Previously known as Civilbuild Precast, the company was established in 2000 to produce precast concrete products for major infrastructure projects throughout NSW.

Saunders Civilbuild specialise in providing Pre-cast, pre-stressed concrete bridge components as well as specialised pre-cast concrete panels, headstocks, piers and foundations. Saunders Civilbuild is RTA prequalified to CC (the highest pre-cast prequalification) and registered as an Approved Pre-caster with Queensland Department of Main Roads which enables the company to produce complex Pre-stressed Super T (TRoff) and I girders for long span bridges, as well as the usual PSC Planks and piles.

All Saunders Civilbuild products are manufactured in accordance with our accredited Quality, OHS and Environmental management systems and with a “can do” attitude fostering positive contractual relationships.

With a company background in construction, Saunders Civilbuild specialise in complicated, heavy precast items.

Saunders Civilbuild regularly undertakes project deemed too difficult by many of our competitors.

The Saunders Civilbuild Product Range includes:

  • Prestressed bridge planks
  • Pre-stressed Super T (TRoff) and I girders
  • Specialised Post Tensioned girders and segments
  • Prestressed concrete piles – Octagonal and Composite
  • Precast concrete piles
  • Modular ‘Saunders Civilbuild Fast Cast’ deck units
  • Pre-stressed Railway Box girders
  • Pre-stressed power poles
  • Concrete panels for building & noisewall applications
  • Reinforced concrete bridge piers, headstocks, abutments and approach slabs
  • Pre-fabricated building units
  • Miscellaneous repetitive reinforced concrete items.

Saunders Civilbuild are pre-qualified by the RTA (NSW) to Category CC (ie. complex Precasting) and have been registered as an approved pre-caster with Queensland Department of Main Roads.

Precast Concrete

Civilbuild Precast was established in 2000 to produce precast concrete products for major infrastructure projects throughout NSW.

Civilbuild Precast specialise in providing Pre-cast, pre-stressed concrete bridge components as well as specialised pre-cast concrete panels, headstocks, piers and foundations. Civilbuild Precast is RTA prequalified to CC (the highest pre-cast prequalification) and registered as an Approved Pre-caster with Queensland Department of Main Roads which enables the company to produce complex Pre-stressed Super T (TRoff) and I girders for long span bridges, as well as the usual PSC Planks and piles.

All Civilbuild Pre-cast products are manufactured in accordance with our accredited Quality, OHS and Environmental management systems and with a “can do” attitude fostering positive contractual relationships.

Super T Girders

Saunders Civilbuild have two certified, operational Super T beam moulds by the Roads and Maritime services. Saunders Civilbuild manufacture Super T beams in a fast, safe and economical manner. Super Ts are a fully pretension, prestressed, precast concrete bridge girder which incorporates the combination of the structural function, reduction in weight and ability to span large distances.

In accordance with the RMS standards Super Ts are available in various depths ranging from 750, 1000, 1200, 1500, 1800mm deep sections available. Saunders Civilbuild can advise on the most suitable Super T construction for your particular design.

Recently Saunders Civilbuild completed a $4 Million project supplying; 40 Metre Long, each weighing 75Tonne and measuring 3.5m in width Super T beams to Emu Crossing.

Precast Planks

Civilbuild Precast has a 75m long newly installed plank mould. Civilbuild utilise a construction method which is fast, economical and safe. Civilbuild have the ability to cast a number of planks on any given day.

Planks are a fully pretensioned, prestressed, precast concrete bridge girder which incorporates the ease of construction and the ability to span short to medium distances.

Civilbuild apply to RMS specification and are able to construct many RMS standard planks designs with efficiency. Solid planks and planks incorporating a void into the design can be manufactured. PSC Planks and Spaced Planks usually range from 6-20m. Seven standard depths are readily available ranging from 240mm to 700mm.

Civilbuild have conducted many design and construct projects where planks have been utilised. Civilbuild manufactured and installed PSC Planks recently at Board Crossing.

Concrete Piles

Saunders Civilbuild are able to manufacture prestressed/reinforced concrete piles. They are important elements used in the foundations of buildings, bridges and marine structures.

Throughout Australia, many areas have poor soil conditions which therefore make precast, prestressed concrete pile foundations an obvious choice for construction. Prestressed piles are the preferred choice among designers when performance, durability and economy are considered.

When precast prestressed piles are used in aggressive soil or marine applications they can be designed for long-life durability, to safely support vertical loads together with bending moment arising from lateral loads such as wind, waves and earthquake, as essentially un-cracked sections.

Saunders Civilbuild’s reinforced concrete piles can be seen being installed below.

Headstocks, Abutments and Wall Panels

Saunders Civilbuild are capable of manufacturing and installing many irregular shaped concrete elements. Headstocks, Abutments and Wall Panels can be manufactured specific to job requirements in a timely and quality fashion.

Saunders Civilbuild have proved their reliability as they have employed headstock and abutments installation in many of their bridge design and constructions.

Saunders Civilbuild provide a range of earth retaining, storage walls and functional panels for a variety of applications, environments, and budgets. Our wall solutions are available in a wide range of sizes, shapes, colours, and finishes, to meet the needs of any project.

Precast Barriers and Parapets

Saunders Civilbuilds selection of easy-to-install precast concrete barrier systems can simplify temporary or permanent traffic management issues. Our barrier solutions are manufactured to local road authority specifications.

Saunders Civilbuild manufacture precast concrete jersey kerb barriers to suit the local specifications of local road authorities. The reinforced concrete barriers are designed to safely redirect vehicles back to the roadway after leaving. The modular and portable nature of these barriers provides a solution to a temporary problem. Jersey Kerb Barriers can be made to order to a specific length or bought as built.

Saunders Civilbuild also manufacture permanent bridge barriers. These barriers are located at the edge of bridges to redirect vehicles back to the roadway once they have left. They generally have an irregular cross section and are installed using a bolting system to permanently fix them to the bridge with a stich pour. Saunders Civilbuild manufacture these barriers as per design requirements to the highest quality.

Pictured below are the precast parapets.

Other Precast Items

Saunders Civilbuild not only manufacture precast Super Tee girders and Planks but also various other precast elements such as precast panels, culverts and flexmats. Civilbuild are able to provide large volumes of items due to their innovative ideas and vast array of equipment available in the precast yard.

Precast Panels

Saunders Civilbuild is able to manufacture large quantities of diverse panels, these can be used for numerous applications, such as:

  • Noise Walls
  • Sea Walls
  • Deck Panels
  • Retaining Wall Panels
  • Boat Ramp Deck Panels
  • and more…

Precast Concrete Culverts

Culverts are used to help drain water under roads and railways. Precast culverts can provide a cost and time effective solution, since they are easy and quick to install in comparison to a bridge or cast-in situ items.

Flexmats

Saunders Civilbuild also manufacture precast flexmats, these are very versatile product that is easy and quick to install. Flexmats are a mat with spaced concrete blocks on it, they can be used to prevent river erosion, wave attack damage and footpaths just to name a few, they are essentially a concrete geotextile.

Saunders Civilbuild is the only manufacturer of flexmats on the east coast of Australia, but have supplied them to areas such as the Northern Territory.

Precast Storage Units

Saunders Civilbuild precast has recently just finished a job to build Precast Concrete Storage Units for Woy Woy Waste Management Centre, this allowed them to sort and allocate waste into different categories of waste without it flying away due to the wind. Saunders Civilbuild’s Bob Luck also managed the entire project at Woy Woy, which is included managing the installation of Saunders Civilbuild Precast’s units.

Saunders Civilbuild have been involved in various major projects, for example:

Maitland Super T Girders

 

Glenfield to Leppington

 

Chaffey Dam

 

Kempsey to Kundabung

 

Kiama Bypass Bridgeworks

X Girders, I girders, T Girders, PSC bridge planks & piles for stages 1 and 2 of the project – contracts totaling $9 million

Port Waratah Coal Services Upgrade

Miscellaneous precast components for conveyor upgrade including 100t gantry sections – contract value $3.5 million.

Westlink M7 project

20 000m2 of RSol reinforced soil wall panels, 34 off pre-stressed V Girders for shared path bridges and 1200 wide PSC plank units – contracts totaling $ 3.5 million

Coopernook By-Pass Project

110 Super T girders, 374 PSC planks and 260 composite and octagonal PSC piles – contract total $5.3 million. PSC Box girders, Post tensioned I girders, precast piers, abutments and approach slabs for Rail Underbridge replacements at Iron Bark Creek, Killawarra, Styx Creek, Wambo Rail Spur, Dapto, Emu Plains, Hurstville, Wentworthville, Wyee,

Belmore and Lidcomb

Contracts totaling $ 3.5 million

Bonville By-Pass Project

140 octagonal piles and 60 Super T girders – contract total $2.8 million

Chatswood Transport Interchange

13 diaphragm squat I girders – contract total 1.1 million

Revesby Turnback Project

Post tensioned girder segments and precast conctrete walkway landings – contract total 1.1 million

Brisbane Childrens Hospital Bus Interchange

50 off TRoff girders for Northern

Busway Alliance Project

Contract total $1.7 million

Energy Australia Power Poles

260 PSC Power poles for various projects – contracts totaling $1.5 million

Coopernook to Heron Creek Upgrade

180 octagonal and composite piles, 220 PSC planks and 96 Super T girders – contract total $ 6 million.

NAT Grain Rail Pit

NAT Grain Rail Pit

Concrete works for Wambo coal prep plant

Concrete works for Wambo coal prep plant

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