A Mostostal Warszawa and Acciona consortium is using the segments to build the 2.2km tunnel under Grochowiczna Hill.
Since March 2023, around 22,700 segments have been produced in Mostostal Warszawa’s manufacturing hall in Lutoryż. Each tunnel ring consists of 10 elements. Light rings (L) weigh 132 tons, with a single segment weighing 14 tons (key segment – 7 tons). Heavy rings (C) weigh 152 tons, with a single segment weighing 16 tons (key segment – 8 tons).
Mostostal Warszawa said it used high-quality C50/60L and C60/75C concrete, applying modern steam curing chambers, which shortened production time while ensuring strength and quality.
The daily production process consumed an average of 300m³ of concrete, supplied by a dedicated batching plant connected to the carousel.
TBM Karpatka, which has a diameter of more than 15m, was launched in July and Mostostal Warszawa said the final stage of excavation of the first bore is under way.
The twin-bore tunnel is part of a 10km section of the S19. The tunnel will also include an emergency lane, 15 cross-passages, and an emergency passageway.
Mostostal Warszawa and Acciona’s works also include six viaducts and two overpasses; a railway overpass; three wildlife crossings, a tunnel management centre; and two service areas with helipads for the air ambulance service.
The S19 expressway is a section of the Via Carpatia transport corridor. The strategic route will connect Lithuania with Greece, running through Poland, Slovakia, Hungary, Romania, and Bulgaria. In Poland, it will span around 700km, crossing five provinces.
