PROJECTS | LINING & FORMWORK
CASTING ELEMENTS FOR FEHMARN LINK
The world’s largest concrete casting factory is in operation, in Denmark, to make the enormous segments for the world’s longest immersed tube tunnel - the Fehmarn fixed link. The 17.6km-long combined rail and road link is being
constructed between Denmark and Germany, and is part of the EU-backed strategic high-speed rail network for Europe. The Fehmarn tunnel is designed with two separate cells for transport mode (rail, road), for separated travel. The tunnel cross section with its hollowed sections are
formed by casting the floor, then the separating walls, and then the ceiling. This initial casting is to create a ‘segment’ of the overall tunnel but with the tunnel being so long these (while being 24m-long) are like slivers to be joined together to form a tunnel ‘element’.
These elements have bulkhead doors attached into their ends - and out the casting factory they go. Eventually. For these casting tasks are so enormous they take a while. It is almost like they are being gradually extruded from the factory, out of the huge doorway onto the slip ramp, leading toward the dry dock. With 79 of the standard elements (each 217m-long, and
weighing 73,000 tonnes) plus some special-sized elements required for the immersed tube tunnel, one production line is not enough. The factory complex has a few lines, and for each much formwork is employed for the casting works. Peri has supplied significant quantities of steel formwork for the task. The factory started casting in early 2024 and the Fehmarn project is to be completed by the end of this decade.
Top and above left: Formwork and first casting for Fehmarn immersed tube tunnel Above right: Fehmarn casting factory and awaiting docks on Danish coast IMAGES COURTESY OF PERI
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