Case Study
Warringah Freeway Upgrade
THE CHALLENGES
The Warringah Freeway Upgrade is one of Sydney's most complex live-corridor infrastructure programs. Within it, new retaining and stem walls called for engineered formwork — tall one-sided pours cast against staged excavation, built under infrastructure-grade quality and review requirements, in zones with restricted access alongside a live freeway.
OUR APPROACH
Engaged by the formwork contractor, Metric Engineering designed the formwork systems for the RS05 and RS05A stem-wall zones — soldier and waler arrangements in LVL and steel, tied and anchored for full concrete pressure, analysed in SAP2000 with member checks for every component in the load path. The design progressed through a preliminary issue and two staged final issues between February and May 2024.
A full 3D model of the formwork assemblies accompanied the drawings, communicating the system unambiguously to site crews. Related pedestrian-bridge pier formwork within the corridor was also assessed as part of Metric's engagement on the program.
THE RESULTS
Infrastructure-grade formwork engineering delivered into one of Sydney's highest-profile corridor upgrades — fully calculated, modelled and staged for construction against a live freeway.
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