Perfect Contracting was appointed by the Acciona-Ferrovial Joint Venture (AFJV) to carry out the full demolition and decommissioning of the Bays Spoil Shed, Segment Shed, and Cross Belt Conveyor System — a critical stage in the demobilisation of Sydney Metro West’s tunnelling program.
With over 25,000 square metres of steel-framed infrastructure and reinforced slabs to remove, surrounded by heritage culverts, live shafts, and active public roads — this was not just another demo job. It was high-risk engineering-led deconstruction.
Scope Overview
The Bays demolition works were executed across four distinct zones:
- Spoil Shed (126m) – Full structural dismantling, slab removal, heritage culvert protection
- Segment Shed (76m x 65m) – Gantry crane decommissioning, acoustic frame dismantling, slab retention
- Cross Belt Conveyor – Five structural towers and two vertical chute systems removed
- Ancillary Structures – Tasman tanks, concrete pits, retaining walls, piles and slab piers
Perfect Contracting developed and delivered 40+ pages of engineered methodologies, ITPs, and sequencing plans for each asset class, ensuring full compliance with AS2601-2001 and Sydney Metro’s Principal Contractor Standards.
Methodology: Engineered, Sequenced, Certified
Spoil Shed Demolition
- 13-phase dismantling program using high-reach excavators (Volvo EC480) and Fortress shear attachments
- Sheet removal by man-lift and EWP, followed by beam cutting and induced collapses within exclusion zones
- Slab thickness of 1.2m required saw cutting and controlled impact demolition with strict vibration monitoring
- Crane-supported slab lift over a heritage-listed culvert (4.6m deep)
- Crane 650t crower
Segment Shed Decommissioning
- Roof sheeting removed manually and craned off-site in strapped packs
- Three gantry cranes disassembled and lifted using dual 250T cranes with engineered lift plans
- High-reach machine (48T) used on western bay; eastern shed dismantled piece-by-piece
- Permanent shaft protection maintained; access zone barricaded and monitored 24/7
Conveyor & Tower Removal
- Towers 1 through 5 dismantled top-down using riggers and shear-equipped excavators
- Vertical chutes and B1/C1 drive towers cut, rigged, and craned down
- Engineered beams spanning the shaft lifted and transported via detailed rigging plans
Safety, Environmental & Heritage Controls
- Heritage Culvert: Protected via wire saw slab segmentation and craned lift panels
- Live Sewer & Shaft: Marked, barricaded and excluded from all impact zones
- Dust Management: Water cannons, Motorfog mist systems, inline machine spray bars
- Noise & Vibration: Monitored at all times, compliant with NSW EPA standards
- Hazmat Protocols: Unexpected finds process aligned with SafeWork NSW legislation
- Community Protection: Contra-flow traffic systems and 24/7 fencing across Port Access Rd
All work executed under Perfect’s certified Integrated Management System (IMS), covering Quality (ISO 9001), Environment (ISO 14001) and WHS (ISO 45001).
Leadership & Collaboration
Perfect’s delivery team was led by:
- Milad Rowda – Senior Project Manager
- Dedicated Site Supervisor & Spotter Crew
- Demolition Engineers & Crane Coordination Manager
Daily prestarts, weekly client walk-arounds, and coordination meetings with AFJV ensured seamless communication and high-trust execution.
Measurable Success
Metric | Result |
Recycling Rate | 99.5% |
Lost Time Injuries | 0 |
Program Compliance | 100% on-time |
Client Sign-Off | Achieved March 2025 |
Final Area Handover | Levelled, compacted, hazard-free |
Perfect Contracting acknowledges the Aboriginal and Torres Strait Isander people as Traditional Custodians of the country on which we live and work. We pay our respects to the Traditional Custodians and Elders past, present and future, and honour their connection to the land and ongoing contribution to society.