Project Description:
The West Gate Tunnel Project is a major infrastructure initiative in Melbourne, Victoria, designed to ease congestion on the West Gate Bridge and improve freight access to the Port of Melbourne. Located in the city’s
western corridor, the project includes twin tunnels beneath Yarraville, an elevated road above Footscray Road, and upgrades to the West Gate Freeway. It was delivered through a public-private partnership between
the Victorian Government and Transurban, with construction led by CPB Contractors and John Holland.
What sets this project apart is its integration of urban design and environmental features, including a 2.5 km elevated cycling path known as the “veloway,” Indigenous-inspired architectural elements, and restored wetlands - making it not just a transport solution but a transformative urban renewal effort.
Project Challenges:
The engineering scope of the West Gate Tunnel Project encompassed a wide range of disciplines, including civil, structural, geotechnical, and construction engineering. The project involved upgrading the West Gate Freeway from 8 to 12 lanes, constructing twin tunnels beneath Yarraville, building a series of new bridges over the Maribyrnong River, and developing elevated roads to connect with CityLink and the Port of Melbourne. The engineering services provided by Robert Bird Group included design development of over 200 temporary works packages and detailed assessment of the construction sequence of the elevated bridges.
Significant engineering challenges included working within live traffic environments, crossing roads, rail and rivers, which required detailed structural analysis to inform precise lift planning and execution for bridge beams. Complex site conditions - such as narrow rail corridors, water tables, and wind-exposed zones - demanded innovative lifting techniques, multi-crane operations, and strict compliance with safety and environmental standards.
RBG played a pivotal role in the success of the West Gate Tunnel Project by delivering innovative and highly practical engineering solutions across multiple disciplines. One of the most significant contributions was our
detailed fit-up assessments for bridge girder installations. Through complex staged analysis models and survey data fed into these models, the assessments ensured that over 150 girders were installed safely and efficiently without a single lift cancellation - a remarkable achievement in a project of this scale. Our team was physically present on-site for every girder installation we were involved in, providing real-time engineering support and assurance. Additionally, we designed critical temporary works related to crane setups and enabling works, which were essential for maintaining safety and productivity in complex and constrained environments.
Beyond structural and construction engineering, our civil team conducted hydraulic assessments in the Maribyrnong River to evaluate the impact of temporary works on river flows, helping to mitigate environmental risks. We also leveraged advanced digital engineering tools, producing 4D visualisations and 3D fabrication models that supported the fabricator in resolving intricate design details and helped to plan construction activities. These models not only improved coordination but also enhanced buildability and reduced rework. By integrating clever temporary construction engineering with permanent works planning, RBG helped the contractor streamline execution, improve safety outcomes, and achieve cost and time efficiencies. Our holistic and hands-on approach exemplified how engineering innovation can directly translate into project success.
Sustainability:
All our designs complied with the project’s sustainability and environmental requirements. We prioritised the reuse of materials and engineered many of our temporary bridge restraints to be reusable multiple times across the project.