Herrenknecht Receives bauma Innovation Award For Tunnel Modernization Technology
Herrenknecht AG has kicked off bauma 2025 with a prestigious win, receiving the bauma Innovation Award in the “Machine Technology” category for its Tunnel Enlargement System (TES). This groundbreaking solution enables the renewal and expansion of existing railroad tunnels without disrupting rail operations.
The award was presented during the grand opening of the trade fair on April 6 in Munich. The laudator Johann Sailer, Managing Partner of Geda, emphasized, “Tunnel construction technology is always fascinating - this one in particular makes it possible to safely renovate and expand all railroad tunnels while rail operations continue.”
With TES, Herrenknecht is tackling a key challenge of today’s European transport infrastructure: many of the 800 or so railroad tunnels that were built in Germany, Austria and Switzerland between 1850 and 1910 are still in operation - and will need to be extensively modernized in the future. Electrification, larger track gauges, modern safety standards and increasing traffic needs require the tunnel profiles to be enlarged - without interrupting ongoing train operations.
Martin-Devid Herrenknecht, member of the Herrenknecht Board of Management, on the occasion of the award ceremony, said, “With TES, we are setting a new milestone in mechanized tunnel construction. The combination of high technology, safety and efficiency opens up new possibilities for making existing transportation routes uninterrupted and fit for the future. I am particularly proud of our team in Schwanau, which has brought this technology to maturity with experience, creativity and the courage to innovate.”
TES developed by Herrenknecht makes it possible to carry out the tunnel renewal without interrupting rail operations. First, the existing tracks are dismantled, and a track is laid in the middle of the existing tube instead. Rail traffic will continue to run safely on this track during the entire construction work. TES moves forward step by step as the tunnel is being excavated. At the same time, it serves as a protective enclosure and separates the construction work reliably from the ongoing rail traffic.
The front machine section of TES protects the tunnel and the railway from collapse and falling rock. The middle section carries highly developed excavation and safety technology, and the rear machine section supplies power, compressed air and construction materials.
TES was first used on a large scale in January 2024 for the renovation of two historic tunnels of the Lahntalbahn near Limburg an der Lahn: the 426 m long Fachinger Tunnel and the 732 m long Cramberger Tunnel. The tunnel cross-section was extended by around two meters in radius during ongoing rail operations - to dimensions that correspond to today's new buildings. “PORR with TES successfully enlarged the first tunnel and we are delighted that this has now been recognized with the innovation prize,” said Dr.-Ing. Ulf Kirsten, Head of Tunnel Machine Technology Operational Services at PORR, the contractor for the projects on the Lahntalbahn. PORR submitted TES in cooperation with Herrenknecht for the industry-renowned prize.
TES is based on years of development work and has been continuously optimized based on experience from previous applications, including the Gaintxurizketa tunnel in Spain. It offers a new way of upgrading existing tunnels economically, sustainably and reliably for future generations.
