Tunnel element factory

The large production and port facilities of the Fehmarnbelt project in Rødbyhavn are ideal for building the new ships that will strengthen the Royal Danish Navy Fleet.
The three municipalities of Lolland, Guldborgsund and Vordingborg have highlighted in unison the major production opportunities available when the tunnel element manufacturing in Rødbyhavn ends in a few years’ time.

Strategically strong location
“In Rødbyhavn, we have a gigantic work harbour and one of the world’s largest production facilities, that in all cases will be put to new use when the Fehmarnbelt construction is completed. With just ten minutes to Germany, Central Europe next door and open access to the Baltic Sea, it is a strategically strong location, with ideal potential for expansion or adaptation – whatever the need may be,” states Holger Schou Rasmussen, Mayor of Lolland Municipality

He also highlights the close cooperation already existing between Denmark and Germany in the emerging Fehmarnbelt region. A cooperation that can be built on. There is also positive experience of attracting and retaining skilled workers:
“We have seen thousands of workers that have come to work on building the world's longest immersed tunnel, so we are confident we can recruit the right workforce for other major tasks too.”

Will create growth and development
Simon Hansen, Mayor of Guldborgsund Municipality, stresses:
“New activities in Rødbyhavn will create growth and development – not just locally, but for the whole of Lolland-Falster and South Zealand. Large investments are at stake. With Rødbyhavn as the centre for a new fleet production, our entire region will receive a major boost.
It’s not just about jobs and new business development, it is also about education, settlement, networks, cooperation, competitiveness and innovation.”

A visionary proposal
Mikael Smed, Mayor of Vordingborg Municipality, adds:
“We are facing serious challenges – not only in Denmark, but internationally. We share the responsibility to ensure safety and stability. It is important to cooperate, think innovatively and act quickly. Our region can offer well-functioning port and relevant production facilities to help solve serious capacity issues. Our proposal is a visionary contribution to a sustainable and future-proof solution.”

A 21,000-ton concrete element has just emerged from the casting area at the tunnel factory near Rødbyhavn. The element is the first of a total of 10 special elements, which are key components in the construction of the Fehmarn Belt Tunnel, according to Femern A/S.

The element consists of two levels, with the lower level serving as a basement that will house the tunnel's extensive electrical installations. Above, on the "ground floor" of the element, are the separated tunnels for rail and road traffic.

In addition to the basement, the element is equipped with a lay-by in the motorway tunnel, where technical personnel can park without disrupting the rest of the traffic and easily access the basement. This allows for smoother operations and enhances the safety within the tunnel.

A Unique Solution
The use of special elements is the single largest innovation in the Fehmarn Belt Tunnel, which otherwise largely follows the model of the Øresund Tunnel.

“The special element is a unique solution that consolidates the tunnel’s technical installations into 10 hubs, rather than spreading them along the entire 18 kilometers of the tunnel. This reduces both the amount of concrete needed for casting and the excavation of the seabed. At the same time, the solution enables efficient traffic flow and provides safe access for staff who will maintain the tunnel,” says Jens Ole Kaslund, Technical Director at Femern A/S, project developer and subsidiary, of the Danish state-owned company Sund & Bælt.

Over a Year of Casting Process
The special element is 39 meters long and approximately 13 meters high, equivalent to a 4-story building. In addition to the 10 special elements, the tunnel contractor, Femern Link Contractors (FLC), will cast 79 so-called standard elements, each of which is 217 meters long and weighs 73,500 tons.

The special elements are cast almost like a house in three stages: first, the basement is cast, then the walls, and finally, the rooftop. The casting process for the first special element has been ongoing for just over a year, during which valuable experience has been gained for the work on the subsequent elements. Special element number two is already in the process of having its basement cast. These elements can be cast over a longer period since only 10 are needed, each placed approximately every two kilometers along the total 18 kilometers of the tunnel.

“We are very pleased that the casting of the first special element has been successfully completed. These days, we allow ourselves a moment of celebration, but we know that there is still a long way to go, and we have great respect for the complex work that still lies ahead,” says Nick Geurts, Division Manager at FLC, responsible for the production of the special elements.

Five Standard Elements Completed
On the tunnel factory's five other production lines, FLC has completed the first five standard elements and is working on the next ones in line.

The first special element is expected to be lowered into place off the Danish coast during 2025.

The construction of the Fehmarn Belt Tunnel is the largest infrastructure project in Denmark's history and the largest construction site in Northern Europe. The 18-kilometer-long tunnel will be the longest immersed tunnel in the world. Once completed, it will be possible to cross the Fehmarn Belt in 7 minutes by train and 10 minutes by car.

Facts about the Special Element

• Number: 10
• Length: 39 meters
• Width: 47 meters
• Height: 13 meters
• Weight: 21,000 tons

The tunnel element factory, the construction harbour, and the adjacent land area have huge potential, according to Lolland Municipality. International investors are ready.

The Danish Parliament's decision to make the tunnel element factory in Rødbyhavn permanent opens up perspectives that could have a decisive impact on the development, not only in Eastern Denmark but throughout the entire country, says Lolland Municipality.
“Rødbyhavn could become the center of Denmark's green transition,” says Thomas Knudsen, municipal director of Lolland Municipality.
At the conference "Fehmarn Green Build & Construction Challenge" on October 10th at Engestofte Manor near Maribo, Thomas Knudsen outlined a scenario where the tunnel element factory, the associated construction harbour, and it´s upland, are developed into a gigantic industrial business district with companies that not only drive the Danish green transition but also attract foreign projects and investors.

The future dream scenario
Lolland Municipality has been working for some time on plans for this future dream scenario, which is still in a clarification phase but that currently is already attracting international interest.
Municipal Director Thomas Knudsen, along with several local business development actors, recently participated in the international investor fair Expo Real in Munich, where he met investors who not only are aware the future opportunities in Lolland, but who are also ready to invest.
“We could have sold the commercial areas already last Monday,” remarked Thomas Knudsen.

The opportunities are unique
The future scenario is still a dream, but Thomas Knudsen and Lolland Municipality believe that the potential is great and that the opportunities are unique, not only for Denmark, but also in a European perspective.
“The area around Rødbyhavn is one of the few, if not the only place, where motorway, railway, and harbour meet, where no city stands in the way of expansion, but instead, there is a large upland area that can be utilized,” says Thomas Knudsen.
If something similar were to be developed elsewhere, the approvals, etc., would take at least 20 years.
“On Lolland, we have the locations, and only an approved local plan is needed to realize the plans,” says Thomas Knudsen, who points out that expansion of offshore wind needs to increase 100-fold by 2032. A significant part of the necessary production of elements for the wind turbine industry can take place on Lolland, and this, along with other green initiatives, could create an international hub for productions based on renewable energy.

Sund & Bælt is now inviting potential operators to a market dialogue regarding the takeover of the tunnel element factory in Rødbyhavn and its continued operation after 2028, when the Fehmarn connection opens.
As the world’s largest concrete element factory, it has significant potential to supply other projects and purposes, such as tunnels, wind turbines, and other future Sund & Bælt projects. The market dialogue also aims to identify additional potential future uses for the factory.
Sund & Bælt expects to tender a long-term agreement concerning the operation, maintenance, and business development of the tunnel element factory and its associated work harbor to an operator starting in 2028.

Creating the Best Possible Conditions
To create the best possible conditions for the takeover of the factory’s operations, Sund & Bælt is now inviting potential companies and organizations to a so-called market dialogue, informs CEO of Sund & Bælt, Mikkel Hemmingsen.
“Winning a concession for the world’s largest element factory is, of course, a large and highly complex task. Therefore, it is crucial that we engage in dialogue with potential actors to understand their needs, competencies, and opportunities. This enables us to create the right framework for the future operation and development of the factory,” says Mikkel Hemmingsen.

The Factory is Here to Stay
The decision to retain the element factory was passed by the Danish Parliament on December 14, 2023. The law ensures that the factory and the work harbor in Rødbyhavn can be preserved and continue under state ownership through Sund & Bælt, once the production of tunnel elements for the Fehmarn Belt Tunnel is completed.
The factory can, in principle, produce many types of products for various purposes and projects such as tunnels or wind turbines.
The market dialogue consists of an introductory meeting and a tour of the factory in Rødbyhavn. Additionally, interested operators will be asked to complete a questionnaire, after which the further process will commence.
The insights from the market dialogue will be used to draft a tender for a long-term agreement, expected to take effect from 2028.

Facts
The element factory in Rødbyhavn is the largest of its kind in the world. It consists of three production halls designed to produce the 89 concrete elements needed for the Fehmarn Belt Tunnel.
A key part of the facility is the large work harbor, which ensures easy access to raw materials and the shipping of elements.
The total production area is 1.5 million m², equivalent to approximately 210 football fields.
It is estimated that society will save both resources and costs by retaining the factory, as upcoming infrastructure projects can be realized with savings in both time and money.