DIFFERENT
ROBOT APPLICATIONS
The Gotthard Road Tunnel is one of the most important north-south connections in Europe. To improve safety and ensure smooth traffic flow, a second tunnel tube is being built beneath the St. Gotthard Pass. Herrenknecht Formwork supplied highly automated carousel systems for segment production on both the north (Göschenen) and south side (Airolo) of the project.
While the site conditions on each side were vastly different, both projects had one key goal in common: maximum automation, tailored to the available space, workforce, and environmental constraints. The result: two custom-engineered segment production facilities – one inside a former military cavern, the other at over 1,100 meters above sea level – both equipped with state-of-the-art automation technology.
Maximum performance with minimum manpower: Despite the very different starting points, both sites share the same outcome: segment production at the highest level of automation – with a minimum number of workers, consistent quality, and a reliable, streamlined workflow. A landmark project for tunnel lining production in the heart of the Alps.
Scope of supply South:
- Carousel system with 5 sets of hydraulically operated moulds
- Concrete transport (flying bucket)
- Concreting station with automated casting and vibration system
- Heating system (electric) with vaporing
- Evacuation line and handling equipment
- Data management system (SDS)
- Robot for cleaning & oiling, installation of embedded parts and rebar cages as well as surface finishing
- Automatic mould cover system with cleaning
- Automated vibration connection system
- AI-supported surface check
Scope of supply North:
- Carousel system with 5 sets of hydraulically operated moulds
- Concrete transport (flying bucket)
- Concreting station
- Heating system (electric) with vaporing
- Demoulding portal
- Curing and transport line
- Handling equipment
- Data management system (SDS)
- Robot for cleaning & oiling as well as surface finishing
- Automated mould cover system
Engineering milestones under extreme conditions
GÖSCHENEN - NORTH SIDE
Building a segment production plant in a former military cavern was unprecedented. Space constraints, limited access, and the absence of cranes posed significant design and installation challenges. Herrenknecht Formwork developed a semi-automated carousel system tailored to the unique geometry of the underground caverns. Despite the demanding environment, a dedicated rebar production line, a new cross passage, and a complex transport and curing concept ensure smooth production flows and safe working conditions.
AIROLO - SOUTH SIDE
At the southern portal, customer Marti Tunnel opted for the highest level of automation to counter labor shortages and optimize efficiency. The factory is compact and located at an altitude of 1,175 meters – requiring winter-proof design and precise alignment of vacuum equipment. The highlight: a newly developed heavy-duty robot for rebar cage handling and an automated vibration connection system. The entire line can be operated by a team of just three people.