alptransit gotthard and lötschberg – rowa’s contribution · introduction overall view...
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AlpTransit Gotthard and Lötschberg –
Rowa’s Contribution
Introduction
Overall View Lötschberg and Gotthard
Lötschberg Base Tunnel
Mitholz
Raron
Gotthard Base Tunnel
Amsteg
Sedrun
Bodio
Membrane-placing Machine
Brøyt
The Human Being is the Focus of
our Attention
Contents
We take your problems into account at a very early
stage. We studied the AlpTransit project during the
planning stage. This enabled us to submit our inno-
vative solutions to our customers in a very early stage
of the tender procedure.
Rowa’s staff is highly motivated. We know that our
success on the market depends on innovation, high
performance and on putting the customer’s inter-
ests first. Thanks to our expertise, our motivation
and our spirit of responsibility we have created
individual, fully developed and economically advan-
tageous solutions.
In practically all the headings for the Gotthard and
the Lötschberg base tunnels there are Rowa installa-
tions working. In addition to our well-tried existing
products we have realized some interesting new de-
velopments. Their range is impressive and comprises
individual single components as well as complete
logistics systems and back-up systems for tunnel
boring machines and for tunnelling by blasting.
We hope you will enjoy studying this brochure.
Jürg Leuthold
Chief Executive Officer
AlpTransit – Rowa takes part in it
The new Gotthard and Lötschberg railway routes
through the Alps are undoubtedly Switzerland’s
greatest construction projects of the 21st century.
Rowa, as a supplier of special installations for un-
derground construction, was especially challenged
by these projects. Rowa took up the challenge –
with success. This is what we would like to show
you in this brochure.
We are the experts. Rowa is one of the world’s
leading suppliers of back-up installations, special
equipment for rock support, membraning and lining,
logistics systems for supply and removal, as well as
providing consulting and engineering services. Our
installations have proven successful in over 150 im-
portant projects.
Mechanization is the future. We are convinced that
long tunnel headings – be they effected by tunnel
boring machine or by blasting – can only be realized
economically, quickly and safely with a high degree
of mechanization. By following this principle, we
were able to supply, for the Gotthard and for the
Lötschberg projects, several complete systems adap-
ted to the specific conditions of the projects.
Investments result in a net profit. We are conscious
of the need to realize an increased efficiency and
profitability in order to justify the investment. Thanks
to transparent and understandable productivity
calculations and by optimizing the investment and
operating costs, we have been able to convince our
customers of the net profitability of our installations.
The overall view is our strength. We don’t just sell
our products, but we see our Rowa installations
as components of a complex construction process.
Thanks to our know-how in the area of tunnel con-
struction and in the design and manufacturing of
equipment we are able to understand and solve
the interface problems between the construction
process and the installation.
Rowa in the Lötschberg
Two Brøyt Tunnel Excavators
Multi-functional Advance
Installations for three
Drill & Blast Headings
Logistics for three Headings
with 18 km Conveyor Belt
Frutigen
Ferden
Steg
Raron
Mitholz
Membrane-placing
Installation
Advance Installation for
5 km Drill & Blast Heading
Rowa in the Gotthard
Ventilation Installation
and Infrastructure Train
Access Tunnel Lot 552
Muck Tunnel Lot 551
Shotcrete Robot
Brøyt Tunnel Excavator
Four Membrane-placing
Installations
Three Rotary Tipplers
Four multi-functional
Advance Installations
Two TBM High Performance
Back-up Systems
Installation for the Excava-
tion of the Cross Passages
Bodio
Faido
Sedrun
Amsteg
Erstfeld
TBM Back-up System
High-efficiency Advance InstallationRowa supplied 3 high-efficiency advance installations,
which allow for top performances thanks to the high
degree of mechanization. The suspended platform
carries the necessary infrastructure equipment and
allows the tunnel invert to be clear for construction
The construction lot Mitholz plays a crucial role for the completion of the Lötschberg base
tunnel within the agreed time. Two tunnels are driven 8.7 km to the south and one tunnel
6.9 km to the north. The three simultaneous, high efficiency advances, carried out by blasting
come together at the low point Mitholz. Supply and removal for the three tunnels takes
place here. Rowa has developed, for Arge SATCO Mitholz (Strabag, Rothpletz Lienhard, Walo
Bertschinger, Dumez, Skanska International), a fully mechanized complete system with a
logistics concept that caused quite a sensation, in spite of being still widely unknown.
From the Rock Face to the Spoil
Tip at the Touch of a Button
Lötschberg Base Tunnel Mitholz
a short distance behind the face. In addition, there
is an area available for parking, for excavated material
and for other equipment. An area crane, operating
underneath the platform, makes it possible for all
materials to be transloaded and brought to the
respective workplaces without hindrance.
Only the continuous material flow from the rock face to the spoil tip made the desired performances possible. A conventional
transport system would have considerably restricted the capacities.
Conveyor InstallationsRowa developed the logistics system and supplied
the entire conveyor installations with a total belt
length of over 18 km for the removal of the excava-
ted muck from the rock face to the spoil tip at the
low point Mitholz.
The removal of the excavated material for both
parallel headings is by a continuous conveyor. A
reversible conveyor transports the material through
the cross passages to the main conveyor. The trans-
verse conveyors can be relocated without the
operations being interrupted.
Initial DoubtsA logistics system with such a high degree of mecha-
nization as put forward by Rowa had never been
realized before.
Therefore, the people on the construction site initi-
ally had serious doubts about its feasibility. But,
after some minor technical adjustments during the
start-up period, the advance performances which
could be achieved thanks to the Rowa system, filled
the site management as well as the works personnel
with enthusiasm.
Return on InvestmentA mechanized advance means high investment.
Thanks to detailed productivity calculations, Rowa
was able to demonstrate to the customer that
the investment for a Rowa system would be more
than compensated by the corresponding return
from high performances and optimized operating
costs.
Lötschberg Base Tunnel
Dipl. Ing. Oskar Roittner, Strabag AG“The complete system de-
signed by Rowa represents
a genuine innovation for
the conventional advance
by blasting. The perfor-
mances which have been
achieved with this system
confirm that the decision to
entrust Rowa with its sup-
ply was correct, technically
as well as economically.”
Rear of the advance installation with airduct storage for
fresh air and and evacuation of the explosive gases in the
starting phase.
Conveyor belts with a length of over 18 km transport
the excavated material to the spoil tip from three
advances by blasting.
“Rowa-Highlights”
• Continuous material transport
• Reduction of traffic on the construction
site to a minimum
• Uninterrupted supply to the
construction site
High-performance Heading InstallationRowa refined the installations of the Mitholz lot
for the Raron construction site. The heading instal-
lation allowed to a large extent to complete the
invert construction about 200 m behind the rock
face. Extensive support measures can be carried out
during the advance operation, without any adverse
effects on the performance.
TrainingThe higher the degree of mechanization and syste-
matization of the advance operation, the higher
the demands on the personnel regarding control,
maintenance and observance of the work cycles.
Rowa trains the customer’s personnel and thus con-
tributes to safe operation, to accident prevention
and to the best possible performance.
Dipl. Ing. FH François Bertholet, Project Manager Arge MaTrans
“The use of the suspension
platform has proven to be
successful. Thanks to the
continuous material flow
and to the availability of
two working levels top
performances could be
achieved. At the same time,
the suspension platform
guarantees the maximum
workplace safety.”
Rowa experts help staff and workers to get acquainted
with the installation.
The separation of fixed installations from the transport
and excavation equipment increases considerably safety,
quality of the workplace and performance.
Starting from the portals Raron and Steg, two tunnel boring machines have excavated the
Lötschberg base tunnel to the Ferden section. For economic reasons, the 4.6 km long
western tube starting from the portal Raron was excavated by blasting. Rowa refined the
existing concept for the Mitholz installations and supplied to the Arge MaTrans (Marti,
Balfour Beatty, Porr, Züblin, Walter Bau) a high-performance advance installation which
comes up to the highest expectations.
Maximum Performance, Workplace
Safety and less Personnel
Lötschberg Base Tunnel Raron
High-performance Back-up InstallationIn close cooperation with Arge AGN, Rowa developed
the back-up system for the tunnel boring machine.
A suspended monorail railway makes it possible for
the material to be transported without transloading
from the supply train to its destination. Thanks to the
suspended platform and a double-track rail service
up to the invert construction area, the invert can be
built at the same speed as the advance progresses.
A longitudinally movable shotcrete robot with a 360º
working area applies shotcrete support to the exca-
vated section.
Starting from the intermediate point Amsteg, two tunnel boring machines are excavating
about 11 km of the two tubes of the Gotthard base tunnel to the south, to the meeting
point with the advance of the Sedrun section. Rowa supplied to Arge AGN (Strabag AG,
Murer AG) two high-performance TBM back-up systems, as well as an installation for
the excavation of the cross passages, which contribute to the highest possible advance
performances while optimizing the operating costs.
Gotthard Base Tunnel Amsteg
Highest possible availability – the key success factor in mechanized tunnel construction. Rowa back-up systems guarantee functionality,
quality and safety.
“Rowa-Highlights”
• Continuous material flow for supply
and removal
• Reduction of interdependencies to
a minimum
• Separation of the working areas and
processes
• High flexibility
Highest Performance and
optimized Costs – thanks to a well
thought-out Complete System
Gotthard Base Tunnel
Dipl. Ing. Hans A. Treichl, Strabag AG“AGN and Rowa have to-
gether developed a highly
mechanized complete
system, which has been
perfectly adapted to the
construction processes.
Rowa has proven to be a
highly competent and
efficient partner for the
solution of all logistics
problems. Also the assembly and the start-up were
carried out expertly and within the given time limits.”
Thanks to a well thought-out pre-assembly, taking into
account the cramped space conditions, the back-up
systems could be assembled in record time.
The idea of the monorail comes from the mining industry.
Rowa has successfully adapted the system for tunnel
construction.
Direct Placing of the OrderWhilst the tunnel boring machine and the back-
up system are usually supplied together by the
manufacturer of the tunnel boring machine, Arge
AGN Murer/Strabag preferred to place the order
for the back-up system directly with Rowa. This
has proven to function perfectly. The interface
problems could be managed without any diffi-
culties, and the contractor had an experienced
logistics partner available.
Suspended PlatformThe tunnel invert is being constructed simultaneously
with the advance. A suspended platform bridges the
invert construction area. Thanks to the working area
being clear the operations can take place in a flexible
and efficient way, independent from the advance.
The length of the suspended platform has been
optimized, working together with the customer,
for the planned performances and work processes.
Independent MonorailThe monorail is suspended from the tunnel crown
and is independent from the rest of the back-up
system. This allows for rock support material, shot-
crete etc. to be transported without transloading
from the supply train to the workplace.
Cross Passage InstallationFor the excavation of the cross passages, Rowa has
developed a complete installation which makes it
possible for cross passages to be excavated simulta-
neously with the main tunnel advance. With this
installation, the cross passage excavation can be
carried out efficiently, while protecting the installa-
tions of the main advance. The complete equipment
can be moved on the rails of the back-up platform and
thus transported from one cross passage to the next.
AssemblyIn order to keep the launching chamber as short as
possible, the tunnel boring machine started working
with a rudimentary back-up system. After an advance
of 500 m, the tunnel boring machine was stopped
and the back-up installation was completed. Thanks
to the meticulous preparation of the assembly and
good logistics planning, the tunnel boring machine
could resume its operations after a very short time.
Multi-functional Heading InstallationThe installation consists of the special machine for
rock support with working baskets, displacing arms,
shotcrete robot etc., the loading installation for the
loading of the muck trains, a 20 t heavy-duty crane
for the supply to the workplaces, a suspended plat-
form with installations for ventilation, cooling etc.
and a supply train with infrastructure equipment.
An uncompromising mechanization, also in a conventional heading, increases performance, productivity and safety.
“Rowa-Highlights”
• Uncompromising mechanization of the
excavation support
• Performance and safety thanks to two
working levels
• Efficient supply with heavy-duty crane
• Creation of a second working level
At the intermediate Sedrun location of the Gotthard base tunnel two tubes are being driven
through difficult geological zones, 1.5 km to the north and about 3.5 km to the south.
The excavation takes place using heading anchors and radial anchors, with massive steel
reinforcement and shotcrete. Deformations of the diameter of up to 1.5 m have to be expected.
Supply and removal run through an access tunnel and two vertical shafts of 800 m depth.
Rowa has developed, for Arge Transco-Sedrun (Batigroup, Frutiger, Bilfinger und Berger,
Pizzarotti), a complete system for the four highly mechanized special advances and supplied,
in addition, three rotary tipplers for the transloading of the excavated material at the portal.
Know-how, Innovation and
Closeness to the Customer help to
find the best possible Solution
Gotthard Base Tunnel Sedrun
Special Machine for Rock SupportWith the special machine for rock support the ring
beams are placed by bundle and by segment. The
installed shotcrete applicator seals the profile. With
two cutting scissors the previously placed heading
anchors can be removed efficiently and safely after
every blast. Thanks to the suspended construction
and the special machine for rock support the tunnel
constructor has a second working level at his dispo-
sal, as well as a clear working, manoeuvring and
parking space on the invert.
Infrastructure and Supply TrainsThe infrastructure and supply trains, which have
been designed in close cooperation with the con-
tractor, are an important link in the chain of the
mechanized advance operation. Infrastructure and
material supply are at the correct location at the
correct time, in correct quantities.
Rotary Tippler Rowa Rotary IIIRowa designed three rotary tipplers for the discharge
of the muck trains. The rotary tippler takes up two
cars with 24 m3 excavated material. The cars are
centred and held automatically. The entire tippling
process is controlled by the locomotive driver.
During the tippling operation, the driver doesn’t
have to leave the driver’s platform.
Development – not InventionLong tunnels can only be built efficiently with
mechanized processes.
Together with our customers, we analyse con-
struction procedures and construction technology.
We don’t invent new things, but we look for
known technologies and use them in tunnel
construction.
The concept of the special machine for rock sup-
port is being used in mining and was re-designed
by Rowa in cooperation with experienced mi-
ning engineers of the GTA company, in order to
be suitable for the Sedrun advance.
Dipl. Ing. ETH Luzi Gruber, Batigroup AG“The Sedrun project is
extraordinarily challenging
for the tunnel constructor
as well as for the manufac-
turer of the installations.
That’s why we backed Rowa
right from the beginning
and developed together
an installation which is
made-to-measure for our
construction contract. This installation will allow us to
achieve the required performances, even under the most
difficult conditions, while guaranteeing the maximum
possible workplace safety. Rowa has taken our require-
ments into account in a very professional way.”
With the rotary tippler, Rowa Rotary III, the locomotive
driver discharges a train with 150 tons of excavated
muck in less than 10 minutes.
The multi-functional advance installation during assembly.
Gotthard Base Tunnel
Back-up System for the Muck TunnelRowa supplied the back-up system for the tunnel
boring machine in the muck tunnel with a diameter
of 5 m. The preconditions were a daily advance of
25–35 m, the placing of ring beams, mesh reinforce-
ment and anchors, as well as applying shotcrete.
Rowa can also be considered a competitive supplier
in the area of these well-tried installations.
Shotcrete RobotRowa supplied to SikaBau AG two longitudinally and
radially displaceable shotcrete robots for the back-
up system of the main advance. The robots with
their longitudinal pathway of 9 m and their ability
to cover 270º are used for the area L2.
Rowa designed a device consisting of two swivel-
ling motors and two lifting cylinders which allows
the operator of the nozzle to cover the whole area
in a perfect way.
Ventilation Installation andInfrastructure Train Equipment developed by Rowa is also being used in
the area of supply and removal. Rowa supplied the
ventilation installation for the access tunnel (lot 552)
as well as an infrastructure train which is perfectly
adapted to the specific construction procedures.
Thanks to our know-how in construction technology
and procedures we are in a position to optimize the
logistics system.
Shotcrete robot for the back-up system of the Herrenknecht
tunnel boring machine.
Back-up system for a hard rock tunnel boring machine of
small diameter.
Starting from Bodio and up to the intermediate point Faido, the Gotthard base tunnel is
being excavated with two tunnel boring machines. They were transported into the mountain
through a bypass tunnel and assembled in caverns. The excavated material is transported
from the portal to the spoil tip through a muck tunnel. Rowa supplied to Arge LGV, (Pagani,
Infra 2000), a tunnel boring machine back-up system for the lot 551 Bodio muck tunnel.
For the access tunnel (lot 552) Rowa supplied to Arge Batigroup, Frutiger the ventilation
installation and an infrastructure train. In the main advance of the lot Bodio/Faido the
shotcrete robots developed by Rowa are in operation.
The Rowa infrastructure trains are
adapted to construction procedures,
project and customer requirements.
Rowa Products: competitive,
safe and of the highest Quality
Gotthard Base Tunnel Bodio
Consistent further Development
and Cooperation to the Advantage
of the Customer
The highest possible degree of mechanization increases
performance, productivity, quality and safety in the area
of membraning technology, too.
Rowa – membrane-placing machine V
In the project of the century – AlpTransit – safety and quality are essential. This is especially
the case with regard to membrane lining in the tunnels. Hightech installations, the highest
possible degree of mechanization and the uncompromising quality assurance process
guarantee the requested quality as well as the highest performance. The Rowa membrane-
placing installations of the 5th generation were developed upon request of Arge IGS
(SikaBau AG, Tecton AG) and are being used in the lot Bodio/Faido of the Gotthard base
tunnel. Another membrane-placing installation was supplied by Rowa to the membraning
joint venture Züblin, Schmutz for the Steg/Raron lot of the Lötschberg base tunnel.
Dipl. Ing. ETH, lic. iur. Pius Weber,SikaBau AG“In 1972 Rowa designed
for the first time, upon
request by SikaBau AG, a
device for the placing of
tunnel membranes. Its ob-
jectives were to substitute
human labour by machinery
and to increase the safety
of the workers. Since then,
the Rowa equipment was continuously refined and has
been used widely throughout Europe, Latin America and
Asia. Especially for the AlpTransit project Gotthard-Ticino
and according to our preconditions Rowa developed
membrane-placing machines of the newest generation.
They are equipped with an electronically controlled
hydraulic contact beam and a synchronous control of
operator’s basket and contact beam. All the participating
parties, owner/construction management, the contractors‘
joint venture TAT and the membraning joint venture IGS
acknowledge the outstanding system and the quality of
the Rowa-equipment.”
Membrane-placing Maschine
Membrane-placing Machine VThe membrane-placing machine developed in co-
operation with membrane specialists is designed
for maximum performances and corresponds at the
same time to the quality criteria. The installation
is the result of the experiences of Rowa and of
the cooperating membrane specialists from various
tunnel projects.
The Result of the Experiences of many YearsRowa has been manufacturing membrane-placing
machines for the most varying tunnels and membra-
ning systems. The equipment has been continuously
refined in intensive cooperation with the customers
and adapted to the newest developments in mem-
brane lining technology and in the technology of
plant manufacturing.
Lötschberg and Gotthard Base Tunnel
The Tunnel Excavator as Part
of the entire System
Brøyt Tunnel ExcavatorThe Brøyt is acknowledged to be one of the most
robust and capable muck-handling equipment for
tunnel construction.
Especially in the cramped space conditions of the
AlpTransit tunnels, the manoeuvrability of the Brøyt
stands out.
Rowa provides EvidenceRowa provided first-hand evidence for the capability
of the Brøyt tunnel excavator to a gathering of tun-
nel construction experts in the Bodio bypass tunnel.
300 m3/h, no problem for the Brøyt even in tunnels with
small cross section.
The AlpTransit tunnels consist of two separate tubes. The resulting excavated cross sections
of 60 – 70 m2 set space limits for the equipment to be used. The use of a compact, manoeuv-
rable muck-handling equipment which is still capable of top performances can determine
the advance performance. Rowa evaluated the optimum muck-handling equipment for
various construction lots, came up with the Brøyt tunnel excavator as the best solution and
proved it by the subsequent experiences. A Brøyt ED600 operated successfully in the lot 552
of the Gotthard base tunnel (Access tunnel Bodio, Arge Batigroup, Frutiger). Rowa supplied
two additional excavators to Arge Ferden (Losinger, Prader, Bouygues and group LEDIT) of
the Lötschberg base tunnel.
Brøyt and Muck-handling by Conveyor?Rowa developed an economic solution for the
feeding of crushing machine and belt conveyor, so
as to be able to also use the Brøyt in headings with
muck-handling by conveyor.
BrøytLötschberg and Gotthard Base Tunnel
The Human Being is the Centre of our
Attention: qualified and highly motivated
Heinz Jenni,Overall Project Manager Sedrun“It is a unique challenge to have the opportunity
to contribute to the construction project of the cen-
tury. With the Sedrun heading installation, which we
developed in cooperation
with Arge Transco, we can
make an important contri-
bution to overcoming the
problems of one of the
geologically most difficult
sections of the project.”
Jost Wenk, Overall Project Manager Amsteg“We are not inventors ...
Long tunnels can only be built efficiently with
mechanized procedures. Together with our customers
we analyze constructional
technology and construction
procedures. We don’t invent
new devices, but we use
well-tried technologies and
adapt them to the specific
conditions of tunnel
construction.”
Hansruedi Bart,Project Manager Assembly“The customer expects a high degree of availability
of the equipment right from the start. Usually, the
assembly has to take place in a cramped space and
under difficult logistical
conditions. Therefore, de-
tailed assembly and logistical
planning is essential, as
well as a close cooperation
with the customer and third
parties and a continuous
controlling of quality and
deadlines.”
Urs Thali, Project Manager Design“Membrane lining know-how, tunnel construction
logistics and plant manufacturing technology have
to come together in the design of membrane-placing
machines. Thanks to the
intensive cooperation with
the customer we were able
to develop an installation
which meets all the require-
ments regarding quality,
performance, safety and
profitability.”
Mariano Targa, Structural Engineer“Suspended platforms have to be distortion-free and
must resist the highest stresses in tunnel construction.
Thanks to their flexibility the loads can be distributed
in an optimum way, and
therefore economic solu-
tions are possible in spite
of extremely high loads.”
Rinaldo Geronimi, Project Manager Design“In all our designs, the aspect of user-friendliness is
essential. Equipment used in tunnels has to be simple,
sturdy and safe. Good accessability and simple hand-
ling are equally important.
In the case of complex
installations, every design
detail has to be studied and
approved by the customer,
not only the overall
concept of the installation.”
Lötschberg and Gotthard Base Tunnel
Rowa Tunnelling Logistics AG, Leuholz 15, CH-8855 Wangen SZ
Phone +41 (0)55 450 20 30, Fax +41 (0)55 450 20 35
[email protected], www.rowa-ag.ch
We look ahead ...
Pro
f. D
r. In
g. h
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ob
ert
Fech
tig
and go ahead ...