Production of tunnel lining segments for the S19 Rzeszów Południe–Babica expressway section has been successfully completed at the prefabrication hall in Lutoryż, the site of the future Motorway Service Area (MOP Lutoryż). A total of 22,700 reinforced concrete segments, each weighing up to 14 tonnes, have been manufactured. These will be used to construct the tunnel lining in Babica.

Tunnel Lining Production

The tunnel will be lined with 2,230 rings, each made up of ten segments. Additional rings have been produced as reserve. Manufacturing began in March 2023, consuming approximately 118,000 m³ of concrete. Standard elements were cast from C50/60 concrete, while cross-sectional components required C60/75 high-strength concrete.

To support logistics, a storage yard with capacity for 550 rings was built next to the production hall.

The S19 Expressway Project

The S19 Rzeszów Południe–Babica section stretches over 10 km, featuring dual carriageways with two lanes in each direction. Key elements include:

• The Babica trumpet interchange, linking national road DK19 with regional road DW988.
• A 2,255 m twin-tube tunnel, equipped with 15 pedestrian cross-passages and one emergency passage.
• Overpasses, viaducts, and modern road infrastructure.

Each tunnel tube will have two traffic lanes and one emergency lane.

Excavation is being carried out by the TBM Karpatka—a 114 m-long machine, 15.16 m in diameter and weighing 4,400 tonnes. The contractor is a consortium of Mostostal Warszawa and Acciona Construcción.

Safety and Innovation

The project also includes:

• The first Tunnel Management Centre in the Podkarpackie Voivodeship.
• Two Motorway Service Areas (MOP Lutoryż).
• Two helicopter landing pads for the Polish Air Rescue Service, located at MOP Lutoryż and the Tunnel Management Centre.

Methane Detection and Adaptation

During test pumping in July 2023, methane gas was detected in two of the 44 well holes. This prompted a coordinated response from experts at the contractor, the investor, AGH University of Science and Technology (Kraków), the Higher Mining Authority (Katowice), and the District Mining Office (Krosno).

To ensure safety, the TBM was fitted with:

• Methane detection sensors.
• A high-capacity ventilation system.
• Modified components suitable for methane conditions.

Following approval from the Commission for Hazards in Mining Plants and the District Mining Office in April 2024, tunnelling preparations were formally cleared.

Progress Update

After equipping the TBM and completing safety tests, Karpatka began excavation in July 2024. As of 14 September 2025, the machine had excavated 1,551.12 m of the left tunnel tube, with 769 rings installed.

For further information please click here and pl/28 for tunnel builder archive. Visit https://www.gov.pl, https://s19rzeszow-babica.pl, https://www.mostostal.waw.pl and https://www.acciona.com/. 39/25.