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The São Paulo Metro is expanding its network in the São Paulo Metropolitan Area inhabited by 21 million people. Metro Line 6 connects the north of the city to the existing metro network further South. The construction of Line 6 currently represents the largest infrastructure project in Latin America, combining the excavation of tunnel boring machine (TBM) and conventional tunnels, cut‐and‐cover stations and a number of deep emergency exit shafts. This paper presents the main features of the TBM tunnel excavated in the South stretch through the Tertiary soils of the São Paulo Basin and through the challenging Embu Complex, which consists of a mixture of fractured rock, saprolite and residual soils. The alignment runs under the dense urban grid of São Paulo under high‐rise buildings and other infrastructure, such as existing Metro lines. [ABSTRACT FROM AUTHOR] more...