Gubrist Project successfully completes Culvert Element Production

The Gubrist Project has reached another major construction milestone with the successful production of all culvert elements required for the renovation works in the tunnel.

In total, 2.387 culvert elements were manufactured in our dedicated on-site factory. Production activities included:

• Complete fabrication of reinforcement cages,
• Installation of Halfen anchor channels, concrete spacers, tubes and other primary components,
• Casting of the elements,
• Curing in specific curing chambers,
• Logistics and storage on the designated area

In accordance with the approved construction methodology, the factory achieved an average production rate of four culvert elements per day.

Production commenced in December 2022 and, apart from planned maintenance shutdowns, continued uninterrupted until July 2026. Over this period of nearly four years, not a single production day was lost due to operational issues.

The WELK factory was equipped with:

• Four highly automated formwork units;
• Two dedicated workstations for reinforcement cage fabrication;
• Eight stands for ready-made reinforcement baskets;
• Specialized working platforms enabling thorough inspection and quality control of all production processes;
• Wheel loaders with a safe working load of up to 23 tons;
• Dedicated concrete production and handling equipment as well as day and sanitary accommodation.

The fully hydraulic operation of the formwork system ensured high repeatability, short changeover times and precise formwork movements throughout the production process. This led to significant reduction of necessary workers for factory operation.
The factory layout and operational concept were specifically designed to meet project requirements, local site conditions, and all applicable safety regulations issued by the Swiss safety authority, SUVA. Engineering, manufacturing, assembly, operation, and maintenance of the factory were carried out entirely by the in-house teams of the KERN Group of Companies or longstanding partners.

Particularly noteworthy is the project's outstanding safety performance. Throughout the entire production period, zero accidents were recorded, reflecting the strong commitment of all teams to maintaining the highest standards of health and safety.

The WELK factory also served as a platform for development and engineering activities aimed at future applications. During the project, our teams evaluated innovative solutions to reduce noise generated by formwork vibrators and improve workplace conditions. In addition, trial programs were carried out to assess a range of sensors and software solutions for monitoring concrete properties throughout the casting and curing process.

Finally, together with a Swiss start-up we developed a modular rack system for reinforcement logistic and storage.

The knowledge gained from these initiatives will support future projects and contribute to further improvements in efficiency, quality, and sustainability.
We would like to take the opportunity and congratulate the entire team at KERN Group of Companies. Our sincere thank you goes to our client for perfect cooperation throughout the project.

Key Project Figures:

• Total no. of culvert elements produced: 2387 pc.
• Concrete used more than 14.300m³, around 2.400 trucks
• Amount of steel reinforcement exceeding 2.050 tons
• 0 accidents or work disruptions

The formworks will undergo now planned maintenance and refurbishment works and will be prepared for another challenging project.