Tunnel Waterproofing at Neuer Kaiser Wilhelm Tunnel – Cochem, Germany

Persistent Leakage in Historic Railway Tunnel

The Neuer Kaiser Wilhelm Tunnel—over 4.2 km long—is a critical railway corridor along the Moselle River, connecting the Cochem region to Germany’s wider transport network. Despite modern rehabilitation, sections of the tunnel developed persistent water ingress, especially:

• Along construction joints in the invert and walls
• At interfaces between old and new lining structures
• In microcracks resulting from settlement and seasonal movement

The leaks caused:

• Standing water on the track bed, risking safety and compliance issues
• Increased maintenance costs and drainage pump operation
• Degradation of concrete and corrosion of steel fixtures
• Operational challenges due to the high-traffic nature of the tunnel

Standard cement grouting had limited success sealing dynamic, saturated cracks without impacting train service.

EURAS® Gel Type B – Flexible Waterproofing for Transport Tunnels

After thorough evaluation, EURAS® Gel Type B was specified due to its:

• Self-penetrating hydroscopic action, displacing water in live leaks
• Compatibility with wet and variable-thickness concrete linings
• Elasticity to accommodate ongoing settlement and movement
• High-pressure injection capability for deep crack sealing

The project was performed in scheduled night closures to avoid disrupting rail traffic:

1. Mapping and marking infiltration areas using moisture detection and borehole cameras
2. Installation of injection packers along walls and invert joints
3. High-pressure injection of EURAS Gel Type B up to 180 bar to saturate cracks and cavities
4. Monitoring gel flow and back-pressure for confirmation of fill
5. Final watertightness verification before reopening to traffic