Project Overview
Perfect Concrete Care was engaged by Cross River Rail to deliver a package of specialist wall penetrations at the WSB Building, Roma Street Station. These works form part of the services access upgrade for the site and required high-precision execution in a restricted access environment.
Stage 1 of the works focused on two wall penetrations located at Level B3.5 staircase zone:
- 1 x 1.8m (H) x 850mm (W)
- 1 x 1.5m (H) x 2.5m (W)
The upcoming Stage 2 will involve slab penetrations located directly beneath these openings, accessed through the wall penos completed in this stage.
Tools & Method
To ensure accuracy and safety, our team deployed the following methods and equipment:
- Wall Saw: Tyrolit WSE1217 high-frequency unit for precise vertical cutting with zero overcut tolerance
- Corner Pre-Coring: Hilti DD350 + Autofeed and Hilti DD250 + Autofeed for clean, overcut-free corners
- Containment: Plastic sheeting to manage slurry and water during cutting
- Lifting:
- Installed M20 rated anchor points
- Used tested and tagged eyebolts
- Block and tackle rigging system for controlled lowering of concrete sections
- All anchor points load-tested and certified before use
Safety & Risk Controls
Safety was a top priority throughout this project:
- Silica Dust: Controlled with 100% wet cutting and water-fed coring—no airborne dust generated
- Manual Handling: Loads split into manageable sections, 2-person lifts, and stair-carry breaks implemented
- Rigging Safety: All lift points tested and tagged, with rigging inspected before use
- Overcut Prevention: Corners core-drilled before blade cutting
- Fatigue Management: Daily pre-starts and job rotation to maintain operator focus and safety
Outcome
- Zero overcuts and a clean, precise finish on both wall penetrations
- Controlled, safe lowering of concrete sections in a stair-only access environment
- All works delivered on schedule despite logistical constraints
- Site ready for Stage 2 slab penetrations using the same precision processes
Perfect Concrete Care continues to support major infrastructure projects with specialist concrete cutting and coring solutions that combine technical expertise, innovative methods, and uncompromising safety standards.
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Perfect Concrete Care acknowledges the Aboriginal and Torres Strait Islander people as Traditional Custodians of the country on which we live and work. We pay our respects to the Traditional Custodians and Elders past, present and future, and honour their connection to the land and ongoing contribution to society.