Tunnelling Solutions has rapidly evolved from its humble beginnings in 2014 to become a key player in the tunnelling and underground construction industry.
Known for its technical expertise and ability to handle high-risk, complex infrastructure projects, Tunnelling Solutions has garnered a strong reputation for delivering results in the most challenging environments.
Founded as a consultancy in 2014, Tunnelling Solutions began with a small but highly skilled team focused on providing expert tunnelling services.
In 2022, Tunnelling Solutions became a wholly owned subsidiary of Gamuda Engineering. This partnership has proven crucial in bolstering Tunnelling Solutions’ ability to undertake large-scale, technically challenging projects.
Looking back at the early days, the company’s first successful project in 2015 set the stage for rapid expansion.
Co-founder Harry Lyle mobilised a team to take on Project Arncliffe, a 30m long tunnelled underpass, overcoming several key challenges with poor ground conditions including live rail only a few metres above the tunnel.
The company’s expertise spans several tunnelling disciplines, such as shaft excavation, pipe jacking, auger boring, road header and drill and blast excavation, and the management of tunnelling operations across various projects which range in size and scale. To build on this strength, in 2024, Serhat Baycan was appointed the new CEO of Tunnelling Solutions.
With a background in geotech and piling, Baycan has more than 30 years of experience in the construction industry having worked on iconic projects around the world. He knows too well the importance of delivering major projects and adapting the business to market needs.
Over the last few years, as the company continues to grow, Tunnelling Solutions has diversified its expertise to include utilities and water infrastructure projects. This pivot is in response to market trends, as demand for water and sewer systems continues to rise with growing urban populations.
Further strengthening the company’s expansion into the water sector is the recent acquisition of a microtunnelling boring machine (MTBM) from Herrenknecht. This machine is specifically designed for smaller, specialised tunnelling projects, such as those needed for urban sewer and water systems.
The compact design of the MTBM allows it to operate in tight urban spaces, where space constraints are often a major challenge. With this investment, Tunnelling Solutions is well-positioned to lead into the utilities sector, offering tailored solutions for sewer and water tunnelling projects that require precision and advanced technical capabilities. Tunnelling Solutions’ success is built on a well-defined approach to project delivery. Each project follows a clear methodology that prioritises safety, efficiency, and quality at every stage.
“Tunnelling Solutions’ methodology is focusing on innovation and finding ways to do things smarter, including changing designs to better suit the project,” Project Superintendent Matt Lyle said.
“Gamuda has a similar value bringing innovation and technology to improve tunnelling industry capability.”
One of these innovations includes bringing technology developed by Gamuda for automated tunnel boring machines (TBMs) to Australia for use on a major tunnelling project in Sydney.
The sophisticated artificial intelligence software, previously used in Kuala Lumpur, is installed inside the TBM and has the capability to automatically steer, operate, and monitor the machine, while an operator remains in control.
Delivering major infrastructure projects
Tunnelling Solutions has been involved in many major projects, including the Level Crossing Removal Works on Glenroy Road in Melbourne.
The company completed a 1.2m diameter, 360mm pipe jack on a lump sum contract, using an AVN1200 slurry machine provided by the client.
The project faced challenges, including soft clay and low cover (600m) near a live rail, which could have led to delays and increased costs. Tunnelling Solutions responded by making improvements to the slurry treatment plant at 100m into the drive, improving productivity and reducing slurry costs.
Its innovative approach ensured the project was completed on schedule and within budget. In addition to the company’s microtunnelling work, Tunnelling Solutions has also completed drill and blast tunnels in Coffs Harbour and Lake King William in Tasmania.
Growth and future outlook
Tunnelling Solutions’ growth trajectory has been impressive. From a privately owned company led by its industry heavyweight founders Harry Lyle and Craig Farr to a company comprised of more than 250 employees delivering complex projects for Tier 1 contractors on major projects across infrastructure and water.
Tunnelling Solutions, thanks to the backing of a Tier 1 company like Gamuda, has carved out a niche for itself by combining advanced technical know-how with on-the-ground management capabilities, delivering quality outcomes even in high-risk, technically demanding environments.
“Being backed by an international powerhouse engineering company allows us to provide our clients with alternative solutions to complex project delivery,” Lyle said.
This growth is a direct result of the company’s ability to manage high-risk projects, its strategic focus on niche markets, and its investment in state-of-the-art tunnelling equipment.
The company not only has an experienced management team but a qualified workforce who align with the Tunnelling Solutions’ way. Whether it is a mined tunnel, drill and blast, pipejacking or tunnel remediation scope, Tunnelling Solutions has the track record and capability to deliver safely and to high standards.
Looking ahead, the company aims to expand further in the water sector, pumped hydro projects and major infrastructure projects.
With a team of 250 highly skilled professionals and an increasing portfolio of completed projects, Tunnelling Solutions is poised to become an even more dominant force in Australia’s tunnelling industry.
For more information, visit tunnellingsolutions.com.au
This article was featured in the February edition of Trenchless Australasia.
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