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Ein Arbeiter in einer Fabrik steht neben Maschinen und spricht in ein Mikrofon. Links steht der Text „Was uns bewegt: Menschen.“ Rechts der Text „Was uns antreibt: Technologie.“ Die Bildhälften betonen die Verbindung zwischen Menschen und Technologie in der Industrie.

All DIMENSIONS #2

Human and machine

50 years of pioneers underground

 

 

In 50 years of company history, more happens than can fit into an editorial. In the video Dr.-Ing. E.h. Martin Herrenknecht and Martin-Devid Herrenknecht give you a few insights.

 

Under the spell of the machine

Tunnelling in hard rock up close

 

At the Gotthard, miners must accomplish the seemingly impossible. They cut through hard granite and brittle schist, braving extreme conditions and the idiosyncrasies of the mountain. Building a second road tunnel through the Alps requires technology at its most reliable and a team that becomes one with it. Here, man and machine are once again pushing the Boundaries of what is possible. And it's precisely here that service begins: directly on the jobsite, deep inside the mountain and in constant contact with the team on site. Direct insights into work at the Gotthard can be found in the video:
 

 

"Whether the shield operator calls me with an urgent question or the machine foreman sends me a video of a worn component via WhatsApp – TOGETHER WE ALWAYS FIND A WAY."

Hauke Helmerichs, Service Expert Herrenknecht AG

The "Secondo tubo" JV (Implenia Schweiz and Frutiger) and Marti Tunnel are driving a 16.9 kilometer long tunnel between Göschenen in the canton of Uri and Airolo in Ticino from the north and south respectively. To do this, they are moving two Single Shield TBMs from Herrenknecht with diameters of 12,225 millimeters and 12,310 millimeters toward each other inside the mountain.

Service expert Hauke Helmerichs says: “The biggest challenge is the geology. Everything else we can influence.” The Gotthard is on the move – because the African and Eurasian continental plates are pushing against each other, causing the Alps to continue growing. The mountain is under enormous tectonic stress, its layers are slowly shifting. During the drive, the miners are encountering very hard granite, but weathered rock also awaits them along the way. 

The machine operates reliably even under the most adverse conditions, and many processes are already automated – but ultimately, the human factor is crucial. It requires a team that maintains the technology, constantly reacts to unforeseen events, and, above all, communicates with each other a lot.
Hauke Helmerichs knows the tunnel boring machine at the Gotthard inside and out. He planned its assembly, supervised its commissioning and is also regularly on site during tunnelling. As was the case with the maintenance shift and tunnelling shown here. 
 

 

The service expert on "his" jobsite:
Hauke Helmerichs planned the assembly of the TBM on the Gotthard north side jobsite and managed it on site for nine months. He also visits the jobsite regularly during the tunnel advance – and is captivated by TBM "Alessandra."

Jobsite in the Uri postcard:
The second road tunnel is being built parallel to the existing one (bottom left of the photo), which is to be renovated – the supporting struts of the launch shaft can be seen in the photo. Access to the tunnel by car for Hauke Helmerichs and the author is one level higher.
 

Into the Gotthard massif:
Hauke Helmerichs (left) on his way to the maintenance shift, accompanied by the author of the reportage.

Full strength for tool changes:
In a joint effort, the cutting tools at the front of the cutterhead are replaced. The team works together to transport a disc cutter – weighing 191 kilograms – using a pneumatic chain hoist.
 

In the control cabin:
Between the monitors, controls and assistance systems for efficient tunnelling, Hauke Helmerichs opens his computer now and then to discuss everything related to the drive with the team led by machine foreman Alan Balatti.

Markus Lassacher at the pneumatic chain hoist:
The shield operator works primarily from the control cabin, but also lends a hand with tool changes and removal, as shown here.

Ring building following the Swiss system: 
The tunnel rings are built here using the pressure ring building method. The ring is inserted using a tongue-and-groove system.

Ein lächelnder Mann in orangefarbener Arbeitskleidung und einem Schutzhelm steht vor einer technischen Umgebung. Er schaut direkt in die Kamera, während im Hintergrund Maschinen und Rohre sichtbar sind, die auf eine industrielle Arbeitsumgebung hindeuten.
Eine Luftaufnahme eines Tals mit grünen Bergen, das von einer Stadt umgeben ist. Im Vordergrund sind Baustellen, Straßen und Bahngleise zu sehen. Die Landschaft ist dicht bewaldet, und es gibt fließendes Wasser in der Nähe. Das Wetter wirkt bewölkt.
Blick aus einem Fahrzeug auf einen langen, beleuchteten Tunnelabschnitt. Zwei Männer, die Sicherheitshelme tragen, sitzen im Vordergrund. An der Tunnelwand sind verschiedene Lichtsignale zu sehen, während der Boden glänzend und nass wirkt.
Auf dem Bild sind zwei Bauarbeiter in einem engen Schacht zu sehen. Der obere Arbeiter sichert eine Seilwinde, während der untere Arbeiter an einer Leiter nach oben klettert. Beide sind mit Schutzhelmen und orangefarbener Arbeitskleidung ausgestattet. Der Schacht ist staubig und dunkel.
Drei Arbeiter in Sicherheitskleidung stehen in einem Container, der mit technischen Geräten ausgestattet ist. Einer sitzt an einem Computer, während die anderen beiden auf den Bildschirm schauen. Logos von Firmen sind an der Wand sichtbar.
Ein Techniker steht in einer modernen Aufzugszentrale und blickt auf eine große Aufzugsglocke. Er trägt Arbeitskleidung und eine Kappe. Die Umgebung ist industriell und gut beleuchtet, mit sichtbaren Metallstrukturen im Hintergrund.
Ein Blick ins Innere einer Tunnelbohrmaschine zeigt Arbeiter in orangefarbener Kleidung, die an der Maschine und um sie herum beschäftigt sind. Kabel und Rohre verlaufen entlang der Wände. Die Szene vermittelt das Gefühl von industrieller Arbeit und Technik im Tunnelbau.

In Tech We Trust?

why “Human and Machine” is first and foremost a question of task sharing

 

Das Bild zeigt eine menschliche Figur mit Brille und einen humanoiden Roboter. Der Mensch steht auf der linken Seite, der Roboter auf der rechten Seite, mit einem hellen Hintergrund, der Technologie symbolisiert. Diese Darstellung verdeutlicht die Interaktion zwischen Mensch und künstlicher Intelligenz.

“Both TOO LITTLE AND TOO MUCH TRUST in an autonomous system CAN CAUSE PROBLEMS.”

Professor Dr. Christoph Bartneck
Department of Computer Science and Software Engineering | University of Canterbury, New Zealand

Automation makes our lives easier and our work increasingly efficient. In some cases more, in others less. As is so often the case, the right level of trust is key when it comes to human-machine interaction, says our author Prof. Dr. Christoph Bartneck. That is why he is calling on manufacturers to clearly label who is in control in any given situation, whether it is human or machine. Read the entire guest article by Prof. Dr. Christoph Bartneck, professor in the Department of Computer Science and Software Engineering at the University of Canterbury in New Zealand here or in the print edition of our magazine "All Dimensions".
 

Pushing ahead for the energy transition

Elbe crossing for a key grid expansion project in Germany
 

 

Near the Elbe estuary into the North Sea, a Herrenknecht Mixshield is helping transform the energy system. Here, in the far north, a tunnel is being built for one of Germany's most important future power lines. 
 

 

SuedLink is one of the key grid expansion projects for the energy transition in Germany. In future, the ultra-high-voltage direct current transmission line will transport electricity around 700 kilometers from the wind power regions in the north to the industrial centers in southern Germany. A key section of the project is the approximately 5.2 kilometer long crossing beneath the Elbe between Wewelsfleth in Schleswig-Holstein and Wischhafen in Lower Saxony.

Working for grid operator TenneT, the ARGE Tunnel ElbX consortium of PORR and Wayss & Freytag Ingenieurbau AG is building this tunnel, which will house six 525 kV cables as well as the necessary control, safety and monitoring technology. Rail tracks for maintenance and service vehicles are also being installed. The project is representative of more than 4,500 crossings that will be necessary in Germany alone as part of grid expansion.

To make sure tunnel boring machine Elsa can break through at the target shaft near Wischhafen as planned, the Herrenknecht engineers worked closely with their colleagues from contractors PORR and Wayss & Freytag Ingenieurbau AG to develop a machine you don't see every day. It must overcome both very sticky Lauenburg clay and various abrasive sands and gravels on the geologically very heterogeneous tunnelling section. "The challenge was to accommodate the technology of the highly complex Mixshield in a machine with a diameter of just under 5 meters," says Johannes Faisst, Senior Project Manager Traffic Tunnelling at Herrenknecht. The 190 meter long Mixshield with a diameter of 4.9 meters is designed for variable and complex geologies consisting of clay, tidal mud deposits, peat, sand and gravel, as well as for high water pressure of up to 3.8 bar beneath the Elbe River. A multiple sealing system reliably protects the machine from water ingress at a depth of around 20 meters. At the same time, precast concrete elements are installed during the drive to permanently line the tunnel.

The fully assembled machine has been underway since early 2025. On November 16, 2025, the ARGE Tunnel ElbX consortium tunnelling crews had already excavated 2,600 meters of tunnel, half the total length, and celebrated the so-called "Bergfest" marking the halfway point. 

 

Eine große Tunnelbohrmaschine wird mit einem Kran angehoben. Arbeiter stehen in auffälliger Sicherheitskleidung in der Nähe und beobachten den Vorgang. Im Hintergrund ist eine Baustelle zu sehen, die auf Erdarbeiten hinweist.
Luftaufnahme einer Baustelle mit mehreren Bohrgeräten und Lkw. Umgeben von Ackerland und Wasserflächen. Im Hintergrund sind der Horizont und einige Industrieanlagen sichtbar. Die Szene zeigt die Aktivitäten einer Erschließung oder einer Bautätigkeit in einer ländlichen Umgebung.

On the crane hook at the ElbX jobsite: Elsa has completed the last stage of her journey by ship and heavy haulage and is lowered into the launch shaft

Through the polis by metro

A somewhat different journey through Athens

 

Around Omonia Square, traffic crawls bumper to bumper through the streets – the fastest way through Athens lies beneath the surface: the metro. Travel journalist Niklas Hoth and photographer Kate Lang descend into Athens' underworld and discover far more than just a practical way to get around the city: a network of tunnels, some of which were built using Herrenknecht tunnel boring machines. Even now, two Herrenknecht EPB Shields are driving forward the new Line 4. On the way to the existing metro lines, between platforms and escalators, the attentive observer will literally discover an underground archaeology museum. Thus past and present merge in the Athens metro: archaeology that makes you pause for contemplation and state-of-the-art tunnel technology for the transportation of the future.
 

Graffiti on the outside, ancient murals inside: the Athens metro offers unique routes through the urban landscape.

Passing museum pieces such as these clay vases, everyday life in the metro goes on for the people of Athens.

Niklas Hoth is a travel journalist, radio presenter and host of the podcast "Reisen auf Gleisen" (Traveling by Rail). He also devotes himself to what he considers the most beautiful way to travel in his blog "Auf Schiene" (On the Tracks). His mission for the readers of All Dimensions: to take a closer look at the Athens underground.
 

"Come along to the museum": where people either pour into metro stations or spill out into the daylight, there is a third option the author has chosen to profit from: stopping to marvel at the ancient treasures on display here.

If you dig a metro through the underground in the Greek metropolis, you're going to come across archaeological finds: like this replica of the frieze from the Parthenon temple.

Pausing for a moment in the hustle and bustle of the metro: Panathenaic prize amphorae, like those presented to the winners of sporting competitions in ancient times.

“The longer I look at the exhibits, the more I forget I'm not in a real museum, but in the subway.”

Following geological probe drilling, the tunnelling engineers drove smaller exploratory tunnels around the station for safety reasons. History was brought to life: the tunnel's construction uncovered vast quantities of ancient clay vessels that had been washed into the tunnel jobsite.

Decorated clay jugs, pots, and shards: on his journey through the Athens underground, the travel writer can hardly get enough. This find is on display at the Akropoli station.

One of the highlights above ground is the Vallianeo Megaron, the National Library.

Eine Metro-Bahn mit orangefarbener Front fährt in eine Station ein. Auf dem Bahnsteig stehen mehrere Passagiere, während die umliegende Architektur und Graffiti im Hintergrund sichtbar sind. Der Himmel ist teilweise bewölkt.
Drei Tontöpfe stehen auf Podesten in einer Vitrine. Der größte Topf hat eine runde Form mit einem Henkel und einer gestreiften Oberfläche. Die beiden kleineren Töpfe sind einfach gestaltet. Im Hintergrund sind unscharfe Silhouetten von Personen zu sehen.
Ein Mann steht lächelnd vor einem historischen Gebäude mit Säulen. Im Hintergrund sind weitere Personen zu sehen, die die Architektur betrachten. Die Stimmung wirkt entspannt und freundlich.
Eine Person steht in einer U-Bahn-Station. Die Wände der Station sind hell und oval geformt. Im Hintergrund ist eine U-Bahn zu sehen, die am Bahnsteig hält. Der Boden ist plattiert und reflektiert das Licht.
Eine Wand mit einem Relief, das historische Reiterdarstellungen zeigt. Die Szenen sind in mehreren Abschnitten angeordnet und heben dynamische Bewegungen und Kämpfe hervor. Am linken Rand befindet sich eine Informationstafel mit Text. Der Hintergrund ist neutral und schlicht gehalten.
Ein Mann steht vor einer Glasvitrine in einem Museum und betrachtet mehrere große alte Tongefäße. Die Vitrine ist in einem modernen Raum mit hellen Wänden und einem grauen Boden. Licht fällt auf die Gefäße, die neben einer Wand aus Marmor stehen.
Eine Person betrachtet Vasen in einer Ausstellungsfläche, während im Hintergrund weitere Menschen vorbeigehen. Die Umgebung ist modern und gut beleuchtet, mit reflektierenden Oberflächen und minimalistischer Architektur.
Ein Mann steht vor einem großen Wandbild, das einen schmutzigen Tunnel mit Müll zeigt. Der Tunnel wirkt dunkel und unheimlich, während der Mann in einem schwarzen Hoodie und Jeans vor dem Bild steht und es betrachtet.
Das Bild zeigt eine antike griechische Darstellung von Figuren, die musizieren und tanzen. Einige halten Instrumente wie eine Flöte, während andere sich in dynamischen Posen bewegen. Der Hintergrund ist in dunklen Blau- und Grautönen gehalten, um die Szene zu betonen.
Ein imposantes Gebäude mit klassizistischer Architektur, das große Säulen und eine breite Treppe zeigt. Das Dach hat ein Flaggenmast. Um das Gebäude herum stehen Bäume, die eine grüne Umgebung schaffen.

From Kuala Lumpur to Sydney

The long way to an Autonomous TBM

 

Ein riesiges Tunnelbohrgerät wird in einer Baustelle von einem Kran herabgelassen. Im Hintergrund ist eine große, graue Wand zu sehen, die die Umgebung umrahmt. Ein Arbeiter steht darunter und beobachtet die Arbeit.

Photo: Sydney Metro

Clearly, automating processes on tunnel boring machines increases overall efficiency and occupational safety. But equally clearly, the complexity of mechanized tunnelling places the highest demands on the step-by-step optimization of automation and assistance systems. In our magazine "All Dimensions 2026", Gusztáv (Gus) Klados from Malaysian construction company Gamuda reports on the obstacles that had to be overcome on the way to an Autonomous TBM – and how years of development work first on Herrenknecht machines in Kuala Lumpur and later on two Double Shield TBMs in Sydney successfully paid off. His prediction: automation will not replace humans, but it will fundamentally change their role in mechanized tunnelling.

As a long-standing TBM specialist at Gamuda, Gus Klados was instrumental in driving forward the development of the Autonomous TBM.
 

"At the beginning, it's fair to say I was a bit skeptical. But what Gamuda achieved is a huge step forward for our industry – a proof of concept for their approach."

Matthias Schwärzel
Head of a Project Management division at Herrenknecht
 

Ein Mann mit einem nachdenklichen Ausdruck sitzt in einem Anzug und einer Krawatte. Er hat kurze, graue Haare und stützt sein Gesicht mit der Hand ab. Der Hintergrund ist unscharf und zeigt einen Bürobereich.
Ein Mann in einem reflektierenden Warnanzug und einem weißen Helm lehnt an einem Geländer. Er lächelt in die Kamera und steht vor einer industriellen Kulisse, die unbestimmt ist. Die Szene vermittelt ein Gefühl von Arbeitssicherheit und Professionalität.

One Team, one Tunnel

Breaking new ground under the Panama Canal 

 

For the first time in history, a metro tunnel is being built under the Panama Canal – an infrastructural milestone for Panama City. The Metro Line 3 project aims to significantly reduce chronic traffic congestion between the city center and the west of the country and improve mobility for thousands of commuters for generations to come. Herrenknecht is supporting the project with a powerful Mixshield with a diameter of 13.46 meters.

 

"If the tunnel is a success, bridges over the canal will be a thing of the past."

Francisco Avila
CEO I Herrenknecht Panama

Variable geology consisting of tuff, sandstone, argillite and volcanic rock: The Herrenknecht Mixshield is working its way through complex geology in Panama and withstanding high groundwater pressure. The tunnel runs at a depth of up to 68 meters beneath one of the world's busiest waterways without causing even the slightest disruption to shipping traffic. Around 5 to 6 percent of global shipping passes through the Panama Canal. "The canal is sacred. Nothing must interfere with it," emphasizes Francisco Avila, CEO of Herrenknecht Tunnelling Services Panama.

The project is being carried out by the joint venture Consorcio HPH. Herrenknecht is supplying not only the tunnel boring machine, but also a comprehensive system of equipment, services and digital solutions. The Herrenknecht.Connected platform connects people and machines, provides real-time data and enables data-driven decisions at every stage of the project.

"This tunnel will significantly improve the lives of many people – and shape the future of Panama," says Santiago Álvarez, Senior Project Manager at Herrenknecht. The project exemplifies an integrated "one team" approach, where global expertise, modern technology and local collaboration are setting new standards in urban tunnelling.

 

 

Looking into the future of mobility in and around Panama City Project Director Carlos Cedeño (center) at Herrenknecht in Schwanau, Germany, with Francisco Avila (right)

When the size takes shape

the factory assembly of the large-diameter TBM

 

A photo report on the factory assembly of the large-diameter TBM projected for Santa Clara Valley Transportation Authority’s (VTA’s) Bay Area Rapid Transit (BART) Silicon Valley Extension (U.S.A.)

 

Ein großer, kreisförmiger Maschinenbauteil wird von einem Kran angehoben. Der Bereich wirkt industriell, mit Geräten und Elementen im Hintergrund. Der Bauteil befindet sich in einem Werk, und es sind mehrere Arbeiter in Sicherheitskleidung zu sehen, die an dem Projekt beteiligt sind.

The next big thing! The 16-plus meter machine’s main drive alone weighs more than 300 tonnes. It is set up with the gantry crane and lifted to the shield.

The Herrenknecht team secures the necessary stud bolts and the motors after installing the main drive.
 

Gantry crane site manager Rolf Drexler and his team are responsible for ensuring that the work runs smoothly.

The blue-painted cutting wheel center, weighing around 150 tonnes, is then mounted.

Before the TBM digs deep underground, it is checked from the bottom to the very top.
 

Genuine teamwork already in assembly gives birth to engineering marvels.

Completion of the cutting wheel: Once the center is assembled, the four cutting wheel segments follow.

Bernd Kupfer, Head of Pre- & Workshop Assembly at Herrenknecht in Schwanau, supervises the assembly.

Precision work on the conveyor screw: Every centimeter counts. The assembly work on the conveyor screw of the EPB Shield requires precision, experience and teamwork. 

It´s done: The proud Herrenknecht employees and the assembled TBM pass the factory acceptance with honors.

The highlight of the FAT ceremony: Dr.-Ing. E. h. Martin Herrenknecht (right) is proud to hand over the machine to the client VTA and the Kiewit Shea Traylor Joint Venture (KSTJV). Together they press the buzzer that starts the cutting wheel turning.

Precision meets long distance

546 meter record drive in hard rock

 

The expansion of local sewage systems is a key factor in the sustainable development of large cities. The Brazilian city of Rio de Janeiro has made this a priority too. Here, contractor Passarelli relied on project-specific customized technology and competent service from Herrenknecht for the construction of the Faria Timbó sewage collector – with success: the longest pipe jacking drive ever carried out from a single shaft through hard rock in Latin America has been completed.

Ein gelbes und rotes Bohrgerät wird von einem Kran über eine Baugrube gehoben. Zwei Arbeiter beobachten den Vorgang in Schutzkleidung. Im Hintergrund ist ein Lastwagen zu sehen, unter einem blauen Himmel mit einigen Wolken.

A record of 546 meters

The rock in the area consisted of compact, stable gneiss with a compressive strength of 165 mega-pascals and a Cerchar index of 2 to 4, which classifies it as very abrasive. As the drive progressed, this led to numerous tool changes, which became increasingly complex, time-consuming and physically demanding as the length of the tunnel increased. Transporting discs weighing more than 30 kilograms in a tunnel with a diameter of only 1,500 millimeters was a considerable challenge for the site crew. Nevertheless, it was the right decision to use a technology that above all offers safety and agility when carrying out the work. The hard work of the Passarelli team and the proven Herrenknecht technology kept the drive on track.
 

The result is not just a technical record. Together, Passarelli and Herrenknecht have established a global benchmark for trenchless projects. Read more in our “All Dimensions” magazine.

Sink Twice: VSM Deployment in Shanghai

Two shafts, one machine, no people in the danger zone

 

In the densely built-up Pudong district of Shanghai, the Yingbin Waterworks Project is a key infrastructure project for the sustainable supply of drinking water. The construction of new raw water pipelines required TBM launch and reception shafts – in extremely confined spaces, surrounded by residential buildings and transport infrastructure.

Under these conditions, conventional methods were ruled out. Instead, a Vertical Shaft Sinking Machine (VSM) from Herrenknecht was used. With the VSM13000, two shafts were sunk one after the other with just one machine: one 30 meters and one 39.5 meters deep, each with an outer diameter of 14.9 meters. On completion of the first shaft, the machine was repositioned and immediately deployed again. The use of a VSM to construct TBM launch and reception shafts was a first for China.

Greater safety, greater efficiency: In addition to reducing time and space requirements by up to 50 percent, mechanized sinking with a VSM is above all a gain for occupational safety: all work, including securing the shaft wall, is carried out remotely from the surface.

Eine Luftaufnahme eines Kreisverkehrs zeigt Bauarbeiten in der Mitte mit Bauanzügen, Werkzeugen und Materialien. Um den Kreisverkehr herum verlaufen Straßen mit Fahrzeugen. Der Bauplatz ist teilweise eingezäunt und es sind gelbe Maschinen sichtbar.

Works perfectly in urban areas too: As the Yingbin Waterworks Project demonstrates, VSM technology requires less storage space and less heavy equipment than conventional excavation methods such as diaphragm walls. This saves project time and costs. 

Against all Odds

From impossible to breakthrough

 

Very few tunnel drives adhere to textbook theory from the first to the last segment. This is true even when comprehensive planning, sophisticated technology and experienced teams are involved. When the worst comes to the worst, progress can only be made when people and machines combine their mastery. Countless times over the past decades, colleagues from all Herrenknecht disciplines have proven that seemingly impossible tunnelling projects can be successfully completed or unexpected obstacles overcome. This creates trusting partnerships that make the breakthrough to the target shaft possible in the first place. Here is a selection of anecdotal vignettes from five decades.

Eine Gruppe von Arbeitern steht in einem unterirdischen Tunnel vor einer großen, runden Tür. Die Umgebung ist aus Stein und es gibt Wasserpfützen am Boden. Das Licht ist schwach und betont die massive Tür sowie die rauen Wände des Tunnels.

Hallandsås | Sweden

Two previous attempts had failed, leaving behind massive environmental damage in some cases. Only the Herrenknecht machine (Multi-mode TBM, Ø 10,530 mm) managed the successful breakthrough for the twin-tube Hallandsås railway tunnel. Eight years of struggle from 2005 to 2013 for just under 11 km of tunnel through blocky rock and up to 10 bar of groundwater pressure. A completely new cutterhead was installed twice. In some sections, cutterhead inspections took place every 5 m.

More
Ein großes Tunnelbohrgerät ist in einer Baugrube positioniert. Mehrere Bauarbeiter in Schutzkleidung arbeiten an der Maschine. Im Hintergrund sind weitere Baugeräte und Baustellenmaterialien sichtbar. Die Szene zeigt den Bau- und Maschinenprozess in einer urbanen Umgebung.

Pavoncelli | Italy

Since an earthquake in November 1980, the Pavoncelli water tunnel in southern Italy had been so badly damaged that a parallel new construction was necessary. Several conventional tunnelling attempts failed due to complex geology and high water pressure. They left behind tunnel fragments that were partly flooded and partly concrete-filled. In the next attempt, the Italian tunnel builders relied on a Herrenknecht EPB Shield with a compact diameter of only 4.55 m. In addition to water and rock, the methane gas that occurred was a particular challenge for the jobsite. With the machine already in operation, Herrenknecht engineers, together with their service colleagues, devised and constructed extensive modifications to the narrow shield to protect people and machines against gas risks. In 2017, after three years and around 8.5 km of tunnelling, the breakthrough was achieved.
 

Zwei große Tunnelbohrmaschinen stehen nebeneinander in einer Halle. Eine ist rot und die andere blau. Die Maschinen haben charakteristische runde Köpfe mit vielen Öffnungen und technischen Details. Sie befinden sich auf speziellen Unterlagen, bereit für den Einsatz.

Arrowhead | U.S.A.

The Arrowhead Tunnel is intended to help secure California’s water supply. The tunnelling is largely characterized by the San Andreas Fault: extremely high groundwater pressure and severely fractured rock. The two Single Shield TBMs are ideally equipped from the outset, among other things with their convertibility to slurry operation and extensive injection drilling equipment for rock stabilization. The tunnelling is progressing slowly because the miners take their job and their responsibility seriously. Herrenknecht remains on the ball for five years from 2003 to 2008, reliably supporting the construction site with expertise and spare and wear parts. Unlike all previous attempts to build the tunnel, the tunnelling is successful with the two Herrenknecht machines.

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Eine Tunnelbohrmaschine ist sichtbar, im Inneren des Rohrs arbeiten zwei Personen in Schutzkleidung. Das Licht hat einen grünen Schimmer, und technische Ausrüstung ist um sie herum angeordnet. Holzboxen und Kabel sind im Vordergrund zu sehen.

Suez Canal Crossing | Egypt

The Suez Canal in Egypt was to be expanded with a parallel shipping lane. An existing freshwater pipeline had to be be laid underground so that it crosses under the expansion. Tunnel excavation is to be completed before the new canal section is built. There was enormous time pressure. Right at the start of tunnelling in 2014, a seal on the launch structure failed and the shaft filled completely with water. Draining the shaft, troubleshooting and repairing the water-damaged components – all under time pressure and with no alternative but to succeed. In the end, determination and expertise prevailed, and the tunnelling was successful.

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Ein großer, zylindrischer Tunnelbohrer in gelber Farbe steht in einer Werkhalle. Der vordere Teil des Bohrers hat eine kreisförmige Front mit mehreren Schneidewerkzeugen. Die Maschine ist auf Holzgestellen platziert und wird von einem Arbeitsumfeld umgeben.

Palm Island | United Arab Emirates

The tunnelling work proceeded as planned in 2005. The AVND2500AH excavated its way through the ground, pipe segment by pipe segment. Things were looking good for the protective tunnel, which would carry water, power and data lines to Palm Jumeirah off the coast. Until the jacking forces increased steadily and significant damage to the inside of the jacking pipes became apparent at 350 m. From Schwanau and on site, Herrenknecht specialists provided tireless support in analyzing and repairing the damage. First, however, additional steel segments had to be installed at the damaged section to protect the workers in the tunnel. The reason for the sluggishness was found and the solution proved effective: the material that had adhered to the outside of the pipe string was flushed out with high pressure. The drive continued and finally arrived successfully at the target shaft.
 

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Das Bild zeigt eine große Tunnelbohrmaschine in einer Halle. Die Maschine hat eine runde Vorderseite mit einer blauen und weißen Farbgebung sowie gelben Elementen. Im Hintergrund sind weitere Maschinen und industrielle Ausrüstung sichtbar, aber der Fokus liegt auf der Tunnelbohrmaschine.

Lake Mead | U.S.A.

15 bar pressure – and the machine for the Lake Mead water tunnel made mechanized tunnelling history.The water pressure and the abrasivity of the rock took their toll. Material wear was immense. Solutions had to bearings or cutting constantly found during ongoing excavation, and seals, pinion bearings, or cutting tools had to be replaced or refurbished. The 4.4 km long tunnel drive took from 2011 to 2014. Experts had serious doubts as to whether the excavation was even technically possible. The site crew and Herrenknecht support were able to dispel these doubts.

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Das Bild zeigt einen großen Tunnelbohrer an einer Baustelle. Im Vordergrund verlaufen Gleise in den Tunnel, während Arbeiter in grüner Kleidung sichtbar sind. Der Hintergrund zeigt städtische Gebäude und eine winterliche Landschaft. Die Szene vermittelt den Eindruck eines umfangreichen Tiefbauprojekts.

St. Petersburg | Russia

A 30° decline right from the start, with a 10-meter EPB Shield – this was unprecedented. However, it was the only solution for making metro stations in St. Petersburg that were not yet connected to the surface accessible by escalator. Herrenknecht was asked and delivered: the EPB Shield, the steeply declined launch construction, the machine’s protection against uncontrolled descent, the segment logistics and the muck transport by cable pull – everything that had to be rethought compared to horizontal tunnelling. The success of the first escalator shaft in 2012 led to two further follow-up projects under similarly sloping conditions.

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Eine Gruppe von Arbeitern steht in einem unterirdischen Tunnel vor einer großen, runden Tür. Die Umgebung ist aus Stein und es gibt Wasserpfützen am Boden. Das Licht ist schwach und betont die massive Tür sowie die rauen Wände des Tunnels.

Hallandsås | Sweden

Two previous attempts had failed, leaving behind massive environmental damage in some cases. Only the Herrenknecht machine (Multi-mode TBM, Ø 10,530 mm) managed the successful breakthrough for the twin-tube Hallandsås railway tunnel. Eight years of struggle from 2005 to 2013 for just under 11 km of tunnel through blocky rock and up to 10 bar of groundwater pressure. A completely new cutterhead was installed twice. In some sections, cutterhead inspections took place every 5 m.

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Ein großes Tunnelbohrgerät ist in einer Baugrube positioniert. Mehrere Bauarbeiter in Schutzkleidung arbeiten an der Maschine. Im Hintergrund sind weitere Baugeräte und Baustellenmaterialien sichtbar. Die Szene zeigt den Bau- und Maschinenprozess in einer urbanen Umgebung.

Pavoncelli | Italy

Since an earthquake in November 1980, the Pavoncelli water tunnel in southern Italy had been so badly damaged that a parallel new construction was necessary. Several conventional tunnelling attempts failed due to complex geology and high water pressure. They left behind tunnel fragments that were partly flooded and partly concrete-filled. In the next attempt, the Italian tunnel builders relied on a Herrenknecht EPB Shield with a compact diameter of only 4.55 m. In addition to water and rock, the methane gas that occurred was a particular challenge for the jobsite. With the machine already in operation, Herrenknecht engineers, together with their service colleagues, devised and constructed extensive modifications to the narrow shield to protect people and machines against gas risks. In 2017, after three years and around 8.5 km of tunnelling, the breakthrough was achieved.
 

Zwei große Tunnelbohrmaschinen stehen nebeneinander in einer Halle. Eine ist rot und die andere blau. Die Maschinen haben charakteristische runde Köpfe mit vielen Öffnungen und technischen Details. Sie befinden sich auf speziellen Unterlagen, bereit für den Einsatz.

Arrowhead | U.S.A.

The Arrowhead Tunnel is intended to help secure California’s water supply. The tunnelling is largely characterized by the San Andreas Fault: extremely high groundwater pressure and severely fractured rock. The two Single Shield TBMs are ideally equipped from the outset, among other things with their convertibility to slurry operation and extensive injection drilling equipment for rock stabilization. The tunnelling is progressing slowly because the miners take their job and their responsibility seriously. Herrenknecht remains on the ball for five years from 2003 to 2008, reliably supporting the construction site with expertise and spare and wear parts. Unlike all previous attempts to build the tunnel, the tunnelling is successful with the two Herrenknecht machines.

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Eine Tunnelbohrmaschine ist sichtbar, im Inneren des Rohrs arbeiten zwei Personen in Schutzkleidung. Das Licht hat einen grünen Schimmer, und technische Ausrüstung ist um sie herum angeordnet. Holzboxen und Kabel sind im Vordergrund zu sehen.

Suez Canal Crossing | Egypt

The Suez Canal in Egypt was to be expanded with a parallel shipping lane. An existing freshwater pipeline had to be be laid underground so that it crosses under the expansion. Tunnel excavation is to be completed before the new canal section is built. There was enormous time pressure. Right at the start of tunnelling in 2014, a seal on the launch structure failed and the shaft filled completely with water. Draining the shaft, troubleshooting and repairing the water-damaged components – all under time pressure and with no alternative but to succeed. In the end, determination and expertise prevailed, and the tunnelling was successful.

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Ein großer, zylindrischer Tunnelbohrer in gelber Farbe steht in einer Werkhalle. Der vordere Teil des Bohrers hat eine kreisförmige Front mit mehreren Schneidewerkzeugen. Die Maschine ist auf Holzgestellen platziert und wird von einem Arbeitsumfeld umgeben.

Palm Island | United Arab Emirates

The tunnelling work proceeded as planned in 2005. The AVND2500AH excavated its way through the ground, pipe segment by pipe segment. Things were looking good for the protective tunnel, which would carry water, power and data lines to Palm Jumeirah off the coast. Until the jacking forces increased steadily and significant damage to the inside of the jacking pipes became apparent at 350 m. From Schwanau and on site, Herrenknecht specialists provided tireless support in analyzing and repairing the damage. First, however, additional steel segments had to be installed at the damaged section to protect the workers in the tunnel. The reason for the sluggishness was found and the solution proved effective: the material that had adhered to the outside of the pipe string was flushed out with high pressure. The drive continued and finally arrived successfully at the target shaft.
 

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Das Bild zeigt eine große Tunnelbohrmaschine in einer Halle. Die Maschine hat eine runde Vorderseite mit einer blauen und weißen Farbgebung sowie gelben Elementen. Im Hintergrund sind weitere Maschinen und industrielle Ausrüstung sichtbar, aber der Fokus liegt auf der Tunnelbohrmaschine.

Lake Mead | U.S.A.

15 bar pressure – and the machine for the Lake Mead water tunnel made mechanized tunnelling history.The water pressure and the abrasivity of the rock took their toll. Material wear was immense. Solutions had to bearings or cutting constantly found during ongoing excavation, and seals, pinion bearings, or cutting tools had to be replaced or refurbished. The 4.4 km long tunnel drive took from 2011 to 2014. Experts had serious doubts as to whether the excavation was even technically possible. The site crew and Herrenknecht support were able to dispel these doubts.

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Das Bild zeigt einen großen Tunnelbohrer an einer Baustelle. Im Vordergrund verlaufen Gleise in den Tunnel, während Arbeiter in grüner Kleidung sichtbar sind. Der Hintergrund zeigt städtische Gebäude und eine winterliche Landschaft. Die Szene vermittelt den Eindruck eines umfangreichen Tiefbauprojekts.

St. Petersburg | Russia

A 30° decline right from the start, with a 10-meter EPB Shield – this was unprecedented. However, it was the only solution for making metro stations in St. Petersburg that were not yet connected to the surface accessible by escalator. Herrenknecht was asked and delivered: the EPB Shield, the steeply declined launch construction, the machine’s protection against uncontrolled descent, the segment logistics and the muck transport by cable pull – everything that had to be rethought compared to horizontal tunnelling. The success of the first escalator shaft in 2012 led to two further follow-up projects under similarly sloping conditions.

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The jobsite of the future

Innovation meets urgency

 

New Work isn't just confined to the office, far from it: technology and the market are radically changing processes on the jobsite and opening up previously unimaginable possibilities: artificial intelligence, robotics and automation are making work safer and more precise. Concepts such as modular construction and 3D-printed concrete will also gain in importance in the future. And global developments don't stop there: circular design and new legal and financial models are transforming construction, and infrastructure will become increasingly multifunctional and adaptable in the future. 

Eine digitale Grafik zeigt ein abstraktes, kreisförmiges Muster mit geometrischen Figuren in lebendigem Grün. Um das Muster herum verlaufen Linien und Datenströme, die ein modernes, technologisches Gefühl vermitteln. Die Fontanordnungen und Texte scheinen computergeneriert und komplex zu sein.

Digital visualization of tunnelling

As with Herrenknecht.Connected, the visualization of machine parts and data from multiple machines at a glance is becoming an increasingly powerful tool.

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Eine große Tunnelbohrmaschine steht in einem tiefen Graben aus Stein. Der Bohraufsatz ist sichtbar, während einige Baustellenmaterialien im Hintergrund erkennbar sind. Über der Maschine liegt eine blaue Abdeckung.

Multifunctional and adaptable infrastructure

An example of this is the Stormwater Management and Road Tunnel (SMART) project in Malaysia, which serves as both a traffic tunnel and flood protection.
 

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Eine digitale Grafik zeigt ein abstraktes, kreisförmiges Muster mit geometrischen Figuren in lebendigem Grün. Um das Muster herum verlaufen Linien und Datenströme, die ein modernes, technologisches Gefühl vermitteln. Die Fontanordnungen und Texte scheinen computergeneriert und komplex zu sein.

Digital visualization of tunnelling

As with Herrenknecht.Connected, the visualization of machine parts and data from multiple machines at a glance is becoming an increasingly powerful tool.

More
Eine große Tunnelbohrmaschine steht in einem tiefen Graben aus Stein. Der Bohraufsatz ist sichtbar, während einige Baustellenmaterialien im Hintergrund erkennbar sind. Über der Maschine liegt eine blaue Abdeckung.

Multifunctional and adaptable infrastructure

An example of this is the Stormwater Management and Road Tunnel (SMART) project in Malaysia, which serves as both a traffic tunnel and flood protection.
 

More

Jobsite of the future – a dialog about the future.

What is driving the transformation in construction – new technologies, smarter processes or a fundamental rethink? To find out, we spoke to three experts: Hannes Lagger, Director of Priority Pursuits at Arup, Dr. Karin Bäppler from Business Development at Herrenknecht and her colleague Frederic Seng from Technology & Innovation. They provide insights into the development of the industry and explain what is needed to make jobsites smarter, safer and more sustainable.
 

How will planning and implementation of infrastructure change by 2040?

“Advancing urbanization is leading to a concentration of population and putting pressure on infrastructure. By 2050, almost 70 percent of people will live in cities. In the future, underground spaces could house power plants, data centers or agriculture. Adaptive systems that fulfill multiple functions are needed when cities build underground.”

Hannes Lagger
 

How do you envision the jobsite of the future?

"The jobsite of the future will be autonomous, renewable and smarter. All processes, from material transport to assembly, will be automated. By 2040, perhaps only four people will be controlling the entire jobsite from one command and control center."

Dr. Karin Bäppler

Will operators control machines with their thoughts?

"It is quite conceivable that machines will be controlled by thought in the future. Neural interfaces are already being used in medicine and could enable control by thought, for example with exoskeletons. Maintenance by robots is already a reality, for example with automatic tool changers or systems that work behind the TBM."

Frederic Seng

All Dimensions

In our magazine we present the entire spectrum of mechanized tunnelling technology to open up new perspectives for you. Besides project reports, renowned experts and guest authors provide an insight into social policy and the economy. 

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Steffen Dubé President and General Manager Herrenknecht Tunnelling Systems USA Inc.
+1 253 4472300 Download contact (V-Card)
Gerhard Goisser Commercial Manager Herrenknecht Tunnelling Systems USA, Inc.
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