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Port of Melbourne Project uses Foamex EPS Blocks to deliver lightweight fill solution

The Port of Melbourne Port Capacity Project is redeveloping Webb Dock to be able to operate as an international container handling facility. The project, with an estimated cost of $1.6 billion, includes construction of new roads to Webb Dock Drive and Kooringa Way located below the West Gate Bridge. 

An early part of the road project was to upgrade the pipe works beneath the road. Before the roads could be constructed, the project identified that a lightweight fill, layered on top of the pipes, would provide the best protection from the volume and weight of the traffic that would use these roads.

Foamex M Grade Expanded Polystyrene (EPS) blocks were chosen to be layered to specific depths on top of the pipes, then wrapped and sealed before the road surface was constructed over the EPS blocks. 

Foamex EPS blocks were selected for this project because of their inherent lightweight nature as well as the quality of the M Grade blocks. Foamex expanded polystyrene blocks have a range of advantages that make them ideal for this type of project. Their durability, strength and flexibility, coupled with their dimensionally stable quality and low water absorption makes them an ideal, long term lightweight fill; protecting the pipes from additional loading.

Foamex were involved in the project from February 2015 until its recent completion in May 2016. In total, over 1,000 EPS blocks were used to deliver the necessary project requirements. To deliver the project, Foamex worked in conjunction with BMD Construction who were awarded the $80 million plus contract to construct the first stage of the project.

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