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Milestones in Segment Production

Outstanding performances in Sochi and Doha with customized project solutions.

10 years ago, segment production for the combined railroad line and express highway Adler – Krasnaja Poljana started in its full extent. With an overall site surface of 20.000m², the huge plant, including three carousel systems for segment production and two carousels for prefabrication of reinforcement cages, delivered as many as 350 segments per day to the outside storage area. Related to the 2014 Winter Olympics, the project faced a huge challenge: simultaneous segment production for up to six mechanized tunnelling jobsites. The plant was finally repurposed to be used by public utilities.

We proudly look back to this successful project which marked a milestone in the HERRENKNECHT FORMWORK history: For the first-time, our team designed and delivered a turnkey segment factory including three concrete mixing plants with bucket conveyors, gantry cranes as well as customized equipment for handling, transport and turning of the segments.


In the meantime, the team of Herrenknecht Formwork perfected their competence in designing and supplying turnkey segment production plants. When ordering a turnkey segment production line from Herrenknecht Formwork, customers efficiently reduce interfaces throughout all project phases of the segment production. From the first feasibility study through design and commissioning to production support, the customer has only one contact person.

Another flagship project with completely different but not minor challenges was the DOHA METRO project. With a total number of 474 precision moulds supplied for Green Line, Gold Line and Red Line North, it counts among the largest projects ever realized by HERRENKNECHT FORMWORK.

Between 2014 and 2016, our project partners produced 350,000 tunnel lining segments in total with an inner diameter of 6,170mm, processing approx. 1.25 million tons of concrete. This segment production marathon went hand in hand with a record-breaking tunnelling performance of 20 TBMs working simultaneously at peak times, thus even gaining a place in the Guinness Book of Records.


Projects with such a large number of precision moulds to be supplied on time require reliable and flexible production capacities as well as experienced logistic experts. With a total production area of 8,000m² and a production capacity for steelwork of 2,000 tons per year, Herrenknecht Formwork is able to assemble more than 1,000 moulds per year. In order to get the equipment quickly to its place of operation, our transport managers offer professional packing and preparation for transport and cooperate with reliable logistic companies. Supported by our regional subsidiaries, smooth customs clearance is self-evident.