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Madrid M30

Spain Projects

The M30, a major highway that circles the central district of Madrid, is one of the busiest highways in Spain and contains the longest urban motorway tunnels in Europe. In 2004, the city embarked on the £3.5bn scheme which would see the highway rerouted through tunnels to alleviate congestion, reduce travel time, improve traffic flow, and significantly reduce the environmental and acoustic impact of the M30 operations on Spain’s capital city.

TECHNICAL CHARACTERISTICS

CLIENT

Madrid Town Council

VALUE

£639m

DATES

Construction: 2004 – 2007
Operation and Maintenance: 2007 – 2039

CONTRACT TYPE

PPP

The Madrid M30 scheme was delivered under a Public-Private Partnership (PPP), Madrid Calle 30, realising the benefits of delivering this large scale, complex programme under a PPP approach. Our sister company, Ferrovial Services, owns 50% of the private share of the company.

The construction works were divided into 15 contracts for 96km of new highway to be delivered within a very demanding timeframe. We successfully constructed, on time and on budget, two of the 15 contracts of the M30 scheme under lump sum contracts – the north tunnel of the south bypass and the west tunnels. The north tunnel comprised a total of 4.2km of which 3.6km was bored by an Earth Pressure Balance (EPB) TBM (the longest TBM tunnel of the scheme) and the remaining 600m by cut and cover. The west tunnels comprised 3km of cut and cover works up to 25m depth, excavating under existing structures with low clearance such as the 16th Century Segovia Bridge and the local railway line C-5.

We collaborated closely with Madrid Town Council to ensure all programme interfaces were successfully achieved. To optimise the overall scheme programme and ensure safety and on-time opening of the scheme, we undertook additional scope by constructing all 16 cross passages facilitating the delivery of the South tunnel.

ADDED VALUE:

  • While maintaining the river flow, we constructed a temporary embankment within the river to alleviate traffic disruption, maintaining the M30 traffic (260,000 vehicles per day). This innovative solution ensured no additional land was required for construction
  • For the bored-tunnel, we optimised the client’s design to a three-tier tunnel, eliminating intermediate column supports to the road slab from the emergency gallery, maximising usable space and eliminating impact risks.
  • We developed the largest EPB TBM in the world at that time at 15.16m external diameter, which used two cutting wheels to improve performance for tunnelling in highly cohesive geotechnical conditions (similar to London Clay). Line and level were controlled by advancing first with the 7m shield and following with the larger 15.16m shield in 400mm increments
  • Our TBM design optimisations delivered a tunnel drive that achieved a peak rate of 500m/month, nearly twice the average of 300m/month
  • We developed a unique air intake/exit, with clean air intake via the emergency gallery and extraction through the ventilation gallery. Innovative particle filtering stations removed 90% of contaminants, a first for tunnel designs and delivering significant environmental benefits

AT A GLANCE

  • 15.16m diameter EPB TBM, the largest in the world at the time
  • 4.2km bored tunnel and 16 cross passages
  • 3km of cut and cover
  • 50,000+ points monitoring settlement with live data shared via intranet
  • 2.5 million litres/year of fuel consumption reduction due to smoother flowing traffic
  • 708 million hours of travel time to be saved over the next 30 years

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