S19 Rzeszów Południe–Babica: rotation of the TBM “Karpatka” underway

The rotation process is proceeding according to plan and is combined with comprehensive servicing. At the same time, inspection and technical review works are being carried out to enable a detailed assessment of the machine’s key components. After the rotation is completed, maintenance work and further inspection of individual subsystems will continue, followed by the start of excavation of the second tunnel bore.

Innovative Air Mover Technology

The TBM rotation is being carried out using an innovative Air Mover hovercraft system. This consists of a special steel frame equipped with pneumatic cushions that lift the machine on a thin layer of air, allowing for the safe movement and rotation of components weighing thousands of tonnes.

This solution significantly reduces the need to dismantle the TBM — the machine has been divided into only four main sections, which shortens the duration of the operation and enhances safety.

A Solution Rarely Used Worldwide

Air Mover technology is rarely used worldwide and, at this scale, represents an exceptional solution. Thanks to this method, there is no need to disassemble the machine into hundreds of components, which reduces risk, limits the number of assembly operations, and enables more precise and controlled execution of the works.

The entire rotation process is a complex logistical and engineering operation requiring meticulous preparation of the site, continuous monitoring of safety systems, and close cooperation between engineering and technical teams. The works are being carried out under constant supervision by specialists and in accordance with the highest safety standards.

Next Stages

Following completion of the rotation and servicing works, the TBM “Karpatka” will be positioned in the launch cradle at the northern portal and prepared for excavation of the second tunnel tube — the next stage of the S19 Rzeszów Południe–Babica section.

Key Data

• The Babica tunnel will be 2,255 metres long and will consist of two unidirectional bores connected by 15 cross-passages and an emergency crossover. Each bore will include two traffic lanes and an emergency lane.
• The tunnel structure is the most important and technologically advanced element of the 10.3-kilometre S19 section, part of the international Via Carpatia transport corridor.
• The project is being delivered by a consortium of Mostostal Warszawa S.A. and ACCIONA. Its value exceeds PLN 2 billion and it is being implemented on behalf of the General Directorate for National Roads and Motorways (GDDKiA).
• The tunnel is being excavated by the TBM “Karpatka,” which is 114 metres long, 15 metres in diameter, and weighs approximately 4,400 tonnes. Equipped with a hydraulic-electric drive system and 12 motors rated at 1 MW each, it has been designed to operate in the challenging geological conditions of the Carpathian flysch.
• The heart of the TBM is a cutterhead weighing approximately 400 tonnes, rotating at up to three revolutions per minute and equipped with 471 cutting tools.

Material: Mostostal Warszawa