M7-M12 Integration – Hydro .
Partial removal of existing bridge deck concrete to facilitate an in-situ concrete stitch pour between old and new pre-cast units.
As part of the M7-M12 Integration Project led by John Holland, the M7 Motorway is being expanded from three to four lanes in each direction between the M5 Interchange and Richmond Road in Western Sydney. This major infrastructure upgrade is designed to improve traffic capacity and flow, and will support the new M12 Motorway connectaion—providing a vital transport link to the upcoming Western Sydney International Airport (Nancy-Bird Walton).
Direct Inject was engaged to deliver precision concrete removal across 10 bridges located between Redmayne Road and Angus Creek along the M7 corridor. Our works involve the targeted removal of concrete from pre-cast planks and Super T girders, typically in strips measuring approximately 600mm wide, 300mm deep, and up to 80 metres in length. The process requires preserving dual layers of existing reinforcement while maintaining the original profile of each bridge element to enable in-situ stitch pours between existing and newly installed pre-cast units.
Our operations are being conducted within the median strip of the M7, directly between live northbound and southbound traffic lanes, and in some cases above active roads, rail corridors, and sensitive waterways. These high-risk conditions demand meticulous planning, specialist equipment, and close coordination with the principal contractor. Environmental protection measures are central to our approach, including effective management of hydro-demolition runoff and flying debris to safeguard both public safety and local ecosystems
