Perfect Contracting delivered the decommissioning and demolition of major temporary tunnelling infrastructure at The Bays Precinct, Rozelle, as part of the Sydney Metro West Eastern Tunnelling Package.
The scope included the demolition and removal of the segment shed, spoil shed, internal gantry crane systems, slurry treatment and separation plant, sliding system, five steel tanks, silo support works, access bridge structure and associated temporary infrastructure.
The works were completed within a live Tier 1 infrastructure environment involving a live station box, active construction interfaces, other trades, live services and a live water treatment plant operating nearby.
A key part of the methodology was protecting the live water treatment plant and completing demolition works safely beside it without damage, disruption or impact to its operation.
At peak, the project involved heavy mobile crane operations using cranes ranging from approximately 120 tonne to 750 tonne capacity, with a 750 tonne mobile crane used during the segment shed works.
Perfect Contracting completed the works safely, efficiently and on programme.
Sydney Metro West Project Context
Sydney Metro West is a major transport infrastructure programme connecting Greater Parramatta with the Sydney CBD through a new underground metro railway.
The Eastern Tunnelling Package includes approximately 3.5 kilometres of twin metro tunnels between The Bays and Hunter Street in the Sydney CBD, including tunnelling beneath Sydney Harbour and excavation works for the future Pyrmont and Hunter Street stations.
The Bays site played a key role in the tunnelling programme. It operated as a major tunnelling support location for tunnel boring machine operations, spoil handling, segment logistics, plant operation, material movements and temporary site infrastructure.
Once this temporary infrastructure was no longer required, it had to be carefully decommissioned and removed so the site could move into the next stage of construction.
Perfect Contracting was engaged to complete this work safely inside a constrained, live and heavily coordinated infrastructure environment.
Services Delivered
Perfect Contracting delivered a broad decommissioning and demolition package, including:
- Infrastructure decommissioning
- Segment shed demolition
- Spoil shed demolition
- Gantry crane decommissioning
- Slurry treatment plant demolition
- Slurry separation plant demolition
- Sliding system demolition
- Steel tank demolition and processing
- Silo removal support
- Access bridge and stair structure removal
- Heavy crane-assisted dismantling
- Structural steel cutting and processing
- Live site demolition
- Working over and around a live station box
- Working beside a live water treatment plant
- Material segregation and disposal preparation
- Coordination with other trades
- Tier 1 infrastructure demolition support
The Challenge
This was not a standard shed demolition.
The works were carried out within a constrained and active infrastructure site, with multiple live interfaces and a high level of programme pressure.
The main challenges included:
- Demolition of large temporary tunnelling sheds within a live construction site
- Decommissioning internal gantry crane systems before the main shed demolition
- Removing structural elements above and around a live station box
- Working immediately beside a live water treatment plant that had to remain untouched
- Protecting live services and nearby operating infrastructure
- Demolishing a slurry treatment and separation plant with residual material still present
- Processing and separating material before disposal
- Demolishing a sliding system and five steel tanks
- Managing heavy structural steel requiring engineered lifting and controlled dismantling
- Working around other trades and active construction activities
- Supporting the removal of two silos
- Completing late client-requested works before plant demobilisation
- Maintaining safety and programme certainty for the principal contractor
The project required detailed sequencing, strong supervision and constant coordination with the principal contractor and other site teams.
Gantry Crane Decommissioning
A key component of the project was the decommissioning and dismantling of the internal gantry crane systems.
These gantry cranes had been used during tunnelling operations to support the movement and handling of heavy materials within the sheds. Before the shed structures could be demolished safely, the crane systems had to be isolated, dismantled, cut, lifted and removed in a controlled sequence.
Perfect Contracting treated the gantry crane works as a high-risk engineered dismantling package.
The works included:
- Reviewing the gantry crane layout, support points and structural connections
- Confirming isolation of electrical and mechanical components
- Establishing exclusion zones below and around the work area
- Planning lift points, rigging arrangements and crane positions
- Cutting and separating crane beams and steel members
- Supporting major components with mobile cranes before final separation
- Lowering steel sections safely to ground level
- Processing steel for recycling and removal from site
The gantry cranes were integrated into the shed structures, which made sequencing critical. Removing the crane systems in the wrong order could have created structural, safety and access risks.
By removing the gantry crane systems first, Perfect Contracting reduced overhead risk and created safer access for the next stage of demolition.
Segment Shed and Spoil Shed Demolition
Perfect Contracting demolished the segment shed and spoil shed using a staged, controlled methodology.
The approach combined:
- Manual preparation
- Cladding removal
- Structural steel cutting
- Crane-assisted dismantling
- High-reach excavator demolition where suitable
- Processing and removal of steel and demolition materials
The work required different demolition methods across different zones of the structures, depending on access, slab support, crane reach, station box interface and proximity to other active works.
Multiple mobile cranes were used throughout the project, ranging from approximately 120 tonne to 750 tonne capacity. The 750 tonne mobile crane was used during peak segment shed works to support the controlled removal of large structural sections.
This crane-assisted methodology allowed large sections to be removed safely and efficiently while maintaining control over structural movement and dropped-object risk.
Slurry Treatment and Separation Plant Demolition
Perfect Contracting also demolished the slurry treatment and separation plant infrastructure.
This part of the project required careful planning because the slurry plant included:
- Structural steel framing
- Elevated plant components
- A sliding system
- Five steel tanks at the bottom level
- Residual material remaining inside parts of the system
The slurry treatment and separation plant was demolished using a controlled top-down approach. The upper steelwork and sliding system were progressively dismantled first, allowing the team to safely work through the structure before accessing the lower-level tanks.
A key challenge was that residual material remained within parts of the plant. Perfect Contracting had to carefully process, separate and segregate the material before disposal. This ensured each waste stream was managed correctly before transport to approved tip sites.
The five steel tanks were then demolished, processed and separated for removal.
This work demonstrated Perfect Contracting’s practical decommissioning capability. The team had to manage more than structural demolition. They also had to deal with material handling, waste separation, plant dismantling and disposal logistics inside a live construction environment.
Working Beside a Live Water Treatment Plant
One of the most important live interfaces on the project was the existing water treatment plant.
Perfect Contracting did not demolish this plant. The live water treatment plant remained in place and had to be protected throughout the works.
Demolition activities were carried out beside it, requiring strong controls to prevent impact, vibration damage, falling material, service strikes or disruption to its operation.
Controls included:
- Clear separation between demolition works and the live treatment plant
- Protection of nearby services and infrastructure
- Exclusion zones and controlled access
- Sequenced demolition to reduce impact risk
- Supervisor control during high-risk activities
- Careful material handling and processing
- Coordination with the principal contractor and site teams
This was a key part of the project’s risk profile. Perfect Contracting had to remove the redundant slurry treatment and separation infrastructure while maintaining the integrity of the live water treatment plant nearby.
Sliding System Demolition
The sliding system formed part of the slurry treatment and separation plant infrastructure and required controlled demolition from the top down.
Perfect Contracting progressively removed the surrounding steel structure, then worked through the sliding system in sequence before accessing the lower-level components and tanks.
This reduced the risk of uncontrolled movement and allowed the team to maintain safe access throughout the demolition process.
Silo Removal Support
Perfect Contracting also assisted with the removal of two silos on site.
Crane operations were managed by others, with a specialist subcontractor leading that part of the work. Perfect Contracting provided supervision, labour support and site assistance to help with dismantling, landing, processing and making components safe once they were lowered to ground level.
This is one of the reasons Tier 1 contractors value Perfect Contracting. The team does not only complete its own work package. It supports the broader site team when practical help is needed to keep the programme moving.
Access Bridge and Stair Structure Removal
Late in the programme, Perfect Contracting was asked to assist with the removal of an access bridge and stair structure connecting the office area to the work zone.
The request came at short notice, with Perfect Contracting’s machine due to demobilise from site.
The team responded quickly, completed the required cut-away works before the machine left site and helped avoid unnecessary remobilisation or delay.
This was a small but important example of Perfect Contracting’s practical site culture: when the client needs help, we respond quickly and safely.
Working Over and Around a Live Station Box
A major risk on the project was working over and around the live station box.
The demolition sequence had to prevent dropped objects, uncontrolled movement and any impact to the structure or work areas below.
Controls included:
- Engineered lift planning
- Sequenced cutting and dismantling
- Controlled lowering of materials
- Tethered tools
- Elevated work platforms
- Exclusion zones
- Spotters and supervisors
- Hold points and sign-offs
- Coordination with the principal contractor and nearby trades
Every steel member, cladding panel and lifted section had to be secured and controlled before removal.
This level of discipline was critical to completing the project safely inside a live infrastructure environment.
Live Site Coordination
The project required constant coordination with the principal contractor, subcontractors and other trades on site.
Perfect Contracting worked around:
- Active construction interfaces
- Live services
- Live station box interfaces
- The operating water treatment plant
- Crane operations
- Material movements
- Other subcontractors
- Programme milestones
The site could not simply be shut down for demolition. The works had to be carefully staged around the broader construction programme.
Perfect Contracting’s supervisors and crews maintained clear communication, practical sequencing and safe execution throughout the works.
Capability Demonstrated
This project demonstrated Perfect Contracting’s capability across complex infrastructure demolition and decommissioning, including:
- Major temporary works decommissioning
- Gantry crane dismantling
- Segment shed demolition
- Spoil shed demolition
- Heavy crane-assisted demolition
- 120 tonne to 750 tonne crane coordination
- Top-down demolition methodology
- Slurry treatment plant demolition
- Slurry separation plant demolition
- Sliding system demolition
- Steel tank demolition
- Residual material processing
- Silo removal support
- Access bridge removal
- Live station box interface management
- Working beside live treatment infrastructure
- Live service protection
- Structural steel cutting and processing
- Working at height
- High-risk cladding removal
- Material segregation and waste preparation
- Coordination with Tier 1 infrastructure contractors
The Outcome
Perfect Contracting successfully completed the decommissioning and demolition of the segment shed, spoil shed, internal gantry cranes, slurry treatment and separation plant, sliding system, five steel tanks, silo support works, access bridge structure and associated temporary infrastructure.
The project was delivered:
- Safely
- On programme
- Within a live infrastructure environment
- Around active site operations and other trades
- Without impact to the live water treatment plant
- Without disruption to critical services
- With flexibility to assist the principal contractor with additional works
- With the work area handed back ready for the next stage of construction
Why This Project Matters
The Bays project is a strong example of Perfect Contracting’s ability to deliver complex demolition works in live infrastructure environments.
This was not only about removing temporary sheds. It required engineered planning, crane strategy, gantry crane decommissioning, slurry treatment plant demolition, steel tank processing, protection of a live water treatment plant, live station box interface management and coordination with multiple trades inside a Tier 1 project.
Perfect Contracting brought the right people, plant, supervision and practical problem-solving mindset to complete the work safely and efficiently.
Frequently Asked Questions
What did Perfect Contracting demolish at The Bays, Rozelle?
Perfect Contracting demolished temporary tunnelling infrastructure including the segment shed, spoil shed, internal gantry crane systems, slurry treatment and separation plant, sliding system, five steel tanks, silo support works, access bridge structure and associated temporary works.
Was the project part of Sydney Metro West?
Yes. The works were connected to the Sydney Metro West Eastern Tunnelling Package at The Bays, Rozelle.
Did Perfect Contracting decommission the gantry cranes?
Yes. Perfect Contracting decommissioned and dismantled the internal gantry crane systems before progressing with the main shed demolition.
What crane capacity was used?
Multiple mobile cranes were used, ranging from approximately 120 tonne to 750 tonne capacity. A 750 tonne mobile crane was used during peak segment shed works.
Did Perfect Contracting demolish the live water treatment plant?
No. Perfect Contracting worked beside the live water treatment plant and left it untouched. The team protected the operating plant while completing demolition works nearby.
What plant did Perfect Contracting demolish?
Perfect Contracting demolished the slurry treatment and separation plant, including the sliding system, surrounding steelwork, residual material areas and five steel tanks.
What made the project complex?
The project involved demolition within a live Tier 1 infrastructure environment, including work over and around a live station box, internal gantry cranes, heavy structural steel, a slurry treatment and separation plant, residual material processing, steel tanks, silos, live servicesand an operating water treatment plant nearby.
Was the work completed on programme?
Yes. Perfect Contracting completed the works safely and on programme, while also assisting the principal contractor with additional site support works.
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.