Official opening of Gotthard Base Tunnel: Many BASF products used in construction of world’s longest rail tunnel

Figure 1: A special fire protection mortar from BASF near the south portal of the Gotthard Base tunnel ensures the concrete structure to bear up for at least 90 minutes against heat caused by fire up to a temperature of 1400° C. Thus giving precious time in case of emergency.

After nearly 20 years of construction, the Gotthard Base Tunnel in Switzerland will be officially opened on June 1. Construction chemical products from BASF helped make the construction of the world’s longest rail tunnel possible. "We are proud that we were able to contribute our innovative solutions and know-how to help our customers master the challenges of this monumental construction project," said Ralf Spettmann, President of the Construction Chemicals division at BASF.

The 57 kilometer Gotthard Base Tunnel was built with around four million metric tons of concrete – roughly 40 times as much as was used in Burj Khalifa, the world’s highest building. BASF supplied concrete admixtures, cement injections to stop water ingress, and fire-protection mortar for the tunnel construction project.

Long distances and high temperatures in the tunnel

In the 20 kilometer section between Erstfeld and Sedrun, the two parallel tunnel tubes and the connecting galleries that link the two tunnels approximately every 300 meters were built using BASF concrete admixtures. "In underground construction, there are contradictory demands on concrete: While being transported several kilometers deep into the mountain, it has to remain workable for hours and cannot solidify. But the concrete also has to set almost immediately when sprayed onto the tunnel wall. In the Gotthard Base Tunnel this was one of the greatest challenges," said René Bolliger, head of the Underground Construction unit at BASF for Germany, Austria and Switzerland. This was made possible thanks to the right combination of BASF concrete admixtures: MasterGlenium superplasticizers make the concrete especially flowable and workable, while shotcrete accelerators from BASF cause the concrete to solidify and harden within seconds after being sprayed on the tunnel wall. Furthermore, BASF developed an admixture especially for the construction of the Gotthard Base Tunnel which considerably slows down cement hydration. In combination with the BASF superplasticizers, it ensured the concrete could be used optimally even after being transported long distances and exposed to the high temperatures in the interior of the mountain. The system of superplasticizers and retarding agents was used for initial securing measures after excavation as well as during the concreting of the inner shell.

Concrete solutions for deep shafts

Two vertical shafts descend more than 800 meters from the mountain village of Sedrun into one of the two multifunction stations in the tunnel, which serve as emergency stops and house ventilation equipment and other technical infrastructure. BASF solutions can also be found here: Just like the tunnel, these were first secured with sprayed concrete and then outfitted with a wall of poured concrete. "Transporting the concrete via a vertical downpipe through the shafts was particularly challenging. We had to make sure that while the concrete fell down, its components did not segregate from each other," explained Bolliger. By choosing the right concrete superplasticizer and finding the optimal dosage for the application conditions, BASF experts ensured that the concrete was still easily workable after falling freely for several hundred meters. To prevent water ingress, a microcement was also injected into rock crevices and cavities.

Fire protection with BASF

Fires are a major danger in tunnels and there are strong fire safety requirements. If concrete gets hotter than 1,000°C, it loses its load-bearing capacity and the tunnel collapses. The wall of the Gotthard Base Tunnel near the south portal was therefore coated with a special fire protection mortar from BASF. "With this product, the tunnel walls can withstand temperatures of up to 1,400°C for at least 90 minutes. This is valuable time for fire-fighting operations," said Frank Clement, a BASF expert for fire protection solutions in underground construction.

Swiss megaproject Gotthard Base Tunnel

The Gotthard Base Tunnel is the longest rail tunnel in the world and cost around €9 billion to build. This route through the Alps will reduce travel time between Zurich and Milan by around one hour. The slope of the tunnel was reduced considerably; the highest point (550 meters above sea level) is only 90 meters higher than the northern portal in Erstfeld. As a result, freight trains can carry twice as much weight and travel twice as fast through the tunnel. In comparison, the old Gotthard railway has to cover a height difference of around 700 meters between Erstfeld and the apex of the first Gotthard Tunnel, which opened in 1882.

About BASF

At BASF, we create chemistry for a sustainable future. We combine economic success with environmental protection and social responsibility. The approximately 112,000 employees in the BASF Group work on contributing to the success of our customers in nearly all sectors and almost every country in the world. Our portfolio is organized into five segments: Chemicals, Performance Products, Functional Materials & Solutions, Agricultural Solutions and Oil & Gas. BASF generated sales of more than €70 billion in 2015. BASF shares are traded on the stock exchanges in Frankfurt (BAS), London (BFA) and Zurich (AN). More information at: www.basf.com.

About the Construction Chemicals division

BASF’s Construction Chemicals division offers advanced chemicals solutions for new construction, maintenance, repair and renovation of structures: Our comprehensive portfolio encompasses concrete admixtures, cement additives, chemical solutions for underground construction, waterproofing systems, sealants, concrete repair & protection systems, performance grouts, performance flooring systems, tile fixing systems, expansion control systems and wood protection solutions.

The Construction Chemicals division’s about 5,500 employees form a global community of construction experts. To solve our customers’ specific construction challenges from conception through to completion of a project, we combine our know-how across areas of expertise and regions and draw on the experience gained in countless construction projects worldwide. We leverage global BASF technologies, as well as our in-depth knowledge of local building needs, to develop innovations that help make our customers more successful and drive sustainable construction. The division operates production sites and sales centers in more than 50 countries and achieved sales of about €2.3 billion in 2015.