Project and construction management sets SAGE apart for major ITS project

Following the completion of Stage 1 of the Monash Freeway Upgrade in 2018, construction for Stage 2 was set to begin in 2020. Stage 2 of the project would see 36km of new lanes added to two major freeways, improved connectivity with new ramps, and upgrading of an interchange.

Installing smart on-road technology enhances traffic management, and a new extension with a shared walking and cycling path enables alternative transportation

The project was to be underpinned by an Intelligent Transport System (ITS), extending the newly installed ITS from Stage 1 to incorporate the near 40km extension. Significant planning and coordination was required to ensure that the Victorian Government’s Department of Transport and Planning’s (DTP) new and existing infrastructure continued to remain operational during construction in Stage 2.

Instrumental in the successful delivery of Stage 1, SAGE Automation was also chosen as the ITS delivery partner for Stage 2, working with CPB Contractors, who were awarded the design and construct contract.

Under the guidance of SAGE, a robust strategy was devised to navigate the complexities of integrating new ITS components without disrupting the operational efficiency of the existing setup.

This required extensive pre-planning, coordination, and collaboration with CPB to ensure business continuity throughout the project.

Critical to the success of the project were:

• Ensuring the safety of CPB workers during construction
• Uninterrupted operation of the Monash Freeway, and
• Navigating the challenges surrounding the early stages of COVID.

Two scopes required significant planning and coordination to ensure that DTP’s existing infrastructure continued to operate during the construction changes; the new fibre network and Lane Use Management System (LUMS) delivered as part of Stage 1.  

Fibre Network Cutover

A major aspect of the work involved extending the fibre network along both carriageways of the freeway to improve the redundancy of the eastern section of the M1. This involved the installation of 16km of new fibre, which had to be integrated into the existing trunk fibre network via a major cutover.

SAGE has a successful track record of planning and implementing complex network upgrades with minimal impact on road users, without affecting the day-to-day operation of valuable ITS assets. In close collaboration with CPB, SAGE Automation prepared Detailed Implementation Plans, change requests, and regularly presented proposed changes at client meetings.

An example of this critical planning was illustrated before the main cutover when inspections by SAGE uncovered discrepancies in the as-built drawings at two node huts. SAGE updated the drawings, and two node huts were prepared with new hardware and patch leads using detailed patching drawings — completing the end-to-end cutover of existing active network rings between the two nodes in a single shift.

The carefully managed work used multiple site teams to splice the fibre in three different locations simultaneously and in a way that ensured no loss of service to existing ITS assets. Throughout the successful cutover, the SAGE site team worked seamlessly with traffic management teams, the client’s network maintenance team, and the Traffic Management Centre (TMC) to ensure every step of the Detailed Implementation Plan was followed.

This careful planning and implementation by SAGE and CPB mitigated the risk of communications being lost to hundreds of ITS assets along a critical 8km section of the Monash Freeway. With in-house design and installation teams, SAGE was also responsible for all ITS-related physical works, including cable hauling, termination and testing, roadside cabinet terminations, splicing in pits, node hut upgrades, and installation of overhead vehicle detection (OHVD) systems.

Lane Use Management System (LUMS)

Another critical element of the Monash Freeway Stage 2 Upgrade involved SAGE installing a Temporary LUMS (Lane Usage Management System) to maximise traffic flow, reduce congestion, and enable business continuity during the project. SAGE's Temporary LUMS solution included:

Supply, Fabrication, and Installation 

Temporary LUMS brackets allowed for more efficient installation and relocation of LUMS signs to suit ongoing lane changes. The fabrication process was through SAGE’s installation partner, involving custom sets of brackets tailored to different gantry types, dimensions, and lane configurations.

Documentation Excellence

SAGE contributed significantly to the project's success by developing comprehensive documentation, including Bills of Materials (BOM), work procedures, planning and tracking sheets, Inspection and Test Plans (ITPs), and location schematics. This meticulous approach ensured a systematic execution of tasks at each LUMS site.

Resource Optimisation

Executing the Temporary LUMS scope required a strategic approach to resourcing. SAGE maintained efficiency while managing two crews, comprised of electricians, ground personnel, scissor lifts, light towers, and necessary support vehicles.

Adaptive Fabrication Process

Facing a last-minute change in bracket design, SAGE’s material management expertise allowed the project to seamlessly adapt and reallocate materials to ensure no disruption to the project timeline.

Operational Coordination

Before each shift, meticulous coordination with CPB was conducted to align with planned LUMS groups, driven by the line marking program. This foresight ensured smooth transitions and minimised disruptions during the implementation phase.

Safety and Testing Protocols

Prioritising safety, SAGE teams conducted Proof of Performance (POP) tests at critical junctures. This included POP Stage 1, testing the completed slow lane LUMS for issues, and POP Stage 2, validating the entire LUMS group after fast lane modifications.

Post-Implementation Verification

On shift completion, SAGE communicated with the Traffic Operations Centre (TOC) regarding operational readiness and any outstanding LUMS errors.

Stage Two of the Monash Freeway Upgrade integrated advanced ITS technology into a critical thoroughfare linking Victoria’s south-eastern suburbs to the Melbourne CBD.

The successful project demonstrated:

• Business Continuity: key highlights demonstrated SAGE’s ability to maintain operational continuity amid complex transitions.

• Extensive Pre-planning: undertaken to synchronise with the client's program and the on-ground realities.
• Coordination and Collaboration: the project stakeholders committed to a coordinated approach of delivery.
• Project and Construction Management: The project achieved timely and within-budget delivery.
• Client Partnership: the relationship between CPB Contractors and SAGE saw challenges addressed quickly, ensuring the project succeeded.
• Technological Advancement: the augmentation marked a significant leap in the ITS domain, setting a precedent for future projects.
• Overhead Vehicle Detection (OHVD): the integration of OHVD marked a significant upgrade, facilitating real-time monitoring and data acquisition.

SAGE delivered the certainty needed and required by CPB Contractors for a significant ITS scope of work for a major infrastructure project. SAGE identified and mitigated the risks associated with hundreds of essential ITS assets connected to the Department of Transport network by taking assets offline and implementing collaborative and effective project planning.

A world leader in delivering comprehensive industrial digitalisation solutions, SAGE’s understanding of end-to-end ITS solution delivery ensured a wider service offering for the project while mitigating overall risk.

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