Sydney Metro West has reached a major engineering milestone, completing a world‑first application of Lining Erector Machine (LEM) technology to line its mined service tunnels at Clyde. The custom‑built system delivered a faster, safer and higher‑quality outcome for the two tunnels leading to the project’s future stabling and maintenance facility.

Traditionally, service tunnels excavated by roadheaders require cast‑in‑situ concrete lining, a process involving large formwork, surface concrete pumping and multiple staged pours. By contrast, the LEM—drawing inspiration from tunnel boring machine techniques—was designed to install precast segments manufactured at the Eastern Creek precast yard. Engineers refined the machine throughout the project, enabling it to build a complete tunnel ring of four segments in around one hour.

The final service tunnel, measuring 762m in length and 6m in diameter, was fully lined within two months. This approach not only accelerated construction but also achieved a more consistent and watertight finish comparable to TBM‑built tunnels, while improving safety conditions for workers.

LEM performance at a glance:

• Approx. 55m long and 6m wide
• 310 tonnes in weight
• 3,438 segments installed to date
• Service tunnels over 700m long
• One ring completed in roughly 60 minutes

This innovation marks a significant step forward for Sydney Metro West and showcases how emerging techniques can streamline tunnel construction across Australia’s infrastructure pipeline. The successful application of the LEM is expected to influence future tunnelling practices, supporting safer, faster and more sustainable delivery.

Source: Tunnelling Journal

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