Sydney Metro - Western Sydney Airport project reaches new major construction milestone

The Sydney Metro – Western Sydney Airport project has reached a major construction milestone with three of four massive tunnel boring machines (TBMs) completing their journey building the metro rail tunnels. 

TBMs Catherine, Eileen and Peggy have now concluded their historic journeys after 13 months of tunnelling alongside a team of 553 tunnellers, TBM operators and support personnel. 

“This historic breakthrough of the new Metro tunnels at Western Sydney Airport are just another way we are building the essential infrastructure Western Sydney needs. 

“We are committed to building better communities in Western Sydney, and public transport projects like this that are creating jobs and cutting travel times are a critical part of our plan,” NSW Premier Chris Minns said. 

“I am delighted to see the wonderfully-named Catherine and her TBM friends bringing us closer to a world-class transport option to the new Western Sydney International Airport and major job hubs, including the new Aerotropolis. 

“This milestone is a critical step towards connecting the suburbs that will grow around this brand-new metro line, giving Western Sydney the opportunity to attract more jobs and housing opportunities. 

“This city-shaping metro line will service travellers and airport workers with major population centres like Penrith, Parramatta and the Sydney CBD via St Marys,” Minister for Infrastructure, Transport, Regional Development and Local Government Catherine King said. 

TBM Peggy has recently broken through at the newly named Bradfield Railway Station site – formerly known as Aerotropolis Station – while TBM Eileen had its breakthrough at Bradfield on 29 May, completing tunnelling works on the 5.5-kilometre tunnels that run from Airport Business Park, under the new Western Sydney International Airport, to Bradfield. 

Meanwhile, TBM Catherine wrapped up its tunnelling journey on 20 May at the opposite end of the alignment. This TBM worked its way building the 4.3-kilometre tunnel from Orchard Hills, under the M4 Motorway and the Great Western Highway to St Marys. 

TBM Marlene will be the last to make its breakthrough at St Marys in the coming weeks after working hard to complete the final 230 metres of tunnel for this Sydney Metro project. 

“It is great to see these 4 TBMs have completed their tunnelling journeys under Western Sydney. 

“The NSW Labor Govenrment, together with the Australian Government, is committed to delivering the vital, major infrastructure needed to deliver for our growing Western Sydney community,” NSW Deputy Premier and Minister for Western Sydney Prue Car said. 

“This is first-hand proof that the Albanese Government is committed to delivering vital infrastructure for Western Sydney as part of a genuine partnership between levels of government that will enhance liveability and support the growth of industry and enterprise. 

“World-class metro services will be a game-changer for Sydney’s Greater West in every sense and this major milestone in construction is another closer step to making that a reality,” Member for Werriwa Anne Stanley said. 

Breakthrough of TBMs Catherine, Eileen and Peggy (source: Sydney Metro)

Since starting their journeys, the TBMs have worked around the clock, seven days a week to dig over 1.4 million tonnes of material and install 68,360 concrete segments that now line the new tunnel walls. 

Work will continue inside the tunnels to complete the delivery of 39 cross passages and prepare for track laying. 

With tunnelling works almost complete, construction will now focus on the six metro stations at St Marys, Orchard Hills, Luddenham, Airport Business Park, Airport Terminal and Bradfield. 

Major work to build the new St Marys Station is now underway while the sites for the new stations at Orchard Hills, Luddenham and Bradfield are being prepared for construction – expected to commence in the coming months. 

“This is a job well done for 3 of 4 mega machines and a huge achievement for everybody involved. 

“More than 550 workers spent many hours deep below ground and across the site to drive these borers across the finish line. 

“It’s a phenomenal milestone for Sydney’s second airport rail link. 

“While tunnelling is almost finished on the Western Sydney Airport line for now, we are planning the public transport links of the future. 

“Our business cases are underway to plan more future rail links in Western Sydney as these communities continue to grow,” NSW Transport Minister Jo Haylen said. 

The Sydney Metro – Western Sydney Airport project will deliver a new 23-kilometre railway that is set to become the transport spine for Greater Western Sydney, connecting travellers and communities to the up and coming Western Sydney International (Nancy-Bird Walton) Airport as well as the growing region. 

This project is jointly funded by the Australian and New South Wales governments. The new railway line is due to open in late 2026 with the start of airport operations. 

A total of 14,000 jobs are expected to be created during the construction of this Sydney Metro project. As of April 2024, the project has created 10,348 jobs including 250 apprenticeships. 

“We are delivering a future made in Australia and this project is a fantastic example of how we are doing that in Western Sydney. 

“Sydney Metro and the new Western Sydney airport will transform Western Sydney into a global economic hub. 

“Today’s major milestone is tribute to the great work of the more than 10,000 people that are working on this project. 

“This project demonstrates how government leadership and co-investment with industry can deliver world class infrastructure assets resulting in significant value for future generations,” Prime Minister Anthony Albanese said. 

Source: NSW Government – Media Releases; Minister for Infrastructure, Transport, Regional Development and Local Government; Sydney Metro (1, 2); Roads & Infrastructure Australia; Infrastructure Magazine