Refurbishment of the Wipkingen Tunnel – General Contractor Tunnel

The “Wipkingen Tunnel Refurbishment” project comprised the rehabilitation and modernization of the historic railway tunnel in Zurich. It was originally excavated using mining methods in 1856. The tunnel was refurbished in 1986 and 1989, and a covered section was constructed on the Wipkingen side. The project described here involved the refurbishment of this structure. 

The main tasks included:

• Repair of the tunnel vault 
• Demolition and renewal of the shotcrete lining 
• Rehabilitation of the masonry and joints 
• Improvement of the drainage systems 
• Waterproofing of the tunnel vault 
• Removal of structure encroachments into the clearance profile

• Excavation of the existing ballasted track and construction of a new slab track including turnouts 
• Renewal of turnouts and substructure, as well as installation of cable systems 
• Construction of the new drainage level

• Construction of a cable installation for pulling in the 132 kV power supply 
• Formation of an integrated cable duct within the shoulder

• Temporary cable route in the vault, track 404 
• Ballast bonding 
• Lighting

• Coordination with subcontractors and SBB specialist services 
• Rail logistics 
• Environmental measures 
• Surveying services 
• Monitoring services

The project was divided into two construction phases: the “vault refurbishment” phase, carried out in 2023, and the “track” phase in 2024. Works on the vault were executed track-bound during short night closures. Track refurbishment was carried out during a continuous single-track closure with nightly operating breaks on the respective operational track.

• Project Manager: Pius Jochum 
• Site Manager: Pius Jochum 
• Construction Managers: Sven Meyer, Patrick Vogl 
• Foremen: Ymer Gashi, Curdin Davaz, Dietmar Winkler

The project was successfully completed despite numerous challenges. The close cooperation with SBB, subcontractors and other parties involved, as well as the individual competencies within the RSRG Group, made a significant contribution to this success. The proactive approach of the RSRG managers and flexible project management enabled the project to be completed on schedule while meeting all quality and safety standards.

• Works under ongoing rail operations
  Throughout the entire construction period, at least one track had to remain operational. Rail operations had to be maintained without any restrictions on speed. This constraint required precise planning of the construction processes and perfect coordination of the works. By implementing a dynamic construction schedule and making use of short but intensive work intervals, the works were completed on time.
• Complex logistics and restricted access
  The construction site was located in an inner-city area with limited storage space and difficult access routes. Rail-bound logistics ensured smooth supply to the site.
• Coordination
  Construction works at Wipkingen station and on the adjacent viaduct and bridge structures were carried out in parallel with the tunnel refurbishment. Through regular coordination and close communication with all project participants, overlaps were avoided and the works were coordinated seamlessly.
• Environmental protection requirements
  The project was partly located in an area affected by contaminated sites and polluted rail ballast. All necessary protective measures were taken to prevent construction wastewater from being discharged into the River Limmat and to ensure the proper disposal of contaminated material.

Line 751, Zurich HB – Zurich Wipkingen – Zurich Oerlikon
KM 2.568 bis KM 3.613

The following main quantities were carried out in the project:

Tunnel vault refurbishment

• Demolition of existing shotcrete lining: 220 m² 
• New shotcrete lining: 360 m² 
• Milled slots for vault drainage outlets: 350 m 
• New drainage outlets: 37 pcs. 
• Adjustment of existing drainage outlets: 200 pcs. 
• Rehabilitation of masonry joints: 100 m²

Track

• Excavation of ballast: 4,800 m³ 
• Renewal of drainage inspection chambers: 30 pcs. 
• Shoulder: 940 m
• Cable duct: 1,950 m 
• Concrete (track and shoulders): 4,500 m³ 
• Turnouts: 4 pcs. 
• Slab track: 1,960 m 
• Ballasted track: 120 m

132 kV cable system

• Protective cable pipes DN200: 8,000 m

Temporary works

• Slotted pipe DN150: 1,000 m 
• Ballast bonding: 1,040 m