Model of Wirth TBM for Castellanza Tunnel on Exhibit at SamoterIn Lombardy, Italy the Malpensa airport is connected to Milan by the Malpensa Express, operated by the private railway company Ferrovie Nord Milano Esercizio (FNME). The connection to the airport will at least partially be built as a double-track railway. On the Saronno-Malpensa section, a bored tunnel in the municipality of Castellanza, about 20 km to the east of Milan Malpensa airport, must be built to take the tracks underground. Two parallel tunnels will be bored in alluvium to pass under the river Olona and reduce the exposure of residents to noise generated by train services. FNME has awarded the design and build contract for two 1,850 m shield-driven tunnels to Castellanza Scarl, a JV formed by Torno Internazionale, Strabag, Romagnoli and Cogeis. There will also be four connecting galleries to be driven using conventional methods and eight shafts. The tunnels will be 7.85 m OD and 7.25 m ID and will be lined with concrete segments. Due to the relative short distances to be bored and the tight time schedule until the project start, a new TBM was out of the question and a suitable second hand machine had to be found. The segment lining also had to be determined on the basis of an existing EPB TBM. The most important criterion for the purchase of the TBM was a very short delivery time. The TBM finally chosen was one of two originally delivered in 2002 for the Channel Tunnel Rail Link (CTRL) Contract 240. The delivery of the first components to the jobsite in Italy took place from mid-December 2004 while the overhauling and checking of the main components in the plant commenced in January 2005. The assembly has started in March 2005 and is planned to be finished in May/June 2005, for tunnelling start in July 2005 and completion in March 2007.The TBM length is 12 m (without the back-up) and 110 m (with it) for a weight of 750 tons. The back-up including equipment weighs 200 tons. The total installed main drive power at the cutter head is 1,500 kW. The total installed power is 2,800 kW, with a TBM transformer rating of 2 x 1,800 kVA. The TBM is equipped with 29 thrust cylinders, able to deliver 2,175 kN at 360 bar (total thrust of 63,075 kN). The cutter head is equipped with 16 cutters, 21 rippers, 102 scrapers and 20 centre tools. A conveyor belt will be used for the mucking-out. Cutting tools and the conveyor belt have been ordered to TunnelTec. Visit www.tunneltec.deThe complete project is scheduled for a period of 20 months, beginning with the assembly, boring of the first tube, disassembly and reassembly for boring of the second tube, and disassembly after completion. A model of the machine can be viewed in parts at the Samoter fair to be held in Verona from 4th to 8th May, 2005. Click it/33. Visit www.ferrovienord.it, www.wirth-europe.com, www.torno.com, www.strabag.at and www.samoter.com 15/05. The Wirth TBM under assemblyClick to enlarge