Tunnel Specialist

Greyton has had significant involvement in the latest major Sydney tunnels including

  • Epping Chatswood Rail Link - Haden/AW Edwards
  • Lane Cove Tunnel - Thiess John Holland
  • Eastern Distributor
  • Airport Rail Tunnel
  • M5
  • Cross City Tunnel
  • Penrith Bus Tunnel
  • Energy Australia SurryHills/Haymarket 132kV Cable Tunnel Project.

Only the highest standard of workmanship and technology can be utilised in tunnel construction because of the seriousness of potential fire sources and type of combustion. This was seen in the British channel tunnel fire.

Most of the systems that we have installed have been tested in Australia and abroad to withstand the heat generated by a Hydrocarbon fire that is caused by car and truck fuel and their cargo.

Our work has included:

  • structural steelFendolite and Mandolite sprays,
  • mechanical ventilation and exhaust fan enclosures and duct protection using Promatect H, Fendolite and Mandolite Sprays,
  • fire stopping of services penetrations in the tunnels and their many plant rooms,
  • Separating east/west lanes with wall barriers using Durasteel and Promatest S steel-faced boards,
  • Construction joint covers using Promatect S steel faced-boards,
  • Lining escalators in calcium silicate board in the Sydney Airport Link Rail tunnels.

structural steelFendolite

fire stopping of services penetrations


Cross City Tunnel

Greyton sealed over 600 wall and floor penetrations for Downer Engineering and BHBB. Most of the penetrations had to achieve a 4 hour rating such as the two photos showing cables passing through block walls. The product is a fire rated mortar called GFS1000.

floor penetrations wall penetrations

Promatect fire rated demountable partitions with 4 hour fire doors and frames. Designed to be dismantled to move large plant and machinery through. The fire rating on the wall is 4 hour -/240/240 and has an acoustic rating of 51 STC. The system is very durable and will withstand very high pressure and damp conditions which is displayed on the photo.


Promatect fire doors and frames rated demountable partition There were a number of fire rated access panels supplied and installed by Greyton. The panel is constructed with a Promatect L500 board, lined with a galvanised steel cover on either side.

Promatect S' four-hour fire rated wall 'Promatect S' four-hour fire rated wall separating east/eest lanes in Sydney M5 Tunnel


fire rated roller shutter separating Temporary four hour fire rated wall with a four hour fire rated roller shutter separating the new tunnel construction from the existing Eastern Distributor Tunnel. This partition has been constructed in Promatect H.



Energy Australia Cable Tunnel Ventilation Chamber

Fendolite barrier system Fendolite barrier system around intake fans providing a fire and acoustic barrier.

Finished Promatect H wall system Finished Promatect H wall system around two of the fan outlets. These fans are approximately 4mx4m each.


cable penetrations Same view point with a finished wall with multiple cable penetrations. The fire doors are 2800mm x 2000mm.

Cable tunnel Cable tunnel before any of the 12 partitions and doors were installed. On the right are the fans in the plant room which was separated from the rest of the tunnel by a Promatect H wall system.


Promatect wall with standard fire door Finished main wall plus small Promatect wall with standard fire door. This smaller wall is demountable to allow removal of the large fan.

Installing the rockwool in the walls Installing the rockwool in the walls. This core provides the basis for the sound and heat insulation.


Promatect wall built Promatect wall built around one of the fans and sealed to the shotcrete.