The ambitious Fehmarn Belt Fixed Link project is set to open by mid-2029, leveraging advanced robotic welding technology to enhance production efficiency and reduce construction time.
Fehmarn Belt Tunnel Poised to Open Ahead of Schedule in 2029
LODDEBYHAVN, Denmark — The Fehmarn Belt Fixed Link, a pioneering undersea tunnel connecting Denmark and Germany, is on track to open by mid-2029, owing in part to the incorporation of two advanced robotic welding machines that have significantly expedited the production of reinforcement steel for tunnel elements.
The 17.6-kilometre tunnel, which will stretch from Rødbyhavn on the Danish island of Lolland to Puttgarden on the German island of Fehmarn, is an ambitious project managed by Femern, a subsidiary of the state-owned Sund & Bælt. Femern’s responsibilities include planning, construction, and future operation of the tunnel, one of the largest infrastructure projects in northern Europe.
Enhanced Production Capabilities
Inside the 13,000 square metre steel production hall, named the Panel Factory, approximately 1,500 tonnes of reinforcement steel are produced every week. The factory, which became operational in 2023, employs around 120 workers operating in two shifts. The steel produced here is crucial for the construction of the tunnel’s concrete elements, each of which will be submerged and interconnected on the Baltic Sea bed.
The Panel Factory boasts advanced capabilities that enhance production efficiency and reduce waste. Steel is cut to precise sizes, ensuring optimal use of materials and reinforcing supply security by making steel grids on demand. This critical aspect of the production process is handled by just two robotic welding machines, which account for over 70% of the work.
Technological Innovation
The robotic welding machines, prototypes by Spanish company DCM-Wire, are pioneering in their application, as this project marks the first time such robots are used to weld reinforcement steel of this thickness. These machines, fed by a magnetic crane capable of lifting up to five tonnes, considerably lighten the physical labour usually associated with welding by eliminating manual heavy lifting and automating the bulk of the workload.
Construction Progress
The tunnel construction will involve 79 large tunnel elements, each 217 metres long, and 10 special concrete elements. Each large element, consisting of nine 24-metre segments, weighs a substantial 73,500 tonnes. The first of these 217-metre-long elements took approximately 10 months to cast; however, going forward, such elements are expected to be produced every nine weeks.
To celebrate the production milestone, the Danish king inaugurated the first completed tunnel element on June 17. This element is scheduled to be submerged later in the year. During the inauguration, a time capsule was sealed and placed at the project’s exhibition centre before being buried near the tunnel portal, symbolising a greeting for future generations.
Upcoming Phases
Following a three-week curing period, the installed element is equipped with steel bulkheads and ballast tanks to stabilize it during immersion. Excavation work continues on both sides of the planned tunnel route. On Lolland, the contractor consortium, Fehmarn Belt Contractors (FBC), is currently excavating the portal and tunnel trench where the first element will be placed later this year.
Partnerships and Contracts
The Fehmarn Belt Fixed Link is a joint effort between multiple contractor consortia. The construction is spearheaded by Fehmarn Belt Contractors (FBC) and Fehmarn Link Contractors (FLC). FBC is tasked with dredging operations at sea and setting up work harbours and new nature areas. FLC handles the construction of the tunnel, including portals and ramps, under contracts that became effective in January 2021.
In subsequent agreements, Femern also contracted Femern Systems Contractors (FSC) in May 2022 for equipping the tunnel with electro-mechanical installations and technology. Additionally, a December 2022 contract with Elecnor will lead to the establishment of a large transformer station, which will provide green power essential for the tunnel’s operations and the railway between Denmark and Germany.
Future Impact
Upon completion, the Fehmarn Belt tunnel will dramatically reduce travel times across the Baltic. The crossing will require just seven minutes by train and ten minutes by car, marking a significant improvement over current transit times by ferry.
As this enormous project progresses, it continues to integrate cutting-edge technology and innovative construction techniques, positioning itself as a significant feat of engineering and a vital link between Denmark and Germany.
