Precast concrete plays key role in Princes Highway Upgrade

Ozcast’s role in the Berry to Bomaderry section of the Princes Highway Upgrade showcases the company’s ingenuity and commitment to quality.

By the National Precast Concrete Association Australia (National Precast).

The Berry to Bomaderry section of the Princes Highway Upgrade in New South Wales is a landmark project designed to improve safety, traffic flow and accessibility along one of the state’s busiest transport routes.

The upgrade addressed longstanding challenges, including traffic congestion and accident-prone areas, while integrating aesthetic enhancements to harmonise with the natural surroundings. A critical component of the project was the installation of shotcrete walls featuring patterned silver fascia panels, combining functionality with visual appeal.

Innovative design meets efficiency

In 2019, Seymour Whyte entrusted National Precast member Ozcast with a challenge: to produce 209 patterned silver fascia panels for the shotcrete wall. Each panel was to be slightly different, creating a seamless yet varied aesthetic. However, fabricating 209 unique designs would have been time‑consuming and costly.

Demonstrating ingenuity, Ozcast optimised production by batching the panels into 60 different types instead of 209, maintaining the desired variation while reducing production complexity. By casting panels in sets of three, Ozcast achieved precision while introducing production tolerances that streamlined the manufacturing process. This approach not only saved time but also reduced costs, making the project more efficient without compromising on quality.

Protecting beauty with durability

Beyond the design and production, Ozcast addressed the panels’ long-term durability through in-house testing of anti-graffiti coatings. The selected product balanced aesthetic preservation with functional resilience, ensuring that the panels remained visually striking and easy to maintain over time. This proactive step minimised future upkeep costs, aligning with the project’s goal of creating a sustainable and low‑maintenance solution.

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A stunning and functional result

The completed shotcrete wall stands as a testament to the transformative power of innovative precast solutions. The patterned silver fascia panels create a visually engaging barrier that complements the natural landscape while enhancing safety and structural integrity. Ozcast’s efficient production methods and attention to detail ensured that the panels not only met but exceeded the project’s aesthetic and functional requirements.

The reduction in the number of unique panel types and the successful implementation of anti-graffiti coatings resulted in time and cost savings, highlighting Ozcast’s ability to deliver high-quality results under demanding conditions.

Collaboration driving success

The Berry to Bomaderry section of the Princes Highway Upgrade underscores the value of collaboration in infrastructure projects. Ozcast’s work showcases the potential for precast concrete solutions to combine durability, aesthetics and cost-efficiency. The project’s success serves as an example of how innovative approaches can address complex challenges while delivering lasting benefits to the community.