Opened in 1886, Hornsby Junction is a network of interconnected tracks serving intercity, metropolitan, and regional rail passenger services, as well as freight services, located within a constrained brownfield site in the Sydney suburb of Hornsby.

Remodelling of the site incorporated new signalling and rail services to deliver faster turnaround times for trains, increasing capacity and improving service reliability for Sydney’s T1 North Shore Line. The challenge for the design and construction teams was how to navigate the brownfield site, twisting and turning the new infrastructure to fit amongst existing services, wiring and signalling, all with nothing clashing.

Novo Rail Alliance, consisting of Transport for NSW in partnership with Aurecon, Laing O’Rourke, and RCR Infrastructure, was selected to take on the task.

Using 3D project models, Novo Rail detected potential clashes between infrastructure and services early in the design phase. This created value for the project as it provided greater certainty and clarity of services locations prior to construction commencing.

Stretching conventional boundaries

The project was one of the most significant rail projects ever undertaken in Sydney. Not in the context of value, but the amount of rail, overhead wiring and signalling in a brownfield operating environment.

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Spanning 3 hectares, the design team mapped thousands of modelling data points across the brownfield site.

The final track possession occurred during a 17-day window. There were 7 turnouts constructed with connecting track, overhead wires and signalling equipment installed and commissioned. This process would have taken more than 3 years to complete had the work been undertaken on standard trackwork weekends only.

Video courtesy from Transport for NSW.

With clash detection undertaken during the design phase, this gave greater certainty to the construction works for the small window of time available on site. The works were installed and commissioned on time.

"With an unprecedented level of complexity and intense external scrutiny, it has been a real privilege to witness the collective team rise to the challenge over the 17 days," said Daniel Roche, Senior Project Manager, Transport for NSW.

"The project has been a shining example of collaboration and will be a benchmark for future projects for rail construction in a brownfield rail environment. The project team has demonstrated professionalism and perseverance to the end and should take enormous pride in the new, improved Hornsby Junction and the legacy of its operational benefits."

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