Train Tunnel

Train tunnels – the special challenge

Train tunnels pose a special challenge: dynamic alternating pressure loads of up to 10 kPa at several million load changes and static pressures of up to 30 kPA are maximally demanding for door and gate systems. Elkuch has mastered the technology that can ensure reliability and operational safety under these conditions over a service life of at least 20 years.

Impressive Swiss GateSystems

Both in operation and in an emergency: nothing may be left to chance when it comes to the functionality of the railway tunnel gates. Already during the development, every component is carefully selected and checked with FE models. The complex steel composite construction of the door leaves and frames as well as the drives and controls are subjected to numerous tests and quality checks. This is the only way to meet the high requirements for fire resistance, smoke tightness, fatigue strength, opening forces and sound insulation and to guarantee absolute operational capability.

Unparalleled references

High-quality engineering and precise working methods enable door and gate solutions that have been successfully installed in major railway tunnel projects. The world's longest railway tunnel, the Gotthard Base Tunnel, completed in 2016 and 57 km long, but also the Loetschberg and Ceneri Base Tunnels are among the remarkable projects that Elkuch has been able to equip with more than 850 safety gates.

Extensive product portfolio

Thanks to its broad experience in railway tunnel construction, Elkuch has a broad and proven product range:

  • Crossover gates
  • Lane change gates
  • Emergency stop gates
  • Cavern gates
  • Portal gates
  • Sluice gates
  • Mobile gates
  • Doors and gates for technical rooms
  • Special door solutions

Crossover Gates

For the self-rescue and evacuation of large numbers of people, escape sliding doors have proven their worth in tunnels with forced ventilation. Sliding doors can be used safely at any time without influencing the opening force when emergency ventilation is switched on.

Technical Specifications
Dimensions 2'000 mm x 2'200 mm
Dimensions (2) 3'000 mm x 2'200 mm

Fire resistance::

EI90 acc. to EN 1634

Pressure/suction load:

± 30 kPa for two million load changes

Leakage:

min. 50 m³/h at 100 Pa

Opening force:

100 N

Service life:

> 30 Jahre

Special design:

upon request

Lane change gate for railway tunnel

Lane change gates are designed for long high-speed railway tunnels and are used in tunnel zones where trains can change from one tube to the other. When they are closed, lane change gates are used for the aerodynamic separation of the two tubes in normal operation or, in the event of an incident, in order to reduce smoke build-up in the counter tube. When they are open, they allow continued – albeit limited – use of the tunnel if sections are closed for maintenance or due to breakdowns.

The lane change gate is designed for assembly in the tunnel and consists of modular stainless steel support frames with refractory cover plates. The integrated insulator allows the catenary to be enclosed when live. An ingenious drive and locking concept, which prevents uncontrolled movement of the door leaves, opens and closes the gate in less than two minutes and meets the SIL-4 safety level. In the event of an incident or power failure, the gate leaves can be operated simply by means of a hand crank. The control system is integrated into the tunnel control system and allows remote control and monitoring of the gate.

Technical Specifications

Version:

2-leaf

Dimensions:

4‘080 mm x 6‘550 mm

Fire resistance:

90 Minutes at 160°C

Pressure/suction load::

± 20 kPa for 1 Million load changes ± 10 kPa for 2 Million load changes

Leakage surface:

< 0.5 m2

Service life:

> 30 Jahre

Safety requirement:

SIL-4

Arrangement:

In the main tunnel or in the lane change zone

Special design::

Upon request

Optional:

Integrated escape doors

Emergency stop gates

This robust fire protection sliding door is designed for the evacuation of large numbers of people in high-speed railway tunnels. The integrated control system allows automatic opening and closing via the tunnel control system.

Technical Specifications

Version:

1-leaf

Dimensions:

2000 mm x 2200 mm / 3000 mm x 2200 mm

Fire resistance

EI90 acc. to EN 1634

Pressure/suction load:

± 20 kPa for two million load changes

Leakage:

min. 50 m³/h bei 100 Pa

Opening force:

100 N

Service life:

> 30 Years

Special design:

upon request

Sluice Gate

Sluice gates are used to compensate for and maintain pressure differences in the tunnel and can be designed for people and/or vehicles. A special feature of sluice gates is the lock control system that ensures that only the doors or gates are open on one side at a time.

In order to withstand the high pressure requirements in railway tunnels, the sluice gates are constructed of a welded stainless steel frame construction. If required, sandwich panels are screwed on for fire protection. High-quality inflatable seals minimize leakage. Personal protection strips on the main and secondary closing edges prevent the risk of injury, e.g. from jamming. Personnel and vehicle locks can be opened manually or electrically and close automatically, even in the event of a power failure. Both passenger and vehicle sluice gates can be supplied as swinging or sliding gates.

Sluice control

The core element of the sluice is the control system, which must work perfectly together with the individual elements such as the actuating pulse, venting of the inflatable seal and unlocking of the doors. Electromagnetic locks on all doors ensure that only the doors on one side are open at a time. If the airlock is part of the escape route concept, the corresponding requirements must be taken into account..

Technical Specifications

Version:

1- or 2-leaf

Dimensions:

Sluice for people:

 900 mm x 2‘200 mm / 1'700 mm x 2'200 mm /
1'700 mm x 2'500 mm

Sluice for vehicles:

3‘500 mm x 4‘000 mm / 4‘000 mm x 4‘000 mm /
5'000 mm x 4'000 mm

Fire resistance:

EI00, EI30 acc. to EN 1634

Pressure/suction load:

± 10 kPa

Leakage Sluice for people :

27 m3/h at 1 kPa (1‘700 mm x 2‘200 mm)

Leakage Sluice for vehicles

128 m3/h at 1 kPa (4‘000 mm x 4‘000 mm)

Service life:

> 30 Years

Special design:

Upon request

Optional:

Integrated escape doors for people in the sluice for vehicles

Cavern Gate

In addition to the technical requirements, it must also be possible to assemble and disassemble the cavern gates in the tunnel. For this purpose, the design is based on a modular stainless steel support frame. Cavern doors can be electrically and manually opened and closed.

Technical Specifications

Version:

2-leaf

Dimensions:

4‘000 mm x 5‘000 mm

Fire resistance:

---

Pressure/suction load:

± 2 kPa

Service life:

> 30 Years

Special design:

Upon request

Fitting chamber door

Power lines supply the railway tunnels with power, which are regularly connected in the fitting chambers along the main tube. Fitting chamber doors must therefore not only withstand the dynamic forces in the tunnel, but also explosions in the cable glands.

In order to meet these requirements, the fitting chamber doors are constructed of supporting stainless steel frames. The door profiles and hinges are massively reinforced. In the event of an explosion, the two stainless steel pressure relief diaphragms burst and protect the door from overload.

Technische Daten
            

Version:

            
            

1-leaf

            
            

Dimensions:

            
            

1‘540 mm x 2000 mm

            
            

Fire resistance:

            
            

---

            
            

Pressure/suction load:

            
            

+26 / -16 KPa (static)

            
            

Pressing load:

            
            

10 kPa (dynamic) at> 1 Million. load changes

            
            

Bursting pressure:

            
            

16 kPa

            
            

Bursting surface:

            
            

2x 0.5m2

            
            

Service life:

            
            

> 30 Years

            

Special Constructions

Elkuch is specialized in technically high-quality door and gate systems to meet the highest demands. In addition to standard solutions for railway tunnels, we also develop and manufacture custom-made products according to customer requirements. A selection of successfully transferred systems:

  • Visitor window
  • Mobile maintenance gate
  • Cavern gates
  • Prefabricated wall element

Visitor window

A tunnel can be shown, preferably through a visitor window. The stainless steel support structure is provided with break and impact resistant safety glass on three sides. Access to the visitor window is provided by 1 or 2-leaf swinging doors with fire protection.

Technische  Daten

Dimensions:

Upon request

Fire resistance:

EI90 acc. to EN 1634 (Türen)

Pressure/suction load:

± 10 kPa

Leakage:

60m3/h m2 at 10kPa

Service life:

> 30 Years

Mobile maintenance gate

The mobile maintenance gate (MET) is a special rail-bound vehicle with a folding gate that closes the tunnel cross-section at defined positions in the Gotthard base tunnel for maintenance purposes.

Technical Specifications

Version:

1 Element with 2 foldable side leaves

Dimensions:

40.62 m2

Fire resistance:

---

Pressure/suction load:

± 6 kPa, 1 Million load changes

Service life:

> 30 Years

 

Cavern Gates

In addition to the technical requirements, it must also be possible to assemble and disassemble the cavern gates in the tunnel. For this purpose, the design is based a modular stainless steel support frame. The structure is equipped with fire protection panels to ensure fire protection capability. Cavern doors can be electrically and manually opened and closed.

Technical Specifications

Version:

1- or 2-leaf

Dimensions:

12‘370 mm x 3‘965 mm

Fire resistance:

EI90 acc. to EN 1634

Pressure/suction load:

± 10 kPa

Service life:

> 30 Years

Sonderanfertigung:

auf Anfrage

Prefabricated wall element (PCE)

With the aim of reducing installation times in the tunnel by 90%, Elkuch developed the "Plug-In Crosscut Element" (PCE). As many systems as possible are mounted and tested on a high-precision wall disc. A special assembly device then makes it possible to move several wall elements in the tunnel during one shift.

Technische Daten

Version:

Rail and road Wall element from concrete or steel

Manufacture:

Upon request

Metro – the tailor-made challenges

Metro systems are the arteries of modern cities.
People, machines and infrastructure must be perfectly coordinated in the tightest of spaces.
Elkuch develops and supplies door and gate systems that meet the various requirements of a metro system.

Adaptable product portfolio
Elkuch systems are designed and manufactured in accordance with system-dependent requirements.

Possible applications include:

  • Portal gate
  • Escape doors
  • Rescue doors