. (180mm HDPE pipe PN16)
• Pressurized Sewer infrastructure: 1.5km of HDPE pipes installation, sewer pump stations and electrical controls installation, valves, air valves, flushing points. (110mm HDPE pipe PN16)
• Fire services infrastructure: 930m of HDPE pipe installation, valves, boosters, above-ground piping, hydrants. (250mm HDPE pipe PN16)
• Storm Water Drainage infrastructure: precast pits and concrete pipes ranging from 350mm to 1000mm diameters. Installation of 300mm slotted pipes for track drainage. 
• Electrical infrastructure: Conduits installation, HV/LV/SL cable installation and termination, HV and LV cables installations, kiosks installations, light poles, and solar poles installation
• Communications Infrastructure: Conduits installation, Fibre optic cable installation, and splicing, Comms cabinets installation and connections, CCTV installation. (24 core fibre cable).

As part of the scope, we encountered challenges related to working near and on live assets, among the examples, we highlight the need for the installation of live tapping bands as well as insta-valves on a 375mm DICL pipe and different points on the 250mm and 180mm HDPE pipes. It was necessary to install quick temporary thrust blocks to ensure double isolation and restrict any undesired movements on the end caps and valves working under normal pressurised conditions of a water main.

All permits were checked before executing any activity with the right gear and right plant for the work. Spotters were always in place accompanying the person executing the task. Edge protection, barrier systems and safety recovery systems were in place when working near deep trenches and when executing high-risk activities, this resulted in a record of zero harm/zero accidents with an achievement of 100% of the planned tasks. 

Ferrycarrig assisted the principal to resolve issues with design changes, that required modification to recently installed infrastructure. Proactively utilising the expertise of our key personnel, Ferrycarrig promoted the best value, fit-for-purpose alternatives to adequately resolve design change issues with minimal impact to all project stakeholders.