CONSTRUCTION UPDATE – 14 APRIL 2010

Posted on Apr 14, 2010 in Construction Update - 2010

A) SOUTHERN SECTION
1. Underground section

All tunnel excavation – a total length of approximately 15.5 kilometers from Park Station to Marlboro Portal – was completed in September 2009. Civil works, tracklaying and associated electrical & mechanical railway infrastructure works within the tunnels between Marlboro Portal and Sandton Station are complete.

Since 26 February 2010, the Gautrain Electrostar trains have been test running between ORTIA and Sandton on a regular basis. Trial Running on this section of the System will begin during April 2010.

Within the remaining tunnel section to Park Station, civil works, including final lining, cable duct installation and walkways, together with the installation of mechanical and electrical equipment, are ongoing. Tracklaying from Sandton Station towards the Johannesburg Park Station has commenced.

The underground works also include the construction of seven emergency access shafts located at intervals along the single-track rail tunnel between Park Station and Sandton Station. These shafts will provide emergency services personnel access to the tunnels below. At the bottom of certain of these shafts there will be safe havens where passengers can gather in case of an emergency. Construction works are ongoing at each of these emergency access shafts.

PARK STATION

Construction and tiling of the Johannesburg Park Station concourse

Vantage point overlooking the construction of the
Johannesburg Park Station parkade

At Park Station, construction of the cut & cover section linking the northern end of the station box to the tunnel portal is ongoing. Within the station itself, internal brickwork and plastering are well advanced and wall and floor tiling at concourse level are substantially complete. Mechanical and electrical (M&E) installations are ongoing and escalator installation has started.

At the parkade structure, work is in progress on the final 6th level deck slab. Erection of precast parapets on the lower levels commenced during the month.

Reinstatement of Wolmarans Street is complete and earthworks for the reinstatement of Smit Street and preparations for the remaining utility relocations in this area are ongoing.

EMERGENCY ACCESS SHAFT E1 (HILLBROW)

Construction works in the safe haven and technical rooms located at the bottom of this shaft are ongoing and construction of the surface head house building is in progress.

EMERGENCY ACCESS SHAFT E2 (THE WILDS, HOUGHTON)

Construction works in the safe haven and technical rooms located at the bottom of this shaft are ongoing.

EMERGENCY ACCESS SHAFT E3 (RIVIERA)

Shaft construction works and the head house structure on the surface are substantially complete, with finishing works in progress. M&E installations are ongoing. Being a shallow shaft with direct access to the surface, there is no safe haven necessary at the bottom of this shaft.

EMERGENCY ACCESS SHAFT E4 (HOUGHTON)

Shaft construction works and the head house structure on the surface are substantially complete, with finishing works in progress. M&E installations are ongoing. Like E3, being a shallow shaft with direct access to the surface, there is no safe haven necessary at the bottom of this shaft.

ROSEBANK STATION

Backfilling of the roof slab over the station box at Rosebank Station for the reinstatement of Oxford Road

Construction of the Rosebank Station platform

At Rosebank Station, backfilling of the roof slab over the station box is approaching completion and is ongoing over the northern cut and cover structure. Preparations are underway for the reinstatement of Oxford Road above the station structure, which will follow in the next few months.

Internal brickwork and plastering at the platform and concourse levels are substantially complete. Wall tiling at both concourse and platform levels is in progress. Escalators have been positioned within the station box and M&E installations are ongoing.

At the parkade structure, foundations and retaining walls are complete and placing of precast slabs to the first floor deck is well underway. Preparations for casting of the ground floor surface bed within the parkade are in progress and erection of precast parapets has commenced.

EMERGENCY ACCESS SHAFT E5 (DUNKELD, ROSEBANK)

Construction of the safe haven and technical rooms located at the bottom of this shaft is ongoing.

EMERGENCY ACCESS SHAFT E6 (ILLOVO)

Construction of the safe haven and technical rooms located at the bottom of this shaft is ongoing.

EMERGENCY ACCESS SHAFT E7 (WESTERN SIDE OF RIVONIA ROAD, SANDTON)

Construction of the safe haven and technical rooms located at the bottom of this shaft is ongoing.

SANDTON STATION

Installation of the structural steel roof over the entrance to Sandton Station

Arrival of the Gautrain at a Sandton Station platform as part of test running of trains between Sandton and OR Tambo International Airport Station

Underground station construction works are well advanced in the cavern section between the south and north shafts where the platforms are located, as well as within the shafts themselves. These works include construction of the various platforms, the technical rooms and operational rooms, as well as the escalator and lift shafts and stairways that are located within the shafts.

Mechanical and Electrical (M&E) installations are in progress and most of the escalators that will transport commuters between the station entrance and the underground platforms have been installed.

Tiling of platforms is well advanced and wall tiling to the platform areas is in progress. Erection of the structural steelwork canopies, that will form the station entrance structure located on the corner of Rivonia Road and West Street, is ongoing.

Construction of the adjacent multi-level parkade structure, is progressing apace, where brickwork, plastering and M&E installations within the completed areas of this structure are ongoing.

Tracklaying within the station is complete and the tracks are energized. Since the first Gautrain Electrostar train arrived at Sandton Station on 26 February 2010, test running of trains between Sandton and ORTIA has been taking place on a daily basis. Trial Running on this section of the route will commence during April 2010.

MUSHROOM FARM PARK CONSTRUCTION SHAFT

Mushroom Farm Park was a temporary shaft, which was used to provide access for tunnel construction in both northern and southern directions simultaneously. All tunnelling and construction works carried out from this shaft were completed during 2009. The shaft was subsequently backfilled and the community park was reinstated, landscaped and upgraded. The park has been handed back to the City.

The aerial balloon facility that operates in the park is nothing to do with the Gautrain project – this is an independent arrangement entered into between the City of Johannesburg Parks Department and an unrelated commercial enterprise.

MARLBORO PORTAL

The portal at Marlboro is the point where the tunnel section ‘daylights’. It separates the underground and surface sections of the route. Apart from final finishings and some landscaping, works in this area are complete. Since 26 February 2010, the Gautrain Electrostar trains have been test running from ORTIA and through the tunnel to Sandton on a regular basis.

2. Surface alignment

VIADUCTS 1A AND 11 OVER JUKSKEI RIVER AND EAST BANK ROAD

Viaducts 1A and 11, which are located between the Portal and Marlboro Station and carry the railway lines across the Jukskei River and East Bank Drive, are both complete, as are the rest of the construction works and railway installations in this area, apart from some finishing works and landscaping.

MARLBORO STATION

Kerbing of the parkade deck for the bus terminus at Marlboro Station

External works for the bus terminus area at Marlboro Station

At Marlboro Station, construction works and M&E installations are substantially complete and internal finishes are well advanced. Platform tiling is approaching completion.

External works at the bus terminus area and on the parkade deck are ongoing, where kerbing is well advanced and erection of the shade cloth carpark canopies is substantially complete. Brickwork and plastering for the station perimeter wall is complete and installation of the steel palisade infill sections has started.

B) NORTHERN SECTION (Depot to Hatfield Station)

VIADUCT 2 OVER MODDERFONTEIN SPRUIT

Viaduct 2 and the two adjacent bridges over the future Frankenwald and Maxwell Roads are complete, with railway infrastructure in place across all three of these structures and this section of the alignment is operational.

TRAIN AND BUS DEPOTS

All Train Depot facilities, including the maintenance workshops, the train system administration buildings and operations control centre, are complete and operational. This centre is the heartbeat of Gautrain from where signalling, telecommunications, automatic fare collection, traction power and overhead distribution CCTV cameras and maintenance will be managed using world-class, high technology systems.

At the Train Depot, Gautrain’s 24 train sets will be maintained, serviced cleaned, and securely stabled overnight.

At the adjacent Bus Maintenance Depot, which will perform a similar function for Gautrain’s dedicated fleet of 125 luxury buses, construction is approaching completion. This facility is located in the area that was occupied by the precast yard, which was dismantled a few months ago. Construction of the bus workshop, canteen, gatehouse, bus wash facility, fuel bay are well advanced and refurbishment of the admin building previously utilized as site offices has been completed. External concrete apron slabs and roadworks are also substantially complete.

RAIL YARD AND TRACKWORKS

All trackwork and the stabling sidings within the Depot area are complete, energized and operational.

On the mainline sections, trackworks are complete from Sandton Station to ORTIA on the East-West Line and to Dale Road in Midrand on the North-South Line. All of these lines are energized and operational.

Tracklaying from Dale Road northwards commenced late last year and by the end of March, tracklaying operations had progressed to the vicinity of the Samrand Road Bridge to the north of Midrand Station.

RAIL CAR ASSEMBLY AND TESTING

Gautrain arrives at Marlboro Station as part of the test running of trains between Sandton and OR Tambo International Airport Station

Gautrain arrives at Rhodesfield Station as part of the testing of the trains

By the end of March, 66 of the 96 rail cars had been delivered to the Depot. This equates to 16 complete four-car trains.

Gautrain’s rolling stock of 96 rail cars is based on the renowned Bombardier Electrostar series, which is used extensively in the United Kingdom.

The first 15 rail cars were manufactured and fully assembled at Bombardier Transportation’s facility in Derby in the U.K. The manufacture of body shells and components for the remainder of the fleet is ongoing. All 15 of these Derby-built rail cars were delivered to the Depot during the first half of 2009.

The body shells and major components for the remaining 81 rail cars are being ‘flat packed’ into crates and shipped to South Africa for assembly in Nigel. Delivery to the Depot of rail cars assembled at Union Carriage and Wagon Partnership in Nigel, which commenced during April 2009, is ongoing, with 51 of these locally assembled rail cars delivered by the end of March 2010.

Dynamic testing of trains continues throughout the full Phase 1 section between the Depot, Sandton and ORTIA on both the north-south and east-west routes. Trial Running on this section of the route will commence during April 2010.

VIADUCT 3 OVER ALLENDALE ROAD

North of the Depot, Viaduct 3 and all bridges, construction works and railway installations are substantially complete to beyond Midrand Station, with only some minor finishing items and completion of landscaping works outstanding. This section of the route includes the test track, where dynamic testing of train sets is ongoing.

MIDRAND STATION

Track laying vehichle passing through Midrand Station

Layer works for the parkade at Midrand Station

At Midrand Station, station building works are substantially complete, with roof cladding to the platforms and over the concourse installed and glazing of the facades is in progress. Interior tiling and finishing works, together with M&E installations, are well advanced. Platforms are substantially complete and platform tiling will commence shortly.

Externally, the upper car park area has been surfaced and erection of carport structures is ongoing. Layerworks on the lower level bus terminus area have commenced and erection of bus canopy and walkway structural steelwork is well advanced. Excavation of the attenuation pond is substantially complete. Layerworks and kerbing on the new section of Grand Central Boulevard, which forms the access road into the station, is in progress.

From Midrand Station to the Technopark area at Centurion, civil works are approaching completion. Completion of fencing, landscaping and finishing works are ongoing. Catenary masts have bee erected along most of this section and tracklaying is ongoing to the north of Midrand Station. By month end, tracklaying operations had progressed to the vicinity of Samrand Road Bridge.

VIADUCT 4 OVER RIETSPRUIT AND OLIFANTSFONTEIN ROAD SOUTH

Viaduct 4 is complete and railway lines and associated railway infrastructure are being installed across this structure.

VIADUCT 5 OVER THE N1, BEN SCHOEMAN AND INCLUDING CENTURION STATION

Construction of Viaduct 5 over John Vorster Avenue in Centurion

Construction of the in-situ balanced cantilever deck over Jean Avenue

Viaduct 5c carries the elevated Gautrain railway lines through Centurion, forming the link between the balanced cantilever viaducts crossing the N1 highway at John Vorster interchange in the south and the Ben Schoeman highway at the Jean Avenue interchange in the north. It supports the elevated Centurion Station platforms located approximately midway along its length. At the end of March, only four spans remained to be completed at the northern end of this viaduct to link it to the southern abutment of the Jean Avenue balanced cantilever viaduct.

Construction of the exceptionally graceful in-situ balanced cantilever viaducts crossing the highways at the John Vorster and Jean Avenue interchanges continues to progress steadily.
At the John Vorster Viaduct, a significant achievement during the month was the casting of the final pair of balanced cantilever deck closure segments on 17 March 2010, so deck construction at this viaduct is now complete. Cable trough construction, parapet erection and finishing works are ongoing. At the Jean Avenue Viaduct, deck construction is also approaching completion. The final pair of deck segments was cast by the end of March, with completion of the last pair of closure sections to follow in April 2010. Cable trough construction is ongoing, parapet erection has commenced and finishing works are in progress.

The Centurion Station platforms are elevated and are located on Viaduct 5, which runs immediately adjacent and parallel to West Street. The concourse buildings and parking area are at ground level. Structural works are complete, apart from the reinforced concrete escape stairs, where construction is ongoing. Station building works are substantially complete. Platform and concourse roof cladding is complete and glazing of the West Street and parking area façades is well advanced. Within the concourse, M&E installations and finishing trades are ongoing, with floor tiling and wall tiling both well advanced. Dynamic compaction and earthworks at the parking area are ongoing, as are layerworks to some of these areas. Construction of the bus terminus buildings has commenced.

Glazing of the West Street and parking area façades at Centurion Station

Internal finishes for the Centurion Station concourse and ticket offices

The Centurion Station platforms are elevated and are located on Viaduct 5, which runs immediately adjacent and parallel to West Street. The concourse buildings and parking area are at ground level. Erection of the precast platforms and parapets atop the viaduct is complete and platform roof cladding is well advanced. Station building works, platform access stairs and lift shaft construction are all substantially complete. The structural steel curtain wall framing to the concourse area is in progress. Finishing trades within the concourse have commenced and mechanical and electrical installations within the technical rooms are ongoing. Earthworks and dynamic compaction of the parking area continue and layer works are in progress.

VIADUCT 6 OVER EEUFEES ROAD

At Viaduct 6, construction of the southern abutment has been completed and five of the six deck spans had been erected by month end. Erection of the final span will follow in early April 2010.

VIADUCT 7 OVER NELSON MANDELA BOULEVARD

Construction of this set of viaducts and flyovers is progressing apace. The deck to the section that will carry the railway lines across Nelson Mandela Boulevard is substantially complete and parapet erection is in progress. Pier and trestle beam construction for the remaining sections of this “Y-shaped” structure that will cross over the existing railway lines is also complete and all of the M-beams for the bridge decks have been placed. Deck slabs, parapet installation and finishing works to these structures are ongoing.

PRETORIA STATION

M&E installation and internal finishing works for the concourse and ticket offices at Pretoria Station

M&E installation and internal finishing works for the platforms at Pretoria Station

At Pretoria Station, construction works for the station buildings and platforms are substantially complete, with curtain wall glazing approaching completion. Internal finishing works are well underway, as are mechanical and electrical installations. Parking area construction is ongoing and refurbishment of the historically significant coach washing shed, that has been incorporated into the station design, is in progress.

HATFIELD STATION

Construction of the adjacent multi-level Hatfield Station parkade

Installation of the steel roof structure over the concourse level at Hatfield Station

At Hatfield Station, where the concourse slab over the existing PRASA tracks and the future Gautrain railway lines was completed at the end of February, erection of the structural steelwork for the concourse building located on top of this slab is ongoing and concourse brickwork is in progress. Preparations for platform construction below the concourse level are underway. Structural works for the eight level parkade structure are complete and the adjacent lift shaft is approaching completion. Precast parapet erection at the parkade is well advanced and M&E works and finishings within the structure are in progress. At the adjacent Grosvenor Street Bridge, the final deck span was cast by month end. Construction of the bus management facilities within the bus terminus area is in progress.

Between Pretoria Station and Hatfield Station, a number of bridges crossing the existing PRASA railway line require to either be widened or lengthened to accommodate the adjacent Gautrain tracks. Whilst most of these bridges have already been completed and reopened to traffic, works on the remaining structures are ongoing. Extensive lateral support works in cuttings, together with the earthworks and construction of the retaining structures necessary to widen the existing embankments, are ongoing.

C) EAST-WEST AIRPORT LINK

3. Airport Link (Marlboro Station to OR Tambo International Airport)

Civil construction works are substantially complete along the entire airport link, which includes eleven bridges, three viaducts and a number of other structures, including the platforms for a future station at Modderfontein. Remaining works are limited to some final finishings and completion of landscaping in certain areas.

Trackworks and associated railway infrastructure are also complete, with this section of the route now energized and operational.

VIADUCT 13 OVER CENTENARY WAY, MODDERFONTEIN

Viaduct 13 is complete, with the railway lines across this structure now in use.

VIADUCT 14 OVER ZUURFONTEIN ROAD AND RAILWAY LINE

Viaduct 14 is complete, with the railway lines across this structure now in use.

VIADUCT 15 INCLUDING RHODESFIELD STATION

External finishes for Rhodesfield Station and Viaduct 15

Erection of the carport structural steelwork for the parkade at Rhodesfield Station

Rhodesfield Station is positioned approximately one third of the way along Viaduct 15, directly above the existing PRASA railway lines running between Isando and Kempton Park. The platforms are elevated, with the station entrance, concourse and parking area located at ground level, on the eastern side of the existing railway lines.

Construction of the station is approaching completion. The platforms, access ways and the station buildings are all substantially complete, as are internal finishes and the installation of technical equipment. Platform tiling to both platforms is approaching completion. Railway tracks have been laid through the station and the lines are in use. Externally, the attenuation pond is complete and parking area construction, apart from the area immediately surrounding the station concourse, is well advanced. Bus canopy structures are approaching completion and erection of carport structural steelwork is in progress. On the western side of the elevated station, emergency escape staricases have been installed.

Immediately adjacent to the Gautrain station, the Passenger Rail Agency of South Africa (PRASA) continues with construction of a new station on its system. This will provide commuters with a convenient transfer link between the Gautrain and PRASA systems. Construction of the PRASA station is making good progress and it is expected that this station will be completed in time for the Soccer World Cup.

Viaduct 15 is complete, with the railway lines across this structure now in use.

VIADUCT 15 INCLUDING OR TAMBO INTERNATIONAL AIRPORT STATION

The concourse at OR Tambo International Airport Station

Installed fare gates at Rhodesfield Station

The ORTIA Station concourse is located at the eastern end of viaduct 15 and is directly linked to the departures level of the adjacent new Central Terminal Building, one level below.

Finishing works within the station concourse shell are substantially complete, as are electrical and mechanical installations. Ticket vending machines and fare gates have been installed and are operational, with final testing in progress.

Externally, the platform structure and platform roof are complete and platform tiling is in progress. Rail tracks have been installed through the station and are in use. Erection of the three sets of emergency evacuation staircases is complete, with finishing works to these structures in progress.

D) OVERALL PROGRESS

Construction started at the end of September 2006. Gautrain will be completed in two phases:

  1. The first phase has a duration of 45 months. It includes the network between the OR Tambo International Airport and Sandton and includes the stations at OR Tambo, Rhodesfield, Marlboro and Sandton, together with the Depot and Operations Control Centre located near Allandale Road in Midrand.
  2. The second phase, being constructed concurrently, will be completed in 54 months, during 2011. It includes the remainder of the rail network and stations linking Sandton to Park Station in Johannesburg and the route from Midrand to Hatfield.

Toll-free call centre: 0800-GAUTRAIN (0800-42887246). The call centre is operational weekdays between 7am and 7pm with an answering system after-hours. Communities are reminded that regular Community Liaison Forums are held in affected areas.

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