It’s true to say that pretty much every member of the VMT team in Australia and HQ was involved in the WestConnex project. That’s because we supplied 143 guidance systems for 89 roadheaders, as well as 54 rockbolters – and many of these were customised products.
Sydney in Australia is faced with significant population growth and escalating traffic congestion, which meant that new roads were required, particularly along the M4 and M5 corridors. The NorthConnex and WestConnex projects were completed to overcome this. Westconnex is approximately 30km long and involved widening and extending the New M4, duplicating the New M5 and connecting the two motorways by an underground link. This has created a seamless, free-flowing western bypass of Sydney’s central business district, significantly easing congestion for motorists.
A new era in conventional tunnelling
The A$16.8 billion WestConnex project encountered Sydney Sandstone along its route, a geological formation ideal for tunnelling. Due to accessibility challenges and in order to minimise the impact on the local population, however, roadheader equipment was used rather than Tunnel Boring Machines (TBMs) for the tunnelling works. The M4 required 21 roadheaders and 11 rockbolters across four construction sites to create 50 cross passages and a total tunnelled distance of approximately 14km. Roadheader production averaged 25 to 30 metres per week. The New M5 project featured twin 9km tunnels running parallel to the existing M5 East and required the use of 20 roadheaders and 11 bolting rigs operated 24/7across multiple construction sites.
Seven years of maximum commitment
VMT’s navigation equipment contracts for Australia’s largest transport infrastructure project included:
- TUnIS Navigation equipment for all roadheaders and rockbolters.
- TUnIS Office servers and software for each site office to collect, analyse, and manage machine data.
- Permanent on-site service for system commissioning and support, plus training of surveyors, site engineers and operators.
Australia’s largest transport project was a huge challenge for VMT due to the large numbers of machines that required installation, surveying, and commissioning. The intensive workload lasted from 2016 to 2023 and included training local engineers to operate the systems.
To meet the unique requirements of the WestConnex project, we embarked on a journey of innovation and collaboration. We had to redesign our navigation systems to integrate data from all the roadheaders and bolters working with the machine manufacturers to ensure tunnel alignment and rock bolt placements. The project was a company-wide effort involving collecting comprehensive data sets such as position and profile, as well as operational date such as power consumption and hydraulic pressures. The system also tracked cutterhead paths for post-excavation analysis which helped to assess cutter effectiveness and the accuracy of tunnel profiles relative to geometry.
WestConnex stands out as a landmark project for VMT in every respect. Seven years, 143 guidance systems, innovative solutions and the fostering of a deep, ongoing relationship with our customer. This project has left an indelible mark on our company, setting a new standard for future endeavours.