Customized state-of-the-art segment production

Efficient mechanized tunneling projects, using segments for its structural lining, depend on a harmonized segment production at highest standards in segment quality and accuracy. As a result of a consequent product management, Herrenknecht Formwork has successfully established itself as the world market leader for the supply of segment moulds, handling equipment and carousel plants. Up to now, more than 4,000 moulds were manufactured for 140 realized projects. Herrenknecht Formwork designs and supplies customized equipment for any type of segment production at highest standards. With three workshops in Germany, Slovenia and China, Herrenknecht Formwork is able to offer and manufacture equipment at short notice and in outstanding quality. Due to short project lead times and an increasingly growing demand, contractors often rely on mould manufacturers’ project experience with regards to the selection of a suitable variant of segment manufacturing, determination of suitable sets of moulds for an efficient manufacturing as well as on comprehensive concrete and curing concepts.

Based on increasing world-wide interest in multipurpose tunnels, enabling either a temporary or permanent use of its overall or partial structure for more than the essential purpose, Herrenknecht Formwork is aware of the importance of cutting-edge developments. Especially for tunnels with segmental lining, for conveyance of water and sewage water, Combisegments® has been developed. This segment embedded corrosion-protective liner (CPL) is extended by a liner frame and a mechanically integrated gasket, whereby e.g. welding at radial and circumferencial joints and conventional gasket gluing become obsolete. In addition, Herrenknecht Formwork is active in the field of thermally activated tunnel structures, whereby conventional segmental lining is turned into a heat exchanger for heating of municipal properties.

This paper compares segment productions using immovable stand moulds and a manufacturing carousel with associated handling equipment. In this context, influencing factors such as tunnel length, regional labour cost, lead and assembly time as well as cycle times of segment production are taken into consideration. In addition, new and promising product developments are introduced.