Tunnel Renovation Redefined

During renovation of the Hasselborner Tunnel in Central Hesse, Germany, contractor Baresel used a method they hadn't tried before. Parts of the tunnel lining had to be removed and the areas were subsequently to be shotcreted in preparation for a new tunnel lining, including a plastic membrane. Using a KEMROC patch planer, Baresel was able to grind away the required sections quickly while achieving precisely the required surface profile.

Renovation Project In Central HessenAt the Hasselborner tunnel renovation project in central Hessen, Baresel used a KEMROC patch planer mounted on a railway excavator.
All photos: KEMROC

The 1,300 m long Hasselborner tunnel in Central Hesse, Germany, has a long history. Constructed between 1910 and 1912, the lower section of the tunnel was natural stone while the tunnel crown was constructed with masonry bricks. Today, the single track, non-electrified railway tunnel is located on the Taunus line connecting the towns of Grävenwiesbach and Hasselborn, to the west of Frankfurt am Main. After about 100 years in operation, renovation of the tunnel lining was necessary to prevent water seeping into the tunnel and maintain safety standards to ensure a working life of another 50 years. The contract for this work was granted by the client, HLB Basis AG (Frankfurt am Main), to contractor Baresel GmbH (Leinfelden-Echterdingen), who has earned an extremely good reputation for tunnelling and renovation projects.

In addition to demolition, drilling, shotcreting and anchoring, the specialists at Baresel had to have a plan to grind sections of the tunnel crown in preparation for installation of new tunnel lining, including a plastic geo-membrane at those locations. As early as the calculation phase, it had been decided to include a KEMROC milling machine as the most suitable type of grinder in budgeting a cost for the project.

After the contract was awarded by the tunnel operator, HLB Basis AG, the Baresel Maschinentechnik Tunnelbau team (MTT) led by Josef Galster, and the KEMROC team under the supervision of Managing Director Klaus Ertmer, had detailed technical discussions to determine the correct milling attachment for the excavator to be used. In conclusion, it was decided to go with the KEMROC patch planer type EX 45 HD. This increased the number of KEMROC attachments in the BARESEL equipment park. The main factors influencing the decision was the expected high production rates and minimal wear or potential damage to the excavator or the surrounding brick lining due to the low vibration characteristics of the milling attachment.


Precision over a large area

Among other things, KEMROC patch planers were designed to repair asphalt surfaces or to remove layers of concrete or screed. With eight models, there is a planer to fit all carriers in the 1 to 23-ton operating weight range. Depending on the material to be ground, different designs of drum and tooling can be fitted. Whether mechanical or hydraulic depth control is chosen, the cutting depth is accurate to the nearest millimetre with maximum depth of 190 mm, depending on the model. At the Hasselborner Tunnel, the brickwork layer to be removed was expected to be constant at between 25 and 30 cm, so the version with mechanical depth control was chosen.

In principle, the Exactor can work at any inclination, horizontally, vertically and in between, even overhead as can be found in some tunnelling applications. However, the limited space in the single track Hasselborner Tunnel was a challenge. In the narrow tunnel, only 5 m wide and 5.2 m high, the railway excavator cannot rotate and there was no room to manoeuvre the patch planer into position at the top of the tunnel. For this reason, the patch planer was mounted on a tilt-rotator. With the minimum amount of joystick movement, the excavator operator was able to get the planer into the correct position along the tunnel lining. In practice, the operator placed the patch planer in the starting position, pressed the planer to the required depth into the brickwork and then drove 5 m along the length of the tunnel. The cut mater fell onto a wagon that had been strategically placed in the tunnel. In this way, the contractor completed the grinding work in conjunction with the transportation of spoil material in one operation, leaving the work place clean. According to Baresel MTT, only in those areas where the bricks were made of hard natural stone, located at the very top of the tunnel crown, did they have to resort to using a hydraulic hammer.


The new method prevails

According to their conclusions, working with the EX 45 HD patch planer, Baresel MTT completed the project within a very tight, contractually binding deadline set by Betra, the rules regarding operations and working. While the project in the Hasselborner tunnel was still underway and showing positive results, Baresel MTT took the decision to add a second KEMROC patch planer to the machine park for identical tunnel renovation projects in the Kalmut (124 m) and Talberg (144 m) tunnels near Boppard am Rhein. In these tunnels, a similar amount of material had to be removed from the brick internal tunnel lining. In comparison with conventional methods such as cutting or hammering and the use of rotary drum cutters, Baresel MTT concluded that from their experience with patch planers, they consider them to be economical, effective and non-destructive.

NBM&CW May 2019

Click Here
To Know More / Contact The Manufacturer
Please provide your details we will contact you as soon as possible
Please let us know your name.
Invalid Input
Please let us know your Designation.
Invalid Input
Please let us know your City.
Please let us know your State.
Please let us know your Country.
Please let us know your Contact Number.
Please let us know your email address.
Please brief your query.

Characteristics & Categorization of Tunnel Fires & Their Mitigation

A fire that develops in a tunnel interacts with the ventilation airflow and generates complicated air flow patterns and turbulence in the vicinity. The heat generated warms up the surrounding air, and in case of a slope inside Read More ...

Mapei: Injection Solutions for Underground Construction

Injection can be defined as the introduction of a material with pressure into the ground or a structure for waterproofing and for consolidating voids, cracks and porosity. Generally, the injection can be categorised as Pre Read More ...

GHH adds Shotcreting Machine to its - Tunneling Equipment Solutions

GHH is offering state-of-the-art and proven IS26 Concrete Spraying (Shotcrete) machine in India. The machine is suitable for shotcreting application in medium and large sized tunnels with cross sections ranging Read More ...

Kishanganga Hydro Power project – A New Power House

Inaugurated by the Prime Minister of India, the Kishanganga Hydro Electric Power project is the first mega hydro power plant to be awarded as EPC to HCC by NHPC. Located at Bandipore in north Kashmir, the Read More ...

Tunneling to Prosperity: Solutions, Equipment and Technologies

India is one of the fastest growing markets for tunnel construction due to various infrastructure development projects underway across the country. Tunnels are required for hydroelectric power projects, for improving road Read More ...

CREG: Tunneling Specialist

China-based China Railway Engineering Equipment Group Co., Ltd (CREG) is a subsidiary of the public- listed China Railway Engineering Corporation (CREC), a Fortune 500 company and a key state-owned company under Read More ...

Intermodality & Last Mile Connectivity - Creating Smart Walkable Spaces

Urban congestion needs to be addressed by encouraging high quality and innovative energy-efficient public transport integrating it with other forms of paratransit, ensuring last mile connectivity; working on Read More ...

Ashram Metro Station - An Engineering Masterpiece

One of the main challenges of constructing a station in the Delhi Metro Network, especially in a busy and densely populated area, is designing it according to the ambience and the limited space allocated. Constructing Read More ...

Transit Oriented Development - Challenges and Proposed Regulatory Framework

Transit Oriented Development (TOD) complements the concept of new urbanism. Compact, mixed-use communities are the answer to suburban problems. Due to the dynamic nature and multiplicity of underlying Read More ...

Simulating oversize and heavy vehicle manoeuvres using AutoTURN® from Transoft Solutions.

Use AutoTURN® to design infrastructure adjustments to safely operate trucks transporting wind turbine components. By Er. Alessio Gori - collaborator at POLITECNICA INGEGNERIA ED ARCHITETTURA SOC. COOP. Read More ...

Urgent Course Correction Imperative for Indian Railways

Railways’ freight and passenger businesses over the 5-year period, i.e., 2014-15 to 2018-19 (budgeted) indicate a flat growth. The number of total passenger journeys would record a CAGR of 0.22%, passenger kilometres Read More ...

Meeting Emerging Urban Transport Challenges

The Ministry of Housing and Urban Affairs has envisaged growth of urban transport along with a low carbon footprint through seamless implementation of a New Metro Rail Policy, announced last year Read More ...

Tunnelling Through the Ages

History has seen the evolution of tunnelling starting with cave formation, for water management, underground transportation, mineral extraction and for warfare purposes. The oldest reference of a tunnel was Read More ...

Afcons uses Robbins EPB TBM to Complete Third Bore for Chennai Metro Project

Contractor Afcons Infrastructure Ltd used a 6.65 m (21.8 ft) diameter Robbins EPB TBM to bore through in Chennai Metro, making it the contractor's third tunnel to be bored by the machine for the project. The three Read More ...

Robbins Slurry TBM ramps up for Mumbai Metro Line 3

The first of two Slurry TBMs, a rebuilt 6.65 m (21.8 ft) diameter machine, passed its factory acceptance on September 4, 2017 in Singapore. The machine, fitted with a Robbins cutterhead and outer Read More ...

Tunnelling Technologies & product support keep pace with construction complexities

Advanced technologies, mechani- sation of equipment with heightened safety features, and timely service and technical support to end-users can help the construction industry deal with construction complexities Read More ...

New Building Material & Construction World

New Building Material & Construction World
MGS Architecture

Modern Green Structures & Architecture

Modern Green Structures & Architecture

Lifting & Specialized Transport

Lifting & Specialized Transport

Indian Infrastructure & Tenders Week

Indian Infrastructure & Tenders Week