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

rowa@rowa-ag.ch, www.rowa-ag.ch

We look ahead ...

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