Airport Services Tunnel

The Airport Services Tunnel (TSA) formed part of the strategic infrastructure works included in the expansion of Madrid-Barajas Airport, one of the largest airport development projects undertaken in Europe. The tunnel was designed to provide a direct connection between the future Terminal T4 and the Satellite Building located within the airfield area, enabling the automated transportation of passengers, baggage and service vehicles through a high-capacity underground system. The project comprised the construction of a 2,800 m long reinforced concrete tunnel, running beneath the airport aprons and the third runway

From a structural engineering perspective, the tunnel was designed to withstand the exceptional loads generated by airport operations. The reinforced concrete structure was engineered to resist loads of up to 680 tonnes, significantly exceeding those imposed by the largest commercial aircraft in operation at the time. The TSA consists of two superimposed levels, each divided into three spans. The central span of the upper level, measuring 13 m in width, accommodates the APM (Automatic People Mover) system, while the lateral spans are dedicated to airport service vehicles. The lower level houses the Automated Baggage Handling System (SATE), one of the key technological components of the new airport complex

ERSIGROUP participated in the supply, fabrication and installation of reinforcement for foundations, columns, retaining walls, slabs and other critical structural elements. The scale of the project and the demanding construction schedule required the implementation of advanced reinforcement industrialization processes. Prefabricated reinforcement cages for circular columns were utilized, together with large preassembled reinforcement units for retaining wall buttresses and pumping station structures, with some assemblies reaching weights of up to 5 tonnes. This approach minimized work at height, improved worker safety and significantly increased installation productivity

For the reinforcement of slabs and walls, industrialized unidirectional reinforcement panels were employed to ensure accurate bar spacing, proper concrete cover and compliance with project specifications. In addition, specially prefabricated reinforcement assemblies were developed for the structural beam-to-slab joints within the upper deck, where the complexity of the reinforcement geometry would have made traditional bar-by-bar installation highly labour-intensive. The combination of prefabrication, specialized logistics and industrialized installation methods accelerated construction cycles while maintaining the highest standards of quality and traceability

The implementation of industrialized reinforcement solutions developed by ERSIGROUP enabled construction rates of up to 340 m²/day for slabs and 210 m²/day for walls, contributing significantly to the successful delivery of one of the most technically demanding underground structures associated with the Madrid-Barajas Airport expansion programme

KEY MILESTONES

• Construction of a 2,800 m long airport services tunnel
• Strategic infrastructure forming part of the Barajas Airport Expansion Programme
• Underground connection between Terminal T4 and the Satellite Building
• Structural design capable of resisting loads of up to 680 tonnes
• Two-level reinforced concrete structure comprising six primary spans
• Upper central span measuring 13 m in width, accommodating the Automatic People Mover (APM) system
• Lower level dedicated to the SATE Automated Baggage Handling System
• Prefabrication of reinforcement cages for circular reinforced concrete columns
• Fabrication and installation of preassembled reinforcement units weighing up to 5 tonnes for retaining walls and pumping structures
• Use of industrialized unidirectional reinforcement panels for slabs and walls
• Development of specially prefabricated reinforcement assemblies for complex structural joints
• Construction productivity reaching 340 m²/day in slabs and 210 m²/day in walls
• Implementation of advanced reinforcement fabrication, prefabrication and installation processes developed by ERSIGROUP, optimizing construction schedules, quality control, safety and productivity