Veteran TBM rebuild for major flood mitigation project - Robbins marked a major project milestone in October 2025 with the substantial completion of the factory acceptance test (FAT) for a refurbished Main Beam TBM at its Solon, Ohio manufacturing facility. The veteran machine, rebuilt in partnership with contractor Kiewit, is set to excavate the 1.5 km (0.9 mi) long Ellicott City North Tunnel, a critical flood mitigation project in Howard County, Maryland, USA.
The 5.6 m (18.4 ft) diameter TBM, originally manufactured by Robbins in 1991, has a distinguished global track record. The machine has successfully excavated multiple tunnels totalling more than 18 km (11 mi) and is now entering its next chapter as part of Maryland’s largest stormwater infrastructure project to date.
“Robbins and Kiewit share a long-standing partnership focused on quality TBM rebuilds and performance,” said Doug Harding, Robbins Vice President. “We are marking not only the acceptance of the machine, but also a continued commitment to delivering durable tunnelling solutions that meet the evolving demands of major infrastructure projects.”
The Ellicott City North Tunnel is a centrepiece of Howard County’s Ellicott City Safe and Sound plan. Designed to divert stormwater runoff away from the historic downtown area—an area hit by multiple catastrophic floods in recent years—the tunnel will convey up to 26,000 gallons (98,000 litres) of water per second during major storm events. The TBM will bore through a mix of granitic rock beneath Ellicott City, minimizing surface disruption in the densely built, heritage-rich area.
“Excellent Engineers, Craft and Managers of Robbins and Kiewit have worked together at Robbins’ plant in Solon on a daily basis over the last year to achieve this milestone of substantial completion of the FAT. Synergy efforts were required and well delivered to get the TBM to increased technical and safety standards,” said Christof Metzger, Area Manager for Kiewit.
The TBM is expected to begin tunnelling in early 2026 following TBM assembly and launch shaft construction in Maryland. Its performance will be supported by Robbins’ field service team to ensure smooth operations throughout the project’s duration. For further information please visit the robins company website https://www.robbinstbm.com/ 03/26.
