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  Building a tunnel starting with the end (Opening Completion) in mind - The Tunnel

  The WestConnex M4-M5 Link Tunnels (WCX Stage 3A) project is a 7.5 km Sydney underground link connecting the WestConnex M4 East Tunnel at Haberfield and the WestConnex New M5 (M8) Tunnel at St Peters Interchange. The project commenced in June 2018 and is due for completion in 2023. The project comprises 21.6 km of roadheader tunnel excavation, tunnel civil fit out works, surface civil works, Mechanical & Electrical (M&E) installation and Testing & Commissioning (T&C) including integration with M4 and M8 network. To deliver the project on time, to improve the overall logistics, optimise resources and maximise underground productivity & efficiency, a “Tunnel Production Line” (TPL) strategy has been developed from the start of the project. This paper describes how the TPL has been defined, implemented, monitored and refined during project execution, focusing on the activities from tunnel excavation to internal handover to Tunnel Civil and then to Tunnel M&E and finally to T&C phase. It describes the continuous improvement process implemented from the start with a focus on the end product which defines construction methodologies, and temporary works, logistics, adjustments to the design to suit the TPL all driven to provide a safe, high quality end product constructed within the program timeframe. Quality right first time and integrated handover processes were essential to secure the project delivery with nil or minimum rework. By anticipating the problems and by detailing the sequence of works, the co-activities between different disciplines in the tunnel are managed successfully.

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