How a Custom Gantry System Simplified the Removal of HS2 Tunnel Boring Machines with Mammoet and Herrenknecht

Facing the Challenge of Extracting Gigantic Tunnel Boring Machines

When it comes to dismantling large underground machinery, working on the surface is undeniably smarter and safer than wrestling with confined, smoky, and hot underground spaces. This reality became clear in the massive undertaking to remove several tunnel boring machines (TBMs) from beneath the outskirts of London for the groundbreaking HS2 railway project connecting Birmingham with London.

The Scale of the TBMs and the Project

The TBMs used for the HS2 Northolt tunnel segment — a twin tunnel stretching 8.4 miles — were nothing short of colossal. Four machines, supplied by Herrenknecht, worked from opposite ends of the tunnel, boring towards each other until meeting near the Green Park Way ventilation shafts.

The ventilation shafts sit roughly 35 meters above the tunnels and served as the extraction points for these mammoth machines after they completed their jobs. Extracting machines of this size in an urban environment, sandwiched between active rail lines and ongoing civil works, posed a particularly complex logistical puzzle requiring an innovative approach.

Initial Considerations and Risks on Site

Traditional methods would involve dismantling the TBMs piece by piece underground using heavy cranes within cramped shafts—a risky process with tight space, ventilation issues, and potential safety hazards due to smoke and heat from cutting operations. This not only risked longer downtimes but also brought interference with the surrounding active work zones and rail lines.

Safety was paramount, especially given the proximity to two functioning railway lines and busy urban surroundings. Mammoet, tasked with the extraction, collaborated closely with Skanska Costain STRABAG JV and Herrenknecht, looking for a solution that minimized underground work and maximized operational efficiency.

Innovating with a Tailored Gantry System

After nine months of design and five months of detailed engineering, a custom gantry system was developed and built on-site within a month. This system was unlike anything previously assembled, crafted specifically to lift the entire TBM front and central shield sections as single units weighing up to 900 tons.

Features of the Gantry System

• Hydraulic sliding system: Allowed the gantry to laterally move for precise positioning over the two ventilation shafts.
• Integrated equalizer beam with pivot: Enabled smooth rotation of the lifted load to align correctly during the extraction process.
• Remote-controlled operation: The system avoided manual handling of cables and winches, keeping personnel at a safe distance and reducing risk.

This maneuverability was crucial as one ventilation shaft’s design had to account for nearby subsurface rail infrastructure, requiring a controlled turn mid-lift to position each section of the machine accurately onto the transporters.

From Lifting to Transportation

Each lifted section was transferred onto a set of 32-axle Self-Propelled Modular Transporters (SPMTs), which safely moved the heavy loads to a dismantling area nearby. There, the machines were carefully lowered to ground level and disassembled using hydraulic climbing jacks, allowing removal of internal components while avoiding hazardous work at height.

A Collaborative Triumph in Engineering and Logistics

The extraction campaign was a showcase of flawless teamwork among Mammoet, Herrenknecht, SCS JV, and the HS2 project team. Richard Dexter, Herrenknecht’s International Director General, highlighted the extensive coordination needed for multiple 24-hour operating windows timed with weekend rail possessions, supported by months of prior planning, engineering, and community involvement.

The key to success was not only the innovative gantry system but also the spirit of collaboration that reduced extraction time significantly, enabling early access for subsequent construction phases. This synergy between heavy engineering and logistical planning demonstrates how complex challenges demand joined-up solutions.

Potential Broader Impact

Mammoet is already evaluating the potential to reuse this gantry design for other projects requiring heavy lifts in confined spaces, opening doors to more efficient and safer handling of bulky loads across various sectors.

Table: Benefits of the Tailored Gantry System over Conventional Methods

How This Innovation Touches the World of Logistics

While this story revolves around tunneling and heavy machinery, the logistics lessons are clear and impactful. Handling oversized, heavy, and bulky cargo is no walk in the park. The successful extraction and transfer of these TBMs show the value of tailored engineering solutions, strategic planning, and technology-enabled operations in managing complex shipments safely and efficiently.

This know-how parallels critical logistics challenges: moving large shipments, coordinating with busy infrastructure corridors, and managing risks while ensuring on-time delivery. Platforms like GetTransport.com specialize in connecting businesses and clients with reliable and affordable transport solutions, whether it’s office relocations, vehicle hauling, or the dispatch of large, awkward cargo. Leveraging innovative methods akin to the gantry system enriches the logistics sector’s ability to deliver tailored, safe, and timely transportation services worldwide.

The Final Word: Experience Outweighs the Reviews

In the end, no matter how detailed a review or feedback might be, nothing substitutes for actual experience. The complexity and scale of projects like this one highlight that seemingly small innovations can save time, cut costs, and enhance safety dramatically.

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Summary and Wrap-Up

Removing massive TBMs from urban tunnels is no small feat. The custom gantry system engineered by Mammoet and collaborators for the HS2 project serves as a textbook example of innovative problem-solving in logistics and heavy lifting. Its design minimized risk, saved precious time, and allowed big, awkward loads to be managed with precision—paralleling the demands seen in global shipping, freight forwarding, and complex haulage operations.

For logistics professionals and customers alike, this underscores the importance of flexible, tailored solutions and meticulous planning. Platforms like GetTransport.com bring this principle full circle by offering global users access to affordable, reliable transport services for everything from bulky parcels to large-scale relocations, ensuring the logistics chain runs like a well-oiled machine every step of the way.