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 crew came back to the WSB building in September and October 2025 for a further package of core drilled wall penetrations at level B3.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.
Back in the WSB building
Stage 1 ran from July to August 2025. In September and October 2025 the same crew returned to level B3 for a further set of core drilled wall penetrations for services, using water fed coring and the same containment for slurry. See the full Roma Street Station project page for everything else Perfect Group has delivered at Roma Street.
Lessons learned on this job
Every job teaches the crew something. These are the ones we took from the WSB wall penetrations.
What worked
- Pre coring every corner before the wall saw went in, so the openings came out square with no overcut into the retained wall
- Load tested anchor points and a block and tackle for every cut section, so nothing was lowered by hand
- Wet cutting and water fed coring with plastic containment, so no dust and no slurry left the room
What was difficult
- A confined stair zone with one way in and out, where every cut section had to be split small enough to carry
- Working around live services on the walls either side of each opening
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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.