Client: Wel.Co (formerly Goldfields Developments)
Location: Western Freeway, Rockbank VIC
Scope: Design and construction of large-scale acoustic noise barrier
Date of Completion: December 2021
01
Results at a Glance
- 2,155-metre acoustic noise barrier along the Western Freeway
- Barrier heights up to 6.5 metres
- Cor-ten steel and acrylic (Perspex) acoustic panels
- Complex architectural geometry translated into a practical buildable system
- Delivered adjacent to a live freeway under accelerated programme
02
Client Overview
Thornhill Park is a masterplanned residential community adjacent to the Western Freeway in Rockbank. The development required an acoustic noise barrier to reduce traffic noise while creating an architecturally distinctive frontage.
Wel.Co engaged Wallmark to design, engineer, construct and certify a 2,155-metre acoustic barrier that integrated with existing infrastructure, waterways and pedestrian connections while complying with VicRoads (now Department of Transport and Planning) requirements.
03
Engineering Solution
Wallmark constructed approximately 2,155 metres of acoustic barrier incorporating Cor-ten steel and acrylic panels up to 6.5 metres high. The architectural design featured compound angles, cantilevered elements and unique structural bays, requiring detailed engineering to develop a practical construction methodology while maintaining the design intent.
Each structural bay required individual detailing, fabrication and installation sequencing. Wallmark also designed a bridging beam in collaboration with Melbourne Water to span an existing spillway while maintaining hydraulic performance.
Construction was undertaken adjacent to the active Western Freeway and involved extensive rock drilling, existing underground services, including fibre optic infrastructure, and constrained working conditions. Pier locations and structural details were adjusted to avoid service conflicts while maintaining structural performance.
Heavy rainfall and flooding required temporary drainage controls to maintain progress. Tree Protection Zones (TPZs), wildlife habitat protection and consultation with the Wurundjeri Woi Wurrung Cultural Heritage Aboriginal Corporation ensured environmental and cultural heritage requirements were met throughout construction.
04
Project Outcomes
The completed acoustic barrier provides long-term traffic noise attenuation for Thornhill Park while delivering the architectural design intended for the Western Freeway frontage.
The project demonstrates Wallmark’s capability to deliver architecturally complex acoustic barriers within constrained infrastructure environments while meeting authority, environmental and stakeholder requirements.
