The construction of Cell I2 at the Ballarat Regional Landfill stands as an example of the complex, high-stakes infrastructure increasingly required to support Victoria’s waste and resource recovery sector. Delivered through 2022–23, the project tested the resilience, adaptability and cooperative capacity of all parties involved. What began as a routine cell construction quickly evolved into a technically challenging and time-critical undertaking that required innovative engineering responses to unforeseen geotechnical conditions, supply constraints, and intense program pressures.
The project commenced during one of the wettest periods on record in late 2022. Persistent rainfall limited access, reduced equipment productivity, and created challenging conditions for excavation and subgrade preparation. As the site dried sufficiently for the next stages, the project team discovered a network of historic mining shafts and drives—remnants of Ballarat’s 19th-century gold-mining era—beneath the proposed cell footprint. These underground voids introduced significant geotechnical uncertainty and posed both structural and safety risks to the planned landfill lining system.
Responding to this unforeseen challenge required the excavation of an additional 40,000 cubic metres of soil to remove the compromised subgrade and replace it with engineered fill. Compounding this challenge, the site did not contain sufficient accessible clay to meet design specifications, necessitating the transport of clay to site at a scale not originally anticipated. This represented a major logistical effort under already tight time constraints. In parallel, extensive excavation was required to remove legacy slimes pits within the footprint as prescribed by the design, adding further complexity.
These challenges unfolded under extreme schedule pressure. The City of Ballarat’s existing active cell was nearing capacity, and failure to commission Cell I2 before winter 2023 would have forced the transport of municipal waste to Melbourne Regional Landfill at significant cost to Council. The project therefore carried an operational imperative with clear financial consequences.
The successful completion of Cell I2 was ultimately achieved through a highly collaborative and solution-focused approach. Council, the Contractor, the Superintendent and the Project Manager worked cohesively to prioritise risks, adapt methodologies, modify staging, and maintain momentum despite disruptions. Shared problem-solving, transparent communication and an unwavering commitment to the program enabled the project team to overcome challenges that could easily have resulted in major delays.
This presentation by Jeremy Rudd and Lya Assef will explore the technical, logistical and project-management responses that ensured Cell I2 was delivered on time and ready for waste in 2023. We will share lessons learned in geotechnical risk management, contingency planning, wet-weather construction, resource sourcing, and the value of collaborative contracting. The project offers a practical case study for councils, engineers and waste-sector practitioners facing increasing infrastructure demands, constrained resources and growing operational risk.