Nowadays, road tunnels are highly complex infrastructures that require diverse and advanced equipment. Technological developments and regulatory updates have increased the challenges in terms of engineering and safety management due to the unique characteristics of these passages.
In this context, the European Directive 2004/54/EC, has been a significant step forward in establishing minimum safety requirements for tunnels over 500 meters in the road network. These regulations ensure a homogeneous and rigorous safety standard, which is essential for user protection and the operational efficiency of infrastructure.
Elements such as lighting, markers with reflectors, pavements, emergency exits, drainage systems, surveillance systems, fire protection, ventilation, and communication systems must be included in projects to meet current requirements.
For this reason, the supporting infrastructure for these devices must be resistant to adverse conditions inside the tunnel, such as corrosion and impact. At Unex, we have played our part in this evolution by providing innovative, customised solutions that have contributed to meeting safety standards for tunnel installations across Europe. In this article, we explore three success stories in which we have used our technical expertise and production capabilities to assist our clients in adapting these vital road infrastructures to European standards.
Challenge: anchored LED markers to abutments
At the beginning of 2017, we were challenged to offer the ideal product for cable routing and protection for the installation of markers in three tunnels in Catalonia, Spain, which required updating according to new regulations. These projects, tended by the Spanish Ministry of Transport and Sustainable Mobility, included the N-340 tunnel through Vallirana, the A-27 tunnel connecting Valls with Montblanc (Tarragona Province), and the B-40 tunnel between Viladecavalls and Abrera (both in Barcelona Province).
According to Article 2.14.5 of the Spanish Royal Decree 635/2006, marker lights should be placed every ten meters outside the boundary lines. In addition, as the length of the interurban tunnel exceeded 500 meters, marker lights had to be anchored to the sidewalls (abutments) at a height of approximately 70 centimeters and also spaced 10 meters apart.
Going beyond regulatory requirements, it was decided to equip the tunnel with LED technology, which required an appropriate cable management system.
With 60 years of specialisation in manufacturing innovative insulating cable management systems, we knew we could provide a superior solution tailored to the specific installation needs with the advantages of surface installation.
Tailor-made solution
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After several tests and trials, we successfully developed an insulating trunking system with integrated LED lights.
With our aluminium-coloured Trunking 93 made of U23X with a lid of 80 mm, it was perfectly integrated with Norka’s (Swareflex) LED marker lights, meeting the technical requirements of our client.
The performance of the raw material of our trunking, as well as the aesthetics of the installation, led the owner to prescribe our solution for both LED marker lighting and emergency lighting power supply.
Some advantages of the Trunking 93 include the following:
- Insultating and anticorrosive system: ideal for environmental conditions inside tunnels.
- Flexible system: the system allows easy integration with other devices.
- High impact resistance: this material complies with the IK10 standard.
- Regulatory compliance: this ensures conformity with various national and international regulations, including European directives on tunnel safety.
Vallirana bypass tunnel on the B-24 motorway
The first success story, year 2019. Located in the Province of Barcelona, the Vallirana Bypass on the B-24 motorway is an outstanding example of new tunnel design.
In fact, due to the technical difficulty involved in the construction of the final section, the state-of-the-art safety measures, and the integration into the environment, this tunnel received the Best Infrastructure Award 2019, conferred by the Council for Infrastructures of Catalonia (Consell Assessor d'Infraestructures de Catalunya – CAdIC).
In this tunnel, which is a critical section of the N-340 road, Norka’s (Swareflex) LED lights integrated into Unex’s Trunking 93 offer a durable solution that is resistant to corrosion and impacts, ensuring continuous operation even after several vehicle accidents inside the tunnel.
Coll de Lilla Tunnel (A-27 between Valls and Montblanc)
Second success story, year 2023. Thanks to the impact resistance of the Trunking 93, demonstrated after four years of intensive testing in the Vallirana Bypass Tunnel (N-340), the Spanish Ministry of Transport and Sustainable Mobility once again placed its trust in us to replicate the marker and emergency lighting as well as the power supply solution. This time, in the new Coll de Lilla tunnel.
Located in the Province of Tarragona, this A-27 tunnel connects Valls with Montblanc. It comprises two twin tunnels of 1.5 kilometers in each direction with two lanes each.
Once again, the implementation of the Unex solutions has enabled compliance with the strict safety and operational requirements set out by European and national regulations.
B-40 Tunnel between Viladecavalls and Abrera
Third success story, year 2024. Inaugurated in February, this is another significant infrastructure project for the Province of Barcelona. The B-40 tunnel connects Viladecavalls with Abrera, and according to data from the Spanish Ministry of Transport and Sustainable Mobility, the new dual carriageway envisaged by this project will bring "significant benefits in terms of safety, speed, and costs to the more than 43,000 vehicles expected to use this route daily, 20% of which will be heavy vehicles" (Magazine Revista Tramos, N° 746, April 2024, page 4).
Here, the aluminium-coloured Trunking 93 again powered the autonomous emergency lighting and LED marker lights.
Unex’s solution keeps the cabling organised and protected, preventing corrosion and ensuring infrastructure safety against potential impacts and adverse conditions.
Unex: 60 years of customer orientation
In conclusion, these three experiences demonstrate, once again, our clear customer orientation, primarily due to our team, which enables a close, professional, and 100% technical approach. Additionally, our six decades of experience in the electrical sector, daily proximity to our clients, and our presence in international norm-setting committees allow us to offer the best solutions.
And you, do you know us yet? I
f you have a project, do not hesitate to contact us. We would be delighted to help you.
On the Unex blog, we cover a wide range of topics of interest and share experiences from our clients. We remind you that all legal information and information regarding compliance with applicable regulations can be found on our official website. We invite you to consult it for a more comprehensive and accurate understanding.
