Kalkallo Creek Trunk Sewer Main Stage 1

VIC
Yarra Valley Water
2017 - 2019
3,369m

GRP pipe installed

15m

tunnel depth

13

sewer manholes installed

3.5km

sewer tunnel constructed

Abergeldie was engaged by Yarra Valley Water (YVW) to design and construct the trenchless portions of Stage 1 of the new Kalkallo Creek Main Sewer (KCMS), which was part of the Kalkallo Sewer Servicing Strategy for the Northern Growth Corridor. The total length of the proposed sewer was over 13km, comprising three stages, with Stage 1 being approximately 3.5km long. 

Scope of works

The works involved:

  • Excavation of launch and receival shafts for tunnel boring and pipe jacking. 
  • Tunnelling and pipe-jacking of 3369m of ID1388 PN2 SN40,000 GRP pipe. 
  • Installation of 40m of ID525 GRP PN2 SN16,000 pipe to satellite maintenance hole KLD01, ending with backfilled construction shaft. 
  • Laid 15m of ID450 GRP PN2 SN32,000 to satellite maintenance hole LSB01. 
  • Construction of a 2500mm diameter maintenance hole with a 4m internal drop and plunge pool, ID525 connection and ID450 connection. 
  • Construction of a 3200mm diameter maintenance hole with a DN300 pipe stub. 
  • Construction of a 2400mm diameter vortex drop. 
  • Construction of 2 x 2400mm diameter maintenance holes with a 90-degree change in direction. 
  • Construction of a 2400mm diameter hole with an ID1050 connection stub for Kalkallo Creek Main Sewer Stage 2. 
  • Construction of 4 x 2400mm diameter straight-through maintenance holes with internal drop pipes and pipe stubs, allowing for the future connection of DN225 reticulation. 

Skilful tunnel alignment and infrastructure integration 

The tunnel alignment involved crossing beneath key landmarks like Merri Creek and the Hume Freeway, connecting to an operational sewer at Amaroo where the tunnel boring access shaft was converted into a manhole. The tunnel and pipe boring were carried out using Abergeldie’s in-house owned, maintained and operated Herrenknecht equipment. 

Detailed surveying was undertaken to confirm the alignment and level of new and existing sewers at tie-in positions. Close interface management was crucial with stakeholders in neighbouring real estate and infrastructure projects, including Kalkallo Development, Cloverton Development, Arrowsmith Development, Klandy Drive Branch Sewer, Lockerbie South Branch Sewer, and Merrifield Central Branch Sewer. 


Infrastructure to support future growth

The completed sewer is the critical outlet that was needed to service developments in the Urban Growth Boundary around Melbourne and connects to the Amaroo Main Sewer (completed in 2017).

This 3.5km of critical sewerage infrastructure supports the growth of communities in the Northern growth corridor of Melbourne.