FORMING YOUR PROGRESS

As part of the expansion of the Kühtai power plant, a new pumped storage power plant is being built with a 25.5-kilometer-long supply tunnel, a central structure for supplying the Kühtai reservoir with water from the surrounding valleys in the future. The mechanical tunnelling is taking place under challenging conditions: at an altitude of over 2,000 meters, with up to 40 meters of advance per day, high demands on logistics and supply and the goal of going into operation as early as 2026.

A fully automated production line was delivered with 26 hydraulically opening and closing invert moulds, a carousel system, a robot with associated tools for automatic cleaning of the moulds and installation of built-in parts, as well as comprehensive safety technology, concrete logistics, and the SDS Data Management System for digital production control.

Over a period of almost four years, the automation components ran smoothly and enabled the production of around 21,000 concrete segments. The production rate was up to 30 segments per shift, which corresponds to around 800 segments per month. Curing took place within eight hours and the warehouse could hold up to 2,500 invert segments.
The increase in efficiency achieved through the use of automation was particularly remarkable: staffing requirements were greatly reduced – instead of six to seven people, only four employees were needed. Cleaning of the mould was largely automated. The production plant, including the cleaning robots, was serviced once a month and cleaned weekly. The hydraulic mould also proved to be easy to maintain, with low wear and tear and minimal susceptibility to damage.

„We consider the high level of occupational safety to be one of the greatest advantages. There was not a single accident during the entire production period for the invert segments – a clear sign of the safety and reliability of the technology used.“

Günter Auer, Head of Segment Production at ARGE SKW Kühtai

The quality of production was also reflected in the low reject rate: only 14 segments had to be reworked or discarded. Findings from the project, such as those relating to sensor technology and cleaning, were directly incorporated into the optimization of subsequent projects.
After the successful completion of the sole segment production, the plant was dismantled within two and a half weeks and is now awaiting its next assignment.

Conclusion:
The Kühtai project impressively demonstrates how modern automation technology from Herrenknecht Formwork works reliably, safely, and efficiently even under extreme conditions. The combination of hydraulic formwork, robotics, and intelligent control enabled economical and high-quality production over several years: real proof of the performance of these still young automation solutions.