H E R R E N K N E C H T A G | U T I L I T Y T U N N E L L I N G | T R A F F I C T U N N E L L I N G MASTERLY PERFORMANCE IN MADRID: KEEPING THINGS MOVING ON THE M-30 HIGHWAY. S PA I N

3,650 METERS IN LESS THAN 30 MONTHS. Spain’s traffic successfully goes underground. People in Spain recognized early that only efficient transport systems can lead to a mobile and successful future. That’s why Spain has been renewing its infrastructure consistently for years. The transport system is undergoing an unparalleled and comprehensive modernization process. That goes for trans-regional rail lines as well as inner-city subway lines and highways. The best example: the M-30 city highway in Madrid. Requirement: better quality of life. The Spanish capital is experiencing the largest infrastructure...

2 | 3 Realization: a huge challenge. The project posed many difficulties. The high-friction ground with layers of clay and solid gypsum required powerful forces. The distance of the planned tunnel tubes to the subway and railway routes is no more than 6.5 meters in some places. Gradients of 5 percent, overburdens of up to 75 meters and pressures up to 6 bar demand the utmost from man and machine. The logistics also set the highest demands: the removal of the excavated material from the ever growing tunnel tube, the organization of the entire construction site infrastructure, including transport...

Top performances day after day, around the clock. That is where this 4,364t TBM colossus made in Schwanau began its tunnelling journey on November 5, 2005. The experienced team never had to push the envelope of what was technically possible. The amply dimensioned driving power was enough to drive through Madrid’s “underworld” with an impressive degree of constancy. The deciding factor was its impressive final leg. In just 8 weeks – i.e. a quarter of the construction time – the EPB giant accomplished 1,162 meters, which accounts for a third of the entire route. An average of 100 lining segments...

4 | 5 Target shaft Launch shaft Scheduled time: 30 months February 5, 2006: 522m of tunnelling completed OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC 2006 November 5, 2005: start-up in Madrid, tunnelling begins: 7 days a week, 24 hours a day April 2, 2006: 1,426m of tunnelling completed April 21, 2006: 1,825m, 50 percent of tunnel excavated May 7, 2006: 2,178m of tunnel constructed. Best weekly performance - 188m/94 rings May 25, 2006: best daily performance - 36m/18 rings, 108 trucks, ring construction, 720 trucks, excavation June, 2006: more than 3,000m of tunnel completed March...

CUTTING EDGE TECHNOLOGY AT WORK: TWO CUTTING WHEELS, THREE SCREW CONVEYORS. New dimensions require new ideas. The top performance in Madrid is a triumph of teamwork tunnelling and innovation. Herrenknecht developed a completely new cutting wheel concept to master the excavation diameter in this high-friction ground. The S-300 bores with two cutting wheels at the same time, which can be turned in both directions independently of each other. The inner cutting wheel has a diameter of 7 meters, and the outer cutting wheel, mounted in the same working plane, extends the excavation diameter to 15.20...

Just-in-time logistics. The entire backup organization and ring construction also have to keep up with the pace of excavation. The tunnel conveyor, made by the Herrenknecht subsidiary H+E Logistik GmbH, which was installed in Madrid, transports the excavated material out of the tunnel. Each journey of the tunnel train transports all segments for a complete lining ring into the tunnel. This journey cannot take longer than 30 minutes, including loading and unloading, since in that time the next boring stroke will be completed. In the following 30 minutes the delivered segments are assembled to...

Herrenknecht AG D-77963 Schwanau Phone +49 7824 302-0 Fax +49 7824 34 03 [email protected] WWW.HERRENKNECHT.COM Herrenknecht AG is a technology and market leader in mechanized tunnelling. As the only provider of a full range of services worldwide, Herrenknecht delivers high-tech tunnel boring machines for all ground conditions and with all diameters – ranging from 0.10 to more than 16.0 meters. Herrenknecht’s tailor-made machines create pipeline systems for water and sewage, for gas and oil (Utility Tunnelling) as well as tunnelling systems for car, metro and railway traffic (Traffic Tunnelling)...