Bulla Spoil Facility
The site was developed for the storage and treatment of tunnel boring machine spoil for the Westgate Tunnel Project in Melbourne. The boring of two tunnels
produced over 1.8 million cubic meters of material that was to be stored and subsequently treated in the purpose-built facility.
DATE
2021-2023
PRINCIPAL
Bulla Spoil Facility
CLIENT
Symal / Bulla Spoil Facility
SCOPE
Two contracts undertaken at the Bulla Spoil Facility (BSF). Works comprised of the construction of a heavy duty pavement incorporating in-situ cement recycling and plant mix foam bitumen recycling to create an impermeable surface in the receivables area. The second contract was to treat 1.8 million cubic metres of Tunnel Boring Machine (TBM) spoil transported from the West Gate Tunnel Project (WGTP) in Melbourne.
KEY CHALLENGES
Receivable area
Bespoke heavy duty pavement design with site won aggregate.
Resource intensive and a complex pavement design under accelerated build conditions
Spoil Treatment
Highly plastic tunnel spoil with a very high moisture content
Extremely high throughput to match tunnel spoil from 2 TBM’s concurrently
DOLLARS SAVED
28%
overall against traditional design
KG CO2 SAVED
22%
against traditional design
TIME SAVED
30%
over traditional methodology
SOLUTIONS
Our combination of in-situ and plant mix working as a team provided the ability to meet the time constraints. The use of Foamed Bitumen Recycling (FBR) with site won aggregate provided surety of supply, reduced cost and much lower carbon emissions that traditional solutions. Our ability to provide real time advice and unique IP to deal with huge quantities of TBM spoil 24/7 meant programme compliance.
OUTCOMES
Over 300,000m2 of heavy duty pavement successfully delivered
A solution provided which was both cost and carbon effective
1.8 Million cubic metres of tunnel spoil treated successfully In 13 months
