And that’s the FACS

Congratulations to the crews at the Polo Flat Segment Factory, with the last inclined pressure shaft (IPS) segment now cast.

This completes 7101 Force Activated Coupling System (FACS) segments, while also contributing to over 100,000 precast segments for Snowy 2.0.

Site Engineer Bahador Dastorian said he was proud to be part of this global benchmark for hydropower innovation.

FACS uses specially designed pin-socket steel couplers with disc springs, allowing the precast segments to interlock and withstand some of the highest hydraulic pressures ever encountered in tunnel construction. This system strengthens the tunnel lining and eliminates the need for a secondary lining, setting a new benchmark for safety and efficiency in hydropower infrastructure.

“These segments illustrate what’s possible when a diverse, skilled, and dedicated team works together with vision and determination,” Bahador said.

“Breaking world records isn’t just about the numbers—it’s about safely pushing the boundaries of what’s possible. With FACS, we achieved a record 30 segments cast in a 12-hour shift.

“This is more than a milestone; it’s a revolution in hydropower construction and a testament to what’s possible when advanced engineering meets dedicated teamwork,” he said.

Luke Holmes, Leading Hand at the precast factory, said originally crews could produce only five segments per shift.

“At the start, we had a huge challenge with no automation and no established systems,” Luke said.

“Through continuous troubleshooting, collaboration, refining our workflows, and the work ethic of the Polo Flat crew, we were able to exceed expectations while upholding safety as our number one priority,” he said.

Well done to everyone who helped deliver the world’s first FACS-equipped IPS segments. It is an achievement that will inspire future projects worldwide.