At the ITS World Summit 2026, Graham Wilson shared insights from the Heysen Tunnel Upgrade, highlighting the extensive technology and control system modernisation undertaken on one of South Australia's most significant transport infrastructure renewal projects.
Located on Adelaide's South Eastern Freeway, the Heysen Tunnel carries more than 50,000 vehicles every day and forms a critical connection between Adelaide, regional South Australia and interstate freight routes. Opened in 2000, the tunnel required a comprehensive modernisation program to enhance safety, reliability and operational performance while remaining an operational asset.
The project involved the refurbishment and upgrade of a broad range of tunnel systems, including lighting, ventilation, fire suppression, emergency communications and Intelligent Transport Systems (ITS). Working alongside the Department for Infrastructure and Transport, managing contractor McConnell Dowell and designer GHD, the project team delivered a modern tunnel management environment designed to meet contemporary operational and safety standards.
Pictured above: Graham Wilson presenting on the technologies and engineering considerations
involved in modern tunnel operations.
One of the most innovative aspects of the project was the implementation of Australia's first DALI lighting system integrated with a Siemens PLC platform in a road tunnel environment. More than 3000 luminaires were incorporated into a fully monitored and controlled DALI lighting network.
The new system provides precise lighting control, individual device monitoring and automated fault reporting through the tunnel's SCADA system. Advanced luminance monitoring also allows operators to measure lighting effectiveness as tunnel conditions change over time, helping maintain visibility standards while supporting efficient maintenance planning.
The deployment demonstrated how modern digital lighting technologies can improve both operational performance and long-term asset management in critical infrastructure environments.
The project also introduced South Australia's first tunnel misting system. Unlike traditional deluge systems that require large water storage facilities, the misting solution delivers effective fire suppression while reducing infrastructure requirements.
Integrated with the tunnel's ventilation system, the misting network automatically responds to incidents by coordinating with jet fans and fire management systems. This provides operators with enhanced situational awareness and greater flexibility when managing emergency events.
Perhaps the greatest challenge was not the technology itself, but how to install and commission an entirely new control system without disrupting daily operations.
As a critical transport corridor, work was largely restricted to night-time closures. Each shift required meticulous planning to ensure systems could safely return to service before morning traffic resumed. The team effectively built a new tunnel control system within the existing tunnel control system, progressively migrating equipment, communications networks and SCADA platforms while maintaining operational continuity.
This staged approach enabled the installation of new PLCs, fibre networks, CCTV systems, traffic management equipment and operational technologies while minimising risk to tunnel users and operators.
Pictured above: Graham Wilson presenting on the technologies and engineering considerations
involved in modern tunnel operations.
Technology was only part of the story.
The project team worked closely with Traffic Management Centre operators from the earliest stages of development, using training needs analysis workshops and simulation environments to ensure the new systems aligned with operational requirements.
Operator feedback directly influenced system design, including the introduction of light and dark SCADA display modes and scenario-based training using digital twin simulation technology. By engaging end users throughout development, testing and commissioning, the team improved confidence in the new systems and supported a smoother transition during handover.
The completed upgrade delivered substantial improvements across the tunnel network, including:
85 thermal incident detection cameras
18 PTZ cameras
New lane use management signs and variable message signs
Upgraded tunnel ventilation systems
Modern emergency communication systems
Enhanced fire suppression capabilities
New field cabinets, fibre communications and monitoring systems
Upgraded SCADA and plant monitoring systems.
The project also included full offsite testing, emergency simulation exercises and extensive operator training to validate system performance before commissioning.
Reflecting on the project, Graham Wilson highlighted several lessons applicable across transport and critical infrastructure projects. Brownfield environments require significantly more planning than new builds, stakeholder engagement must begin early, and reliability and maintainability should remain central design drivers throughout the project lifecycle.
The Heysen Tunnel Upgrade demonstrates how careful planning, close collaboration and the adoption of modern operational technologies can successfully transform critical infrastructure while maintaining continuous service for the communities that depend on it every day.
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