2 legs · 2 levels · M, F, HV, HL, G, H2, FB, W
The Phase 0 corridor workhorse. Dual-leg, two-deck viaduct carrying freight at 6 m + maglev at 17 m with HVDC arms, gas, hydrogen, fibre, and water services on one structure.
Per-kilometre cost is split into three layers: Structure (the bare elevated platform — foundation, pylon, cap beam, deck, walkway), Services (service-specific equipment installed on the structure), and Install (all field labour and plant). Total per km is the sum of the three. The service items themselves (water, conductors, fibre cable, track, maglev hardware) are catalogued separately on the relevant Service pages and added to deployment cost. Per-km basis: 25 m pylon spacing (40 pylons/km).
The bare elevated platform — foundation, pylon, transverse cap beam(s), longitudinal girders, deck modules, and permanent equipment (walkway, handrails). Module costs are Megafactory pour rate + Hub and die allocation at moderate platform utilisation (~$310/module). Pre-feasibility grade, ±30%.
| Item | Per pylon / span (AUD) | Per-km (AUD) |
|---|---|---|
| Cutter heads (sacrificial hybrid, 2 per pylon — 1 per leg) | $20,000 / pylon | $800,000 |
| Caisson ring segments — 30 rings (15 per leg × 2 legs, 15 m depth) | $20,550 / pylon | $822,000 |
| Caisson anchor caps (2 per pylon) | $1,870 / pylon | $74,800 |
| Pressure grout (2 caissons × 1.5 m³) | $2,400 / pylon | $96,000 |
| Tubulars — 2 × 20″ × 171 ppf L80 13Cr API 5CT, ~20 m each (15 m caisson + 5 m stickup) | $28,800 / pylon | $1,152,000 |
| P1/P2 lower column segments (precast, 4 segments to freight at 6 m) | $3,040 / pylon | $121,600 |
| HB1 transverse cap beam (17 m wide, freight + HVDC arms, 65 t) | $1,950 / pylon | $78,000 |
| P3/P4 upper column segments (precast, 4 segments to maglev at 17 m) | $3,040 / pylon | $121,600 |
| HB3 transverse cap beam (17 m wide, maglev level, 43 t) | $1,950 / pylon | $78,000 |
| Pylon heads (2 per pylon — 1 per leg) | $1,390 / pylon | $55,600 |
| XA-C HVDC arm modules (4 per pylon — bolt-on at HB1 and HB3) | $3,740 / pylon | $149,600 |
| HB2 freight longitudinal girders (25 m, 5 per span) | $6,550 / span | $262,000 |
| HB4 maglev longitudinal girders (25 m, 5 per span) | $6,550 / span | $262,000 |
| Walkway, handrails, fall protection (dual-deck) | $8,000 / span | $320,000 |
| Structure subtotal | $4,393,200 |
Service-specific equipment installed on the structure to enable the services it carries (saddles, brackets, conduits, guideway supports). The service items themselves — track, conductors, water pipe, fibre cable, maglev hardware — are catalogued separately on the relevant Service pages and added to deployment cost.
| Item | Per span (AUD) | Per-km (AUD) |
|---|---|---|
| Freight track ballast + tie supports | $4,500 / span | $180,000 |
| Maglev guideway saddles | $3,500 / span | $140,000 |
| HVDC conductor insulator brackets | $2,000 / span | $80,000 |
| Gas / hydrogen pipe support saddles | $2,500 / span | $100,000 |
| Water pipe support saddles | $1,800 / span | $72,000 |
| Fibre wireway + signalling conduit | $1,200 / span | $48,000 |
| Power feeder supports (auxiliary) | $1,000 / span | $40,000 |
| Services subtotal | $660,000 |
All field labour and plant required to deploy the structure and services. Drilling rig service charged at ~$1,200/hour all-in (crew + plant + fuel). Self-building methodology compresses install cost: rig and crane work from the deck of the already-built section.
| Item | Per pylon / span (AUD) | Per-km (AUD) |
|---|---|---|
| Foundation drilling (SBC dual drilling rig, 8 hrs × 2 caissons × $1,200, 15 m) | $19,200 / pylon | $768,000 |
| Pylon segment erection (8 segs both legs + 2 tubulars + tensioning) | $6,000 / pylon | $240,000 |
| Cap beam placement (HB1 + HB3, 2 × $1,500) | $3,000 / pylon | $120,000 |
| XA-C HVDC arm bolt-on (4 × $400) | $1,600 / pylon | $64,000 |
| QA, commissioning | $1,500 / pylon | $60,000 |
| Girder placement (10 girders × $400) | $4,000 / span | $160,000 |
| Freight track laying | $8,000 / span | $320,000 |
| Maglev guideway laying | $3,500 / span | $140,000 |
| HVDC conductor stringing + insulators | $3,000 / span | $120,000 |
| Pipe runs (gas, hydrogen, water) | $4,000 / span | $160,000 |
| Fibre + power pull | $1,500 / span | $60,000 |
| Install subtotal | $2,212,000 |
Structure + Services + Install. The service items themselves (track, conductors, water pipe, fibre cable, maglev hardware) are catalogued on their respective Service pages and added to deployment cost. Foundation costed at 15 m baseline depth; deeper foundations on river crossings or floodplain sections add cost in proportion.
Pre-feasibility grade, ±30%. Modules costed at Megafactory pour rates from Memo 2 (Megafactory Economics) plus moderate-utilisation Hub and die allocation (~$310/module). Install rates are pre-feasibility benchmarks against light civil construction at corridor scale. All figures AUD. Detailed engineering and quantity surveying required before any binding use.