June 22, 2026
This project is part of the Fulton Hogan – Metropolitan Road Alliance’s “Big Build” effort to remove 100 level crossings in the state of Victoria. The new grade separation at Evans Road in Lyndhurst required a retaining wall solution that could meet demanding design requirements without slowing construction. AIL’s MSE Precast Panel Wall System delivered both: a distinctive custom panel design and measurable installation efficiencies that helped keep the project moving.
Part of Victoria’s broader level crossing removal program, the project placed a premium on speed, constructability and long-term performance. For Evans Road, the challenge was to meet those requirements while also delivering an architecturally distinctive wall finish.
Design challenge
A notable feature of the project was the precast panel design inspired by Australia’s wind-swept grasslands. That visual requirement introduced added complexity, calling for a solution that could balance architectural expression with structural performance.
Delivery advantage
Because the wall design was integrated early in the project, the team was able to refine the system alongside the broader design process. That coordination helped support the project schedule, and the retaining wall scope was ultimately delivered 10% faster than competing product options.
We were pleased to be working with Rockfield Technologies Australia as the wall designer, and our partner, Safe Direction (formerly Australian Construction Products (ACP)*, on logistics and site coordination. Safe Direction aligned their precast workflow with project requirements, helping streamline production scheduling and maintaining quality through completion. That early coordination also positioned the team to respond more effectively when site conditions became more challenging.
Overcoming weather challenges
Significant downpours then threatened to delay progress. In those conditions, the constructability of AIL’s MSE Precast Panel Wall System helped the contractor recover lost time and keep the work moving.
Construction efficiency
That schedule benefit was supported by AIL’s Grid-Strip System, which uses a standardised width to simplify MSE retaining wall design, inventory and construction. Combined with efficient pre-casting and easier on-site handling, the system allowed the contractor to install the strips three times faster than competing products.
Together, those construction advantages supported both project delivery and long-term asset performance. With a design life of more than 100 years and minimal maintenance requirements, AIL’s MSE Precast Panel Walls are well suited to demanding transportation infrastructure.
*ACP is now part of the Jaybro Group and now operates under the name Safe Direction.
