The Skytrain is now making a spectacular appearance on the horizon at Rouse Hill as the concrete columns rise dramatically to support the double track superstructure. The bridge superstructure is constructed from precast concrete match-cast elements, manufactured by contractor Salini-Impregilo at a Mulgrave Precast yard. Each element is a full bridge cross-section and after elevation by crane it is held in its temporary position by a gantry. The group of bridge elements are then post-stressed into final position with stressing strand and the gantry advances on to the next span.
The match-cast method wet casts one concrete unit against its neighbour in the precast yard to form a perfect fit. The units are manufactured under factory controlled conditions and brought to site when required. A total of 1,200 precast match-cast segmental units are being manufactured for the Skytrain.
Salini-Impregilo has installed two gantrys for bridge unit installation and together they are building seventy lineal metres of Skytrain each week. A blistering pace that is possible because of the use of concrete.