A traditional production method in an excavated casting basin will require a basin of about 220,000 m², excavated up to a depth of about 10.5 m below sea level. In addition to this, an area of about 300,000 m² will be required for site facilities, concrete batching plant etc.

A temporary harbour will need to be constructed for the supply of materials and equipment, and adequate access by road will be required. In the event of an industrial production facility being used, the area for the basin can be reduced to about half the size of the basin for a traditional construction method, but the overall area will need to be the same. It is expected that up to 1,000 staff will work at each site at peak production periods.

A dewatering system will ensure dry working conditions in the basins. The excavated soil will be stored temporarily in an area adjacent to the basins and the site facilities, and can be used to return the site to its original state after production of the elements. As an alternative, the basins and site area can be turned into a marina or industrial harbour area.

The production sites must meet all legal and local environmental requirements with regard to noise, dust, vibration, dewatering etc. Main activities such as concrete casting take more than 24 hours and will mean working around the clock. The anticipated requirements for one tunnel element production site with four production lines are as follows:

• Water: The estimated average amount of water used for concrete production and used by personnel on site is 400 – 500 m³/day. The peak water consumption is estimated to 50 – 60 m³/hour.
• Sewage: All water used per day will end in the sewage system with exemption of the water added to the concrete mix. This results on average in 300-400 m³/day of sewage water.
• Electricity: The total estimated consumption is 1,000 kVA.
• Traffic of trucks: The number of trucks coming to the site on a daily basis is depending on where the concrete production takes place (on site or not on site). If the concrete is not produced on site in the initial phase, the average number of trucks coming to the site is 300 trucks/day (on a “concrete casting day” 500 – 550 trucks/day). When the concrete is produced on site the average number of trucks coming to the site is estimated to 20 – 40 trucks/day. It is in this case assumed that the materials for the concrete (sand, gravel and cement) are delivered to the site by sea.
• Noise: It is assumed that the requirements regarding noise for heavy industry are complied with.
• Dust: It is assumed that the main transportation routes on site are asphalted to prevent dust due to transportation.

Figures on the production of tunnel elements (estimates)