S19 Rzeszów Południe–Babica: first tunnel tube excavation completed

16 December 2025

This day has already gone down in the history of Polish road infrastructure. On December 10, 2025, the TBM “Karpatka” broke through to the North Portal, completing the excavation of the first tunnel tube on the S19 Rzeszów Południe–Babica route. This is an event of exceptional significance – both for the tunneling industry in Poland and for the strategic Via Carpatia corridor, which will connect the north and south of Central and Eastern Europe. The project is being carried out by a consortium of Mostostal Warszawa S.A. and ACCIONA.

- Completing the excavation of the first tunnel tube is an example of how good cooperation, commitment, and the allocation of significant financial resources can produce results that we can proudly showcase across Europe. We are proud that construction is progressing. We are fully aware of the challenges and requirements involved. I would like to thank all the engineers, designers, and specialists whose work makes it possible for us to mark the completion of this stage today - said Dariusz Klimczak, Minister of Infrastructure, during his visit to the construction site.

- The completion of the first tunnel tube is proof that Mostostal Warszawa S.A. and ACCIONA deliver on their commitments and are capable of executing the most demanding projects in Poland. It also confirms that Polish engineering can effectively tackle the most complex technological challenges - stated Jorge Calabuig Ferre, President of the Management Board of Mostostal Warszawa S.A.

In the photo: Jorge Calabuig Ferre, President of the Management Board of Mostostal Warszawa S.A., during a conversation with Dariusz Klimczak, Minister of Infrastructure.

The TBM “Karpatka”

The TBM “Karpatka” is one of the largest and most advanced machines of its kind used in Poland. It measures 114 meters in length and 15 meters in width, with a total weight of approximately 4,400 tons, illustrating the scale of the project for the S19 tunnel. It is powered by a hydraulic-electric drive and equipped with 12 motors of 1 MW each, providing the force needed to operate in exceptionally challenging geological conditions.

At the heart of the machine is the cutting head, weighing around 400 tons, which rotates at up to 3 revolutions per minute and is fitted with 471 cutting tools, allowing efficient excavation of the rock mass. During operations, the TBM reached a maximum depth of over 100 meters below ground level.

Geological challenges and advanced TBM technology

The tunnel construction posed a significant challenge, requiring work in the complex geology of the Carpathian Flysch and in conditions with potential methane hazards. Advanced detection and ventilation systems were employed, along with detailed safety procedures. Work was carried out around the clock by specialized teams of engineers, operators, and technical staff.

Transporting the TBM

Transporting the enormous TBM to Poland was a major logistical undertaking and represents the largest road transport operation ever carried out in the country. The machine first arrived at the port of Szczecin by sea from Santander, Spain. Its components were then transferred to barges and pontoons to travel along the Oder River to Opole. The final leg involved road transport from Opole to the construction site in Babica. To minimize traffic disruptions, the machine was moved only at night. The operation was highly spectacular, attracting nationwide attention, with hundreds of local residents observing the precision demonstrated by the transport team.

The tunnel as a key element of the S19 section and the Via Carpatia corridor

The Babica tunnel is 2,255 meters long and will eventually consist of two unidirectional tubes connected by 15 cross passages and an emergency passage. Each tube will have two traffic lanes and a breakdown lane. The tunnel is the most important and technologically advanced structure within the 10.3-kilometer S19 expressway section, which forms part of the international Via Carpatia transport corridor.

Next steps

After completing the first tube, the next stage will involve rotating the TBM “Karpatka” to begin excavation of the second tube. The start of this work will depend on the results of a technical inspection, the scope of necessary repairs, and planned modifications to optimize the machine’s performance. The TBM rotation will be carried out using the airmover system at the North Portal.

Project implemented by the Mostostal Warszawa–ACCIONA consortium

The project, undertaken by the Mostostal Warszawa S.A. and ACCIONA consortium, is one of the most important and technologically advanced infrastructure projects in Poland. Its value exceeds PLN 2 billion, and it is being implemented on behalf of the General Directorate for National Roads and Motorways. The project will significantly improve road safety, reduce travel times, and enhance connectivity in the region and across the Via Carpatia corridor.

Materials: Mostostal Warszawa S.A.