The project involved civil works to upgrade and transform the Cunningham Highway and Lake Moogerah Road intersection, improving safety and operational efficiency along a key section of the National Land Transport Network.

Scope of Works:

• Complex brownfields project requiring intricate staging.
• Pavement widening and rehabilitation of the Federal Highway, including a major intersection upgrade with:
  
  • Upgraded road design standards: re-grading, superelevation corrections, adverse crossfall adjustments, and curve easing through advanced survey and profiling techniques.
  • Enhanced sightlines and added channelised left/right turn lanes, extended turning lanes, and wide centreline treatments.
• Over 3,800m³ of excavation, with disposal of unsuitable material and replacement using 2,700m³ of high-quality Class A1 fill (CBR-compliant).
• Cuts and fills exceeding 5m, including trimming of narrow, constrained subgrades.
• Rock protection placement in challenging terrain, coordinated to minimise disruption.
• Pavement subgrade treatment using Type B methodology, employing high-quality Class 1A fill to address black soil and marginal materials.
• Installation of multi-layer granular pavements (2,500m³), including Type 2.5, 2.3, and 2.1 unbound gravels, with geocomposites (MRTS58) at subgrade level.
• Heavy-duty asphalt pavements with deep-lift EME2 and Stone Mastic Asphalt (SMA):
  
  • 2,650 tonnes of medium-duty dense-graded asphalt and SMA.
  • 4,200 tonnes of EME2 asphalt.
  • 23,500m² of asphalt geosynthetics (MRTS104).
• Pavement layers included:
  • Emulsion prime, C170 seal, two geosynthetic layers, multiple EME2 layers, waterproofing, and SMA.
• Significant longitudinal joints with existing pavements, requiring meticulous execution.
• Major drainage upgrades, including a 5-cell culvert (4m depth) across the Cunningham Highway, delivered with:
  • Accelerated 1-week construction proposal under shuttle flow conditions.
  • Temporary traffic management and geotechnical solutions for steep batter stabilisation.
  • Special foundations using replace-and-remove techniques for long-life concrete mixes.
• Installation of subsoil drainage at various locations.
• High-traffic volume (7,000 AADT, with 30% heavy vehicles).
• Complex staging to maintain two-way traffic during peak periods.