Ralph Küsters, who is responsible, among other duties, for Energy Operations at the internationallyactive Italian tunnelling company I.CO.P. S.p.A., has implemented numerous long-distance pipejacking drives worldwide.
I.CO.P. has worked with VMT’s Joblight communication and lighting system, the predecessor of TunnelHub, for many years. Küsters describes the essential importance of this technology for occupational safety, environmental protection, and operational reliability, such as for a pipeline project in North America. There, Joblight was a prerequisite for the use of the Direct Pipe method, as uninterrupted communication with personnel underground created the safety conditions required for entering the tunnel, for example for control surveys.
“Joblight made it possible to enter these tunnels in the first place,” says Küsters. “It was this technology used on a larger scale for the first time in diameters that were previously classified as inaccessible for safety reasons, that enabled us after all to construct several major crossings using the Direct Pipe method.”
TUNNELHUB’S CONSTRUCTION SITE DEBUT: VERDEN, GERMANY
A seamlessly functioning tunnel communication system, as a central element of a modern health and safety concept, also played a role in the tender evaluation for a pipejacking project in Verden, Germany, according to I.CO.P.
The Südlink power line crosses the River Aller at this location. Grid operator TenneT awarded I.CO.P the microtunnelling contract. Two tunnels with an internal diameter of 2m and a length of 1.1km each were to be constructed. Both tunnels run parallel to each other at a short distance apart. Each was equipped with seven empty cable ducts and finally backfilled with liquid soil. Cable installation takes place after completion.
Construction of the first tunnel began in July 2025. The second tunnel followed in mid-October.
“In the first bore, we drove nearly 300 metres through clay, which slowed down our advance speed, of course,” says Florian Klatt, Site Manager at I.CO.P.
Nevertheless, the very tight schedule was met. For the second tunnel, the construction schedule allowed 66 days; here, too, despite numerous geological challenges, the drive was completed significantly ahead of schedule thanks to the use of proprietary technology.
“Such performance depends on close cooperation between client and contractor, the team on site, and the capabilities of machinery and materials,” explains Klatt. “Everything worked perfectly here.”
The Verden site was used by VMT to deploy the newly developed TunnelHub communication platform under real construction conditions for the first time.
“In May, we estimated that the system would be ready for testing on a construction site in July,” says Jürgen Göckel, responsible for Business Development Microtunnelling at VMT. “And because the drive in Verden was scheduled to start in July, the timing was ideal.” Klatt agrees. “For us, it was a win-win situation,’ he says. “We were able to use the enhanced capabilities of the new system compared to Joblight, and we could also contribute our own ideas and practical improvement suggestions during this development phase.”
In the first tunnel, Joblight was kept as a backup for TunnelHub for safety reasons. However, the test went so well that I.CO.P. used only the new system in the second tunnel.
COMPACT TECHNOLOGY – EASY HANDLING
The functionalities of TunnelHub are based on the further-developed hardware platform MT.connect 2, which is also used by the navigation system. All data are transmitted via one single data line divided into 50m-long sections and each of these ‘Smart System Cables’ is equipped with a ‘Smart Unit’.
The small ‘smart’ boxes not only form wi-fi access points as the basis for communication, but cameras and other standardised industrial sensors can also be easily connected via plug-and-play. Integrated LED arrays can display scrolling text messages or show animated arrows pointing towards the exit – an important feature in emergency situations to guide personnel out of the tunnel quickly. Optionally, the Smart System Cables can be fitted with additional LED modules that provide general tunnel lighting and serve as an additional safety feature for emergency lighting.
The system is controlled by a Main Control Unit located outside the tunnel and houses the central computer and the router for a dedicated internet connection. A Control Unit installed in the launch shaft enables safe pipe changes or rapid power shut-off in emergency situations.
“A major improvement of TunnelHub over its predecessor is the simplified handling made possible by the new MT.connect 2 hardware platform,” says Göckel. “Simply connect the desired components and everything works immediately, without complex configuration.” Göckel sees another significant improvement in the highly compact design of the technology – an opinion shared by Küsters, who says: “I can implement this system much better even in smaller drives.”
SEAMLESS CONNECTIVITY IN THE TUNNEL
One of the central functions of TunnelHub is the WLAN network covering the entire tunnel, allowing communication at any time with personnel underground using smartphones and standard apps, such as WhatsApp or Teams.
“Everyone is reachable everywhere in the tunnel, everyone can make external calls from anywhere in the tunnel,” says Göckel.
Such standard apps also offer video calling. This allows technicians underground to receive direct support from experts who may be located off-site, possibly even on another continent. The WLAN also enables accurate localisation of personnel within the tunnel by section, meaning the machine operator can always see how many people are in the tunnel and where they are located.
In emergency situations, the system also offers firefighters and rescue teams to be integrated into tunnel communication using normal smartphones, adds Küsters.
“With TunnelHub, we can provide the rescue teams with an interface that enables optimal organisation and coordination of their operations.” This also expands the possibilities for developing safety and rescue concepts together with emergency services. Küsters argues that the definition of tunnel accessibility should not be tied to fixed formulas or diameters but rather to the available safety concepts. “In this context, TunnelHub is a way to ensure a very high safety level even in smaller diameters.”
TECHNOLOGY IN FOCUS
The technology also enables the transmission of real-time video from the tunnel. Two cameras can be connected to each access point every 50m.
“There is basically no area in the tunnel that you couldn’t observe if you wanted to,” says Göckel. From the control cabin, devices such as pumps, power packs or interjack stations can be visually monitored during active tunnelling.
Küsters adds: “Normally, inspections of machine components by personnel can only take place when tunnel operations are shut down. TunnelHub closes this gap by allowing comprehensive monitoring of this equipment even during full operation.”
Another aspect of improved efficiency is the reduction of unnecessary trips into and out of the tunnel, for example during surveying, maintenance or repair work. The Smart units on the data cables can also generate visual and acoustic alarms. These are triggered centrally on the TunnelHub control screen to initiate evacuation of the tunnel as quickly as possible in an emergency. Additional alarm spots can be installed anywhere in the tunnel, enabling alarms to be triggered from within the tunnel itself.
PRACTICAL TEST PASSED
Florian Klatt describes the practical experience on site as entirely positive.
“In the first drive, there were some minor teething problems at the beginning, but these were small issues that were quickly and efficiently resolved with the VMT surveying colleague on site.”
He sees the versatility and expanded modularity of the platform, with its many options to integrate different functionalities and thus create a complete package tailored to each specific construction site, as a major advantage of TunnelHub.
“My recommendation to management will be to use TunnelHub on future construction sites as well.”
Original publication in B_I umweltbau 01/2026 Minor editing in T&TI published version.
