TBM Drive Construction Plant and Equipment: 50 Example Fleets by Work Type
This page provides 50 example plant and equipment mixes for different stages of
TBM (Tunnel Boring Machine) drives – shafts and portals, TBM assembly and launch,
segment production, logistics, M&E fit‑out, cross passages, reception, refurbishment and
rehabilitation.
Each card represents a practical plant + equipment fleet that works together as a system.
Use these as starting points when developing methodology‑led estimates, programmes and
Efficient Construction Cost (ECC) models. Always adjust for your specific
TBM type (EPB, slurry, hard rock), geology, drive length, access, interfaces and safety rules.
Launch Shafts, Reception Shafts & Portals
1. Launch Shaft Excavation – Diaphragm Wall
Use case: Deep urban launch shaft using D‑walls and internal struts.
Plant & Equipment Mix
- Diaphragm wall grab + service crane (80–150 t)
- Bentonite/slurry plant and desanders
- 30–40 t excavator for bulk spoil inside shaft
- Crane for reinforcement cages and tremie concrete
- Pumps for dewatering and cleaning
2. Launch Shaft Excavation – Secant Piles
Use case: Circular shaft with secant pile wall and temporary props.
Plant & Equipment Mix
- CFA/secant pile rig
- 80–120 t service crane
- Mini/midi excavators for internal bulk excavation
- Skip & crane or mucking conveyor for spoil removal
- Dewatering system (wellpoints or deep wells)
3. Hard Rock Portal Excavation
Use case: TBM portal in slope/rock abutment (e.g. hydropower or road twin‑tube).
Plant & Equipment Mix
- 35–50 t excavators with rock breakers
- Drill & blast rigs (if blasting permitted)
- Dump trucks for rock haul
- Shotcrete rig and rock bolting equipment
- Dozer for portal platform shaping
4. Soft Ground Portal with Ground Support
Use case: Cut-&-cover or ground‑improved portal in soft soils.
Plant & Equipment Mix
- 20–30 t excavator with trench support system
- Jet grouting/mixing rigs for ground improvement
- Shotcrete & soil nail equipment
- Dewatering pumps and monitoring
TBM Assembly, Launch & Utility Systems
5. TBM Delivery & Lowering into Shaft
Use case: Segmental lowering of TBM shield and back‑up decks.
Plant & Equipment Mix
- Heavy lift crawler or mobile crane (500–1,200 t) – depending on TBM size
- Tail/assist crane (200–400 t)
- Skates and SPMTs (if pre‑assembly and lateral moves at surface)
- Shaft gantry cranes (where used)
6. TBM Shield Assembly in Shaft
Use case: Erect cutterhead, shield sections and main bearings in launch shaft.
Plant & Equipment Mix
- Shaft portal gantry crane or large mobile crane
- MEWPs and internal platforms
- Torque tools and alignment jigs
- Welding sets (if needed for structural connections)
7. Back‑Up Gantry Assembly
Use case: Place trailing gantries, walkways, services and equipment.
Plant & Equipment Mix
- Shaft gantry crane or mobile crane at portal
- Telehandlers/forklifts for modules and pallets
- MEWPs for cabling, hoses and safety systems
8. Utility & Service Setup (Slurry/EPB)
Use case: Slurry/EPB separation plant and utility links at launch site.
Plant & Equipment Mix
- Slurry separation plant/centrifuges/cyclones
- Feed and return slurry pumps
- Pipe racks & mobile cranes for pipe/stringing
- Power generation/distribution units
Segment Casting, Storage & Handling
9. Segment Casting Yard – Carousel System
Use case: High‑volume segment production in dedicated yard.
Plant & Equipment Mix
- Batch plant for segment concrete
- Carousel mould system with gantry crane
- Steam curing system/curing tents
- Forklifts for demoulding and yard stacking
10. Segment Casting Yard – Conventional Bay
Use case: Lower throughput yard using floor/bed casting.
Plant & Equipment Mix
- Concrete batch plant and line/boom pump
- Overhead travelling crane(s)
- Vibrating screeds and finishing tools
- Forklifts and yard tractors
11. Segment Storage Yard
Use case: Stack and manage segments near shaft/portal.
Plant & Equipment Mix
- Rubber‑tyred gantry crane or straddle carrier
- Forklifts (8–16 t) for segment packs
- Stacking frames and dunnage systems
12. Segment Transport to TBM
Use case: Move segments from storage to shaft/portal in sync with TBM advance.
Plant & Equipment Mix
- Segment trucks or SPMTs
- Shaft gantry/portal crane for lowering
- Segment carriers/wagons in tunnel
Muck Handling, Conveyors & Logistics
13. Muck Removal – Rail (Locomotive & Skips)
Use case: Rail‑based muck haulage on long drive in rock.
Plant & Equipment Mix
- Narrow gauge locomotives
- Muck skips or side‑dump wagons
- Shaft hoisting system (if vertical shaft)
- Surface tip & stockpile fleet (excavator + trucks)
14. Muck Removal – Conveyor System
Use case: Continuous conveyor mucking from TBM to surface stockpile.
Plant & Equipment Mix
- Tunnel conveyor belt system (primary + backup drives)
- Transfer towers and surface stacker
- Excavator/loader + trucks at stockpile
- Maintenance MEWPs and belt handling gear
15. Slurry Muck Handling & Disposal
Use case: Slurry TBM with separation plant and filter presses.
Plant & Equipment Mix
- Slurry pumps & pipelines (feed & return)
- Desanders/desilters, centrifuges
- Filter presses or thickeners
- Wheel loaders & trucks for cake removal
16. Logistic Supply Trains
Use case: Supply segments, grout, consumables and spares to TBM face.
Plant & Equipment Mix
- Tunnel locomotives
- Segment/flatbed/material wagons
- Onboard cranes/manipulators on wagons
- Scheduling and signalling systems
TBM Operation Support – Grout, Ventilation, Power
17. Tail Grout Plant & Delivery
Use case: Two‑component grout injection behind segments.
Plant & Equipment Mix
- Grout batching/mixing plant at surface
- Grout pumps and high‑pressure lines
- Storage silos for cement/bentonite
- Quality testing equipment (viscosity, density, set)
18. Ventilation Systems
Use case: Fresh air supply and fume extraction for long TBM drives.
Plant & Equipment Mix
- Primary fans & booster fans
- Vent ducting (flexible/rigid) with suspension gear
- MEWPs/rail platforms for duct installation and maintenance
19. Power Distribution & Cables
Use case: HV/LV feeds from surface substations to TBM.
Plant & Equipment Mix
- Transformers and switchgear at portal/shaft
- Cable reels & pulling gear for trailing cables
- Cable racks or hanging gear along tunnel
20. Foam, Polymer & Conditioning Plants (EPB)
Use case: Soil conditioning for EPB TBM face control.
Plant & Equipment Mix
- Foam generation units
- Polymer storage and dosing systems
- Pumps and mixing lines to TBM
Cross Passages, Emergency Niches & Breakouts
21. Hand/SEM Mined Cross Passages
Use case: Short cross passages between twin tubes.
Plant & Equipment Mix
- Mini roadheader or 5–15 t tunnel excavator
- Shotcrete pump and robotic arm
- LHD/loader and muck boxes
- Ventilation fans/ducts & support jacks
22. Ground Freezing or Grouting for Cross Passages
Use case: Stabilise ground between tunnels before excavation.
Plant & Equipment Mix
- Drilling rigs from main tunnel or surface
- Freezing plant (brine/liquid N2) or grout mixing/pumping plant
- Monitoring instrumentation (temps/pressure)
23. Emergency Refuge Niches
Use case: Local widenings in TBM tunnel for refuges/equipment bays.
Plant & Equipment Mix
- Tunnel excavator or hand mining tools
- Shotcrete rigs & spiling/support
- Segmental or in‑situ lining formwork
24. Breakout Chambers (TBM to Station/Cavern)
Use case: TBM interface with future station cavern.
Plant & Equipment Mix
- Cavern excavation plant (roadheader/drill‑and‑blast)
- Shotcrete and rock bolting fleet
- Segment cutting & temporary support gear
Final Lining, Waterproofing & Secondary Works
25. Segmental Lining – Routine TBM Advance
Use case: Normal segment erection and bolting at TBM tail.
Plant & Equipment Mix
- Segment erector within TBM
- Segment carriers/wagons
- Hydraulic torque wrenches
26. Secondary Cast‑In‑Place Lining (if required)
Use case: Inner concrete lining inside segment or rock tunnel.
Plant & Equipment Mix
- Tunnel lining shutters / forms
- Concrete pump & agitator(s) at shaft/portal
- Ventilation & lighting
27. Invert/Slab Casting
Use case: Invert slab or track bed in TBM tunnel.
Plant & Equipment Mix
- Mini excavator or slab preparation tools
- Trailer‑mounted concrete pump
- Mesh/rebar handling plant
- Vibrating screeds & finishing gear
28. Waterproofing Membrane (Non‑Segmental)
Use case: Spray/fixed waterproofing systems in shotcrete or rock tunnels.
Plant & Equipment Mix
- Membrane spray rigs (liquid) or geosynthetic rolls
- Anchors/fixing tools
- Scaffolds/MEWPs inside tunnel
M&E Fit‑Out, Walkways & Track/Service Install
29. Cable Tray, Ladder & Service Ducts
Use case: Install cable trays, ducts and pipe racks along tunnel walls.
Plant & Equipment Mix
- Tunnel MEWPs or mobile scaffolds
- Light cranes/gantries for heavy runs
- Hand tools & fixings gear
30. Track Slab & Rail Installation (Rail Tunnel)
Use case: Slab track construction after TBM lining.
Plant & Equipment Mix
31. Walkways & Emergency Egress
Use case: Install walkways, handrails, cross‑passage doors, etc.
Plant & Equipment Mix
- Forklifts/telehandlers for walkway modules
- MEWPs inside tunnel
- Hand tools/torque tools
TBM Breakthrough, Recovery & Re‑Launch
33. Reception Shaft Preparation
Use case: Prepare reception shaft structure and invert for TBM breakthrough.
Plant & Equipment Mix
- Shaft excavation/lining fleet (as per Section 1)
- Shotcrete & rock support for breakthrough face
- Dewatering system
34. TBM Breakthrough Management
Use case: Controlled breakthrough into shaft or cavern.
Plant & Equipment Mix
- Excavators and loaders in reception area
- Cranes for shield/back‑up support
- Shotcrete rigs for immediate support if needed
35. TBM Dismantling in Shaft
Use case: Segmental disassembly underground after drive completion.
Plant & Equipment Mix
- Shaft gantry crane or mobile crane at surface
- Internal gantries/chain blocks for sub‑assemblies
- Skates/movers to bring parts under crane
36. TBM Turnaround or Re‑Launch
Use case: Re‑launch TBM from opposite direction or cross passage.
Plant & Equipment Mix
- Cranes for reassembly
- Temporary launch frames & jacking systems
- Logistics trains for moving gantries/plant
TBM Maintenance, Upgrades & Demobilisation
37. Cutterhead Intervention & Tool Changes
Use case: Interventions in hyperbaric or open mode to change tools.
Plant & Equipment Mix
- Hyperbaric chamber and equipment (for EPB/slurry)
- Diving/hyperbaric contractor tooling
- Internal access platforms and lifting frames
38. Mid‑Drive TBM Maintenance Shutdown
Use case: Planned maintenance of key TBM components mid‑drive.
Plant & Equipment Mix
- Maintenance platforms and scaffolding within TBM
- Chain blocks, jacks and lifting beams
- Portable machining and welding equipment
39. Surface Plant Maintenance & Upgrades
Use case: Overhaul slurry plant, conveyors, segment yards mid‑project.
Plant & Equipment Mix
- Cranes/telehandlers for pump and screen changes
- Forklifts and MEWPs for access
- Spare pumps/screens/filters and maintenance tooling
40. Demobilisation of TBM & Surface Facilities
Use case: Strip out and remove TBM, conveyors, slurry plant and yards.
Plant & Equipment Mix
- Heavy lift cranes for large components
- Excavators for structure removal and trench backfill
- Trucks/SPMTs for plant transport
- Dozers/graders/rollers for site rehabilitation
Survey, Ground Monitoring & Safety Systems
41. Surface Settlement & Building Monitoring
Use case: Track settlement and structural response above TBM drive.
Plant & Equipment Mix
- Robotic total stations and prisms
- Automated levelling sensors
- Data loggers and remote telemetry
42. Tunnel Convergence & Lining Monitoring
Use case: Monitor TBM lining deformation and convergence.
Plant & Equipment Mix
- Precise total station setups in tunnel
- Convergence pins & targets
- 3D laser scanning systems
43. Face Pressure & Ground Response Instrumentation
Use case: Monitor face pressure vs. pore pressures/settlement.
Plant & Equipment Mix
- Piezometers and inclinometers
- Borehole installation rigs
- Data loggers & communication systems
44. Safety, Rescue & Emergency Systems
Use case: Safety infrastructure for long TBM drives.
Plant & Equipment Mix
- Rescue locomotives/vehicles
- Refuge chambers and emergency communications
- Gas detection and fire suppression plant
ECC/TOC Pilot Drives & Methodology Option Trials
45. Short Pilot TBM Drive (Geology & Methodology Proving)
Use case: Trial TBM performance in expected ground conditions.
Plant & Equipment Mix
- Same TBM and core plant in shortened drive
- Instrumentation for production, thrust, torque and ground response
- Full muck and segment logistics chain (scaled in distance)
46. Conveyor vs Rail Muck Haulage Trial
Use case: Compare two muck transport systems on comparable distances.
Plant & Equipment Mix
- Muck rail set (locos + skips)
- Trial conveyor section and transfer points
- Monitoring for cycle times, availability and maintenance
47. Different Conditioning Regimes Trial (EPB)
Use case: Test foam/polymer recipes for best face control and ECC.
Plant & Equipment Mix
- Multiple foam/polymer dosing setups
- Lab/field testing gear for conditioned soil properties
- TBM monitoring systems for torque/pressure
48. Segment Logistics Options Trial (Yard vs Just‑In‑Time)
Use case: Compare large stockpile yard vs. JIT supply to TBM.
Plant & Equipment Mix
- Full yard handling fleet (gantry cranes, forklifts)
- Direct delivery fleet (trucks, trailers, local crane)
- Tracking systems for segment availability and downtime
49. Mixed‑Mode Operation: TBM + SEM Sections
Use case: Compare TBM vs. SEM for short problematic zones.
Plant & Equipment Mix
- TBM fleet (baseline)
- SEM fleet (roadheader, shotcrete, rock support)
- Monitoring for productivity, risk and ground impact
50. Integrated ECC/TOC Review Zone Along TBM Alignment
Use case: Full methodology and plant review on representative section.
Plant & Equipment Mix
- Representative TBM + surface plant setup
- Instrumentation for time/muck/segment/productivity data
- Monitoring for surface settlement and service impacts
Need Help Selecting or Optimising TBM Drive Plant and Equipment Mixes?
These example fleets are starting points only. On a live TBM tunnel project, the optimal plant and
equipment mix depends on:
- TBM type (EPB, slurry, hard‑rock) and drive length
- Ground conditions, groundwater regime and overburden
- Access strategy (shafts, portals, intermediate adits) and logistics
- Interfaces with stations, caverns, rail/road/utility networks
- Required advance rates, safety constraints and ECC/TOC objectives
We can help you:
- Develop methodology‑led TBM plant and equipment mixes for each phase of the drive
- Align TBM selection, logistics and surface plant with realistic productivity and Efficient Construction Cost (ECC)
- Compare haulage, conditioning and lining strategies on a time–cost–risk basis
- Feed real project learning back into future tunnel bids and planning
Use the form below to discuss your project.
Our Partners
- FR2 Infrastructure – Constructability advise and project and planning controls
- Staging Diagrams – Staging diagrams for possession planning
✨ Support Our Mission ✨
Help us continue building tools that simplify complexity!
Every contribution fuels new features and improvements
Thank you for being part of our journey! 🚀
