End-to-end equipment solution supports one of Victoria’s largest infrastructure projects

Find out how Coates designed a whole-of-business solution to support one of Victoria’s largest infrastructure projects.

 

The project

West Gate Tunnel is one of the largest infrastructure projects currently being constructed in Victoria. When it opens to traffic in late 2025, the project will improve connections between Melbourne’s west and the northern suburbs, the port, CityLink and the CBD.

The project is being delivered in partnership by the Victorian Government and Transurban, with a CPB Contractors and John Holland joint venture (CPBJH JV) as lead contractor. Coates was appointed preferred supplier to support the delivery of a significant scope of works, that includes:

• A 2.8km eastbound tunnel and 4km westbound tunnel below Yarraville

• A new bridge crossing over the Maribyrnong River

• An elevated road section above Footscray Road

• Widened sections of the West Gate Freeway

• A new traffic control room at Yarraville to manage the new road network

West Gate Tunnel is one of Victoria's largest infrastructure projects

The challenge

Difficult ground conditions and the need to work near live traffic made the West Gate Tunnel Project (WGTP) particularly challenging.

“The WGTP spans a complex brownfield site with a restricted linear project footprint,” says Marko Oreb, Plant Manager for CPBJH JV. “The project was further complicated by working adjacent to Melbourne’s intermodal port and rail hubs, and keeping sections of the M1 open for motorists in the west zone.”

Water management was a significant challenge too. Michael Sfyris, Coates Major Project Manager, explains: “As with any former industrial site, low levels of PFAS contamination also meant that any extracted water had to be treated and discharged in line with standards set by Worksafe Victoria and the local EPA.”

The solution

The Coates Major Project team coordinated input from across the business to support all major construction for the WGTP. This included contributions from product specialists, engineers and other trained specialists from Coates’ Engineering Solutions, Water Management, Industrial Solutions and Power & HVAC teams.

The comprehensive solution included:

• More than 1,000 pieces of equipment, such as excavators; shoring and access equipment; pumps; generators; cooling systems; lighting; tool stores and more.

• Engineered temporary works solutions to support several major excavation packages of works.

• Water management solutions to extract, treat and discharge groundwater, creating a safe environment for excavation and ensuring environmental standards were met.

• Specialist temporary power and HVAC solutions to keep control room servers cool during construction.

• Two experienced tool store controllers to manage all tools and equipment through an on-site tool store.

• Three dedicated technicians to perform vital equipment maintenance and repairs. Having technicians on site every day helped to minimise downtime and ensured the safety, compliance and efficiency of all hire equipment.

“All Coates’ equipment and solutions were backed by a high level of product and industry knowledge, customer service and technical expertise, and there was always someone available to support our on-site team,” says Marko.

With support from multiple teams across the business, Coates is providing an end-to-end solution for a significant scope of works

The impact

Reducing cost, improving efficiency

According to Marko, Coates’ technical expertise helped to drive creativity and innovation that allowed gaps and opportunities to be identified. “Coates’ product knowledge and understanding of best practice and emerging trends highlighted where things could be done differently,” he said. “The team also uncovered new ways to add value, increase efficiency and enhance the performance of hired assets and our project teams.”

• Telemetry-enabled equipment improved cost efficiency and equipment utilisation. “At any time, CPBJH JV could log into Coates Connect to see what was on hire and the location of all equipment on site,” says Michael.

• Greener Choices hybrid and solar equipment, such as electric knuckle booms and scissor lifts, hybrid air conditioning units and solar traffic lights, reduced fuel costs and improved the environmental performance of the project. Coates also designed a system that allowed treated groundwater to be re-used for dust suppression on site.

• Instead of transporting all hire equipment to and from site each day, high-use assets were stored in a designated on-site Coates equipment store. This approach:

  • Mitigated transport costs, saving on average $16,000 each month

  • Reduced CO₂ emissions by an average of 70%

  • Reduced down time for crews waiting for replacement or additional assets

  • Provided the assurance of having access to backup equipment, particularly during high-risk project delivery periods.

Coates has uncovered new ways to add value and increase efficiency during the project

Building strong project partnerships

Coates’ on-site presence enabled smooth integration with the project team. “By managing an on-site tool store and assigning a range of specialists to work on site each day, we were able to build a high level of trust and engagement with this customer,” says Michael. “Attending the daily pre-start meetings also kept communication open and allowed any issues to be raised and resolved.”

For CPBJH JV, the success of its partnership with Coates can be measured by:

• A wide range of efficiency improvements

• Reductions in the cost of transport and fuel

• Improved environmental performance

• The compliant and efficient use of all hire assets

• All project targets being met

“Delivering a project like West Gate Tunnel required a provider that could supply all of the necessary plant, equipment and solutions, but Coates took the next step to create a partnership,” says Marko. “This approach has been pivotal in achieving many of our successes to date, and Coates’ contribution remains integral to the completion of a project that will transform travel in Melbourne’s west.”

Find out how Coates can enhance the delivery of your major infrastructure project.