Use Case: Pipe Jacking

KALVEBOD BRYGGE CLOUDBURST TUNNEL

Collage: Inside view of tunnel surrounded by a 3D TBM and TPC software elements

Location
Copenhagen, Denmark

Owner
HOFOR A/S
Frederiksberg Forsyning A/S

Contractor
Joint Venture NCC Danmark A/S and Smet Group

Construction Period
2022 – 2024

TBM Type
Pipe jacking machine with pressurized bentonite suspension (Slurry)

Geology
Copenhagen Limestone, local flint bands, areas of mixed face and greensand limestone with groundwater at terrain surface

The Future in Real-time

KALVEBOD BRYGGE CLOUDBURST TUNNEL (COPENHAGEN)

Climate change is driving more frequent and severe weather conditions, including significantly more rain. Now and in the future, we will experience more cloudbursts, higher groundwater levels, and more storm surges. Therefore, it is essential to build climate protection solutions that help retain water when it pours down from above.
The Kalvebod Brygge Cloudburst Tunnel is a great example that will stand as a vital component protecting Copenhagen’s city centre from flooding during extreme weather events. The tunnel is one of several main waterways in the Copenhagen and Frederiksberg Municipalities’ cloudburst plan and will be able to collect cloudburst water from the neighbourhoods Frederiksberg and Vesterbro.
Once the tunnel is finished in 2027, it will be 1.3 km long and situated approximately 20 meters below ground in central Copenhagen. With pipes 2-3 meters in diameter and a storage capacity of 10,000 m³, the tunnel will serve as a buffer, temporarily holding cloudburst water inflow until it can be processed at the treatment plant.
Three temporary work shafts for the tunnelling were established in different locations in Copenhagen, and a permanent pumping station will be established at Kalvebod Brygge in order to enable controlled discharge into the harbour.
The Kalvebod Cloudburst Tunnel is owned by HOFOR A/S and Frederiksberg Forsyning A/S and was designed by NIRAS (shafts) and BabEng (tunnel). The tunnel and concrete were constructed by a joint venture between NCC Danmark A/S and Smet Group. NCC Danmark A/S constructed the three shafts via secant piling, excavation, and concrete work. In between these activities, Smet Group constructed the two tunnels between the shafts using closed-mode (slurry) technology. The Kalvebod Brygge Cloudburst Tunnel project exemplifies seamless tunnelling collaboration and technical precision.

Challenges
The tunnel alignment passes beneath dense urban infrastructure, including historic buildings and Copenhagen’s busiest railway hub, and runs within less than a meter of the Metro tunnel. This required not only precise engineering but also expert navigation of strict urban regulations, limited access restrictions, and specific health and safety requirements for compressed air works and heavy groundwater contaminations from former local gasworks. Continuous settlement monitoring in areas with active railway traffic and tunnelling under strict health and safety regulations – prohibiting personnel entry into the tunnel – made remote data access and real-time data integration imperative for project success.

TBM Operations in Real-time

How TPC Supported Kalvebod

TPC Bridges Construction and Supervision
The TPC platform was jointly used by the supervision team and the JV at Kalvebod. Integrated systems include the TBM, the slurry treatment plant, the intermediate jacking stations and the instrumentation for geotechnical monitoring (via FTP interface).

Supervision dashboard showing integrated TBM and slurry plant data in TPC

Shift Reports and Manual Data via Mobile App
Shift reports are added via the native TPC Mobile app — often directly in the tunnel or on-site. Rheological test protocols for the bentonite suspension are recorded by operations staff using the manual data interfaces and the TPC Mobile app. It works offline, enabling seamless on-site data capture even in areas with poor connectivity and is the size of a pocket.

TPC mobile and desktop app screenshots showing mobile shift reporting and manual bentonite test data

Monitoring Settlements
The project required precision tunnelling to stay within the narrow settlement limits. The geotechnical module transfers third party monitoring data into the tunnelling context, links it to the TBM parameters, and distributes the combined information over TPC functionalities, such as real-time overviews, settlement diagrams, and alerts.

Screenshot showing settlement monitoring data linked to TBM parameters in TPC overview

Real-time Views and Automated Reports
In daily operations, TPC was actively used for monitoring: real-time views are displayed on office screens and provide early warnings of irregularities. Retrospective analyses over 24 hours or seven days help prepare for meetings. The “time travel” feature allows visual reconstruction of specific tunnelling situations. This is complemented by automated daily and weekly reports that provide aggregated insights tailored to the addressee and support consistent documentation.

Screenshots pipe jacking: Intermediate Jacking station and the daily report from TPC software

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