{"id":26416,"date":"2026-11-06T17:00:04","date_gmt":"2026-11-06T16:00:04","guid":{"rendered":"https:\/\/www.weissappetito.com\/?post_type=einblicke&p=26416"},"modified":"2026-11-03T13:42:56","modified_gmt":"2026-11-03T12:42:56","slug":"bohrkopf-revision-am-gotthard-120-stahlplatten-in-fuenf-wochen-erneuert","status":"publish","type":"einblicke","link":"https:\/\/www.weissappetito.com\/en\/einblicke\/bohrkopf-revision-am-gotthard\/","title":{"rendered":"Reconstruction of the Gotthard tunnel head: 120 steel plates renewed in five weeks"},"content":{"rendered":"

The second tube of the Gotthard tunnel is being built on behalf of the Federal Road Administration ASTRA<\/a> driven forward by both sides. <\/strong>While the tunnel-drilling machine \u00abPaulina\u00bb is working its way through the mountain from Airolo, the rock leaves clear marks on the cutting wheel. The wear protection plates next to the cutting rollers are also subject to heavy strain. A three-person team from Josef Muff AG was on site for five weeks to replace them. A total of 120 worn or broken protective plates were removed and replaced with new ones. The work took place between 03:00 a.m. and 12:00 p.m. each time. After that, the machine had to be operational again to continue advancing.<\/strong><\/p>\n

A tunnel boring machine with a diameter of 12.31 meters<\/h2>\n

The second tube of the Gotthard railway tunnel is being driven forward from both sides. In the south, the \u00abPaulina\u00bb tunnel boring machine from the German manufacturer Herrenknecht is being used for this purpose. The single-shaft TBM is approximately 110 meters long, weighs 2\u2019118 tons and has an output of 5\u2019600 kW. Its front shield measures 12.31 meters in diameter.<\/p>\n

A machine-driven advance section of approximately 7\u2019750 meters is planned for the southern tunnel section.<\/p>\n

The cutting wheel with the cutting rollers arranged within it is located on the front of the machine. As the wheel rotates, these are pressed against the rock with great force, breaking the rock apart. The surrounding steel components are also subjected to significant loads during this process.<\/p>\n

To protect the cutting wheel from abrasion by the rock, wear protection plates have been fitted between the cutting rollers. On the \u00abPaulina\u00bb many of these plates were already severely worn or had broken off in places. A total of 120 pieces had to be replaced.<\/p>\n

120 wear protection plates on the cutting wheel are renewed<\/h2>\n

The exchange took place directly on the front side of the cutting wheel. The supervisors from Herrenknecht determined which plates should be replaced and at which positions the new components should be installed on-site. The work flow was also coordinated with them.<\/p>\n

The three-member team of Josef Muff AG consisted of two welders and another employee who took on the preparatory work.<\/p>\n

First, the existing protective plates had to be removed. For this purpose, the Arc-Air process was used, in which the material is cut out using a light beam and compressed air. Subsequently, the exposed areas were cleaned and prepared for the installation of the replacement plates.<\/p>\n

The new wear protection plates were 25 millimeters thick and consisted of two layers. The base material used was S355 steel of quality S355. Over this was a hard wear protection layer. The base body of the cutting wheel itself consists of 90 millimeters thick S355 steel in the machined area.<\/p>\n

After preparation, the new plates were aligned according to the positioning specifications from Herrenknecht and then attached. Only after that did the complete welding take place.<\/p>\n

Welding work under exceptional conditions<\/h2>\n

For the welding, the two welders used the MAG welding process 136 with filler wire. This method was particularly suitable for the required position welds. Since part of the weld seams had to be made at an increasing or overhead angle, the supporting effect of the filler wire on the welding bath was advantageous.<\/p>\n

The working conditions on the cutting wheel required a lot from the team. Although the cutting wheel is over twelve meters in diameter, the space between the individual components was severely limited. The two welders had to work partially kneeling or lying down to reach the intended locations.<\/p>\n

In addition, there was mud on the floor, insufficient daylight, and the smoke generated by the welding work. Therefore, the ventilation at the workplace had to be increased.<\/p>\n

Transporting to the work site was also part of the daily routine. At the time of the overhaul, the tunnel boring machine \u00abPaulina\u00bb was already about 300 meters deep in the mountain. The journey to the cutting wheel took about 20 minutes. Tools and necessary materials were transported using a construction machine.<\/p>\n

After the revision, the momentum continued.<\/h2>\n

In addition to the technical requirements, the ongoing tunnel excavation process particularly dictated the work rhythm. For five weeks, the shift for the Josef Muff AG team began at 03:00 a.m. each night.<\/p>\n

By 12:00 p.m., the planned daily work had to be completed. After that, the cutting wheel was needed again for drilling operations.<\/p>\n

In order to be able to process the next plates, the cutting wheel was rotated accordingly. The work thus took place according to the positions that were accessible at any given time and the daily time window.<\/p>\n

Approximately six protective plates could be processed per shift for the welder. While the two welders were busy removing and welding the parts, the third employee was responsible for preparing them.<\/p>\n

The unusual working hours were also physically demanding. The early start of the shift and the associated fatigue were added to the cramped working conditions. At the same time, the team had to organize their work in such a way that the planned drilling operation could be resumed again at noon.<\/p>\n

Five weeks working directly on the cutting wheel of the \u00abPaulina\u00bb<\/h2>\n

Between August and September 2026, Josef Muff AG, on behalf of Marti Tunnelbau AG and the Federal Road Administration (ASTRA), renewed the 120 wear protection plates on the \u00abPaulina\u00bb tunnel drilling machine in Airolo.<\/p>\n

The work was carried out in close coordination with the supervisors of the machine manufacturer Herrenknecht, who specified the positioning of the components and the process sequence.<\/p>\n

For the three-member team, this deployment meant five weeks of unusual working hours, physically demanding positions of standing and a fixed time window. With the renewed protective plates, the cutting wheel was able to continue its further use in the Gotthard.<\/p>\n

Further information about the \u00abPaulina\u00bb tunnel boring machine and the construction of the second tube can be found on the Official project website of the Federal Office for Roads ASTRA<\/a> to be found.<\/p>","protected":false},"featured_media":26493,"parent":0,"template":"","categories":[28],"tags":[],"class_list":["post-26416","einblicke","type-einblicke","status-publish","has-post-thumbnail","hentry","category-rohrleitungsbau"],"acf":{"photo_gallery":{"projektfotos":[[{"id":26493,"title":"JMAG_Revision_Tunnelbohrkopf_Gotthard_39_Einblick","caption":"","full_image_url":"https:\/\/www.weissappetito.com\/wp-content\/uploads\/2026\/11\/JMAG_Revision_Tunnelbohrkopf_Gotthard_39_Einblick.jpg","thumbnail_image_url":"https:\/\/www.weissappetito.com\/wp-content\/uploads\/2026\/11\/JMAG_Revision_Tunnelbohrkopf_Gotthard_39_Einblick-150x150.jpg","large_srcset":"https:\/\/www.weissappetito.com\/wp-content\/uploads\/2026\/11\/JMAG_Revision_Tunnelbohrkopf_Gotthard_39_Einblick-600x400.jpg 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