Case Study: Melbourne Metro Tunnel Project achieves safe, fast tunnel breakthroughs with InfraBuild’s GFRP D-Wall cages

Melbourne Metro Tunnel Project installs 9km tunnel support cages with InfraBuild

The Melbourne Metro Tunnel Project required a method for its tunnel boring machines (TBMs) to safely break through the concrete diaphragm walls of new stations without causing damage or requiring hazardous manual rebar removal. InfraBuild supplied and installed specialized Dextra ASTEC Soft-Eyes GFRP (Glass Fibre Reinforced Polymer) rebar cages as part of the D-Wall system to address this challenge.

InfraBuild's solution involved fabricating steel reinforcement cages and integrating the custom, corrosion-resistant GFRP Soft-Eyes. These components allowed the TBMs to cut through the concrete and GFRP reinforcement cleanly, creating tunnel openings in the fastest, simplest, and safest way. This fully integrated supply chain, managed by InfraBuild, enabled the daily delivery of up to 150 tonnes of fabricated cages, ensuring the project stayed on its tight construction schedule.