Client: Sydney Trains

Duration: 5 years

Location: Sydney Harbour Bridge, Sydney NSW

Once-in-a-century rail upgrade combining engineering innovation, heritage sensitivity, and operational precision

• Five-year staged delivery within live possession windows on Australia’s busiest rail corridor -carrying 200,000+ daily passengers across the Sydney Harbour Bridge
• First use of Ultra-High Performance Fibre Reinforced Concrete (UHPFRC) in Australia -Brefni developed the training manual, QA and work instructions in collaboration with Dura Technologies, and established a full-scale mock trial facility at Chullora for mixing, flow testing, and tensile testing
• All works delivered within strict 48-hour track possession windows -requiring zero tolerance for overrun on Australia’s busiest rail corridor
• Complex bridge deck logistics -coordinating hi-rail plant access, a purpose-built colloidal mixer, and RMS road closures to safely handle large concrete volumes during each possession
• Purpose-built environmental controls including concrete washout on ballast away from the harbour, pre-wetting formwork for leakage testing, and two-hourly supervisory environmental checks throughout every pour
• Zero Lost Time Injuries across 250,000+ work hours; zero non-conformances on QA; 85% of demolished timber recycled; 120+ year design life achieved