Bergville Expansion Project – Ulco Underpass and R31 Bypass

The works carried out on this contract included the construction of an in-situ tunnel under the R31 road. This entailed:

• Installing a pipe bridge.
• Constructing a pipe support.
• Re-routing the pipeline.
• Excavating the south ramp.
• Excavating the R31 Road.
• Constructing the in-situ tunnel.
• Reinstating the R31 Road.
• Excavating the north ramp.
• Constructing a partial river diversion, which included a berm, underpass culverts, and an exit canal section.

• Concrete Supply Constraints: The team implemented a construction sequence that accommodated the limited availability of concrete.
• Scope Creep and Cost Containment: To manage costs, the client supplied materials for constructing the layer works of the approach ramps to the in-situ tunnel.

• Planned Duration: 14 months.
• Actual Duration: 27 months due to:
  • Delays in obtaining the Water Use Licence from the Department of Water & Sanitation.
  • Stringent blasting requirements imposed by the Department of Mineral Resources and Energy.

• Total Personnel: 194 (including contractors and sub-contractors).
• The project highlighted a resilient and cohesive team effort, ensuring successful delivery of contractual requirements.

The success of the project was attributed to the entire team’s effort, demonstrating a strong “can do” attitude and commitment to excellence.

• Concrete Cast: 1,945m³
• Reinforcement: 185t
• Earthworks (Excavated): 38,000m³
• Earthworks (Blasted): 37,000m³
• Manhours: 133,000 hours