Mitigating risks in port infrastructure through team effort for transportation of tunnel boring machines (TBMs)
At a glance
The challenge
One of the main challenges during delivery was transporting the massive TBMs across three critical infrastructure components – a bridge, a wharf, and the road pavement – all of which were in varying states of ageing. Due to the limited or missing as-built documentation, the GHD team had to thoroughly investigate and evaluate the structural characteristics and capacities of these assets. This analysis was essential for assessing risks and developing effective mitigation measures to ensure the safe passage of the TBMs.
Our response
Transporting several oversized and extremely heavy TBM components – each weighing up to 300 tonnes, across ageing infrastructure demanded meticulous analysis and strategic planning. The GHD team assessed various specialist transport solutions, including different configurations of self-propelled modular transporters, to evaluate which would place the least strain on the bridge, pavement, and wharf involved.
Given the high public profile of Sydney Metro West and the critical importance of timely TBM delivery to the construction schedule, effective communication was essential. GHD maintained regular updates with clients, sharing early findings so manufacturing and transport strategies could be adjusted before the TBM parts even left the factory in China.
Success in this complex project relied on GHD’s collaborative network, drawing on the expertise of five teams across two regions to deliver a thorough, risk-focused approach. Support from specialist subcontractors including divers, geotechnical drillers, and remote-sensing surveyors provided the reliable data needed for confident planning and execution.
The impact
After careful assessment, planning and teamwork, this multi-discipline collaboration successfully enabled the delivery of the TBMs to the construction site, with several additional benefits for our clients:
- Optimised transport and manufacturing:
GHD’s evaluation of infrastructure load limitations and recommendations on transportation methodology allowed clients to optimise manufacturing strategies at the factory, minimising re-handling of TBM parts at the construction site. By enabling transportation of the TBMs in larger components, time was saved on dismantling and reassembling – streamlining delivery and enhancing overall project efficiency. - Reduced environmental and community impact:
By using a nearby port infrastructure as the entry point, logistics were streamlined and the need for long-distance road transport eliminated. This approach minimised disruption to local communities, shortened the transportation distances, avoided road closures and multiple truckloads, and reduced the overall carbon footprint of transporting the TBMs. - Protected infrastructure and critical assets:
Through rigorous site investigation and infrastructure capacity assessment, GHD safeguarded port assets as well as the TBMs, ensuring the critical construction equipment was delivered safely and efficiently.