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Transcity Legacy Way — Brisbane's $1.5B Tunnel Project
The Legacy Way tunnel is one of Brisbane's most significant road infrastructure projects — a 4.6km twin-tunnel motorway linking Toowong and Kelvin Grove. Delivered by the Transcity consortium including Acciona, Ghella, BMD, and Wagners, the project required the manufacture, storage, transport, and installation of over 44,000 individual concrete tunnel segments.
Barcode QLD was engaged to design and build the Segment Tracking System — a purpose-built web application and mobile scanning platform that followed every segment from the Wacol precast facility through multiple holding sites and into the Tunnel Boring Machine.
The system connected manufacturing QC data, transport logistics, site storage, and final ring installation into a single, real-time management platform — giving the Transcity team complete visibility and a permanent audit record of every segment on the project.
Six Stages. One Seamless System.
Every segment was scanned at each transition point — from the first reinforcing cage to the moment it was locked into a tunnel ring.
Manufacturing & QC
Reinforcing cage data, mould assignments, and concrete batch codes all connected to a unique segment ID barcode at the point of production. Quality control sheets travel with each piece.
Holding Site Check-In
Forklift operators scan segments into location codes at the production facility holding yard. Incident alerts log any damage or label replacements immediately.
Transport & Dispatch
Segments scanned onto trucks with transport rego recorded. Manifests generated automatically. Truck sign-in and sign-out timestamps calculate demurrage time for billing.
Receiving & Storage
At alternate holding sites or tunnel yards, segments scanned off trucks and into precise storage locations. Full chain of custody from Wacol to tunnel mouth.
Tunnel Installation
At the Tunnel Boring Machine, each ring group of 9 segments is verified by barcode scan before installation. Ring ID linked to all 9 segment IDs — zero duplicate risk.
Reporting & Audit
Management can query any segment by ID, batch, ring, transport, or location. Full historical dataset maintained for the life of the project and beyond.
Built to Handle 44,000 Segments
The scale of the Legacy Way project demanded a system that could handle high-volume data input under site conditions — multiple concurrent users, variable network connectivity, and zero tolerance for data errors when segments were being installed at the TBM.
What the Platform Delivered
Why a Purpose-Built System?
Quality Controlled
Every segment traceable from steel cage to installed ring — full manufacturing and QC data retained permanently.
Complete Audit Trail
Zero gaps in the chain of custody. Every movement, incident, and handover timestamped and stored.
Transport Efficiency
Demurrage calculated automatically. Transport operators held accountable. Manifests generated on the spot.
Live Site Visibility
Management dashboards show stock levels at every holding site and progress of tunnel installation in real time.
Transcity Consortium