The segments are the prefabricated elements needed for tunnel lining

The new facility will produce two prefabricated segments every 7 minutes at full capacity, increasing productivity by 30% and reducing CO2 emissions by approximately 140 tonnes per year

Webuild is a global leader in underground excavation, with approximately 60 TBMs worldwide, 30 of which are in Southern Italy, where the company is carrying out 19 projects that currently employ 7,500 people.
 

Milan, 11 December 2024 – A new industrial initiative from the Webuild Group has taken root in Southern Italy, highlighting technological innovation and Italian excellence in the infrastructure sector. In Bovino, a municipality located on the border between Campania and Apulia, the Group has inaugurated one of the world’s largest automated facilities for producing segments used to line the tunnels of the Naples-Bari high-speed railway. 

These prefabricated segments are essential for tunnel construction. They are assembled on-site to form a continuous ring, providing structural stability to the tunnels. The plant's highly automated production processes offer an efficient solution to enhance construction speed and efficiency. They also ensure the highest safety standards for workers.

Bovino's new facility, named Roboplant 2, is an evolution of Roboplant 1 — the first automated factory for segment production, inaugurated by Webuild in Belpasso, Catania, Sicily, just one year ago. Roboplant 1 has already produced approximately 25,000 segments for the Group’s railway projects on the island. In Belpasso, the Etnaplant facility is also operational, providing both manual and automated support to Roboplant 1. Roboplant 3 is set to become operational between 2025 and 2026 in Dittaino, in the province of Enna. Once complete, the three Sicilian factories will work together to supply segments for the high-capacity railway line linking Palermo, Catania, and Messina.

Overall, the four facilities are expected to create around 450 jobs, mainly from local recruitment. This includes both current and future hires. This is a clear demonstration of Webuild’s commitment to modernising infrastructure in Southern Italy. The Group is currently managing 19 active projects, which involve the construction of over 300 kilometres of new high-speed, high-capacity railway lines. Today, Webuild employs 7,500 people, including both direct staff and subcontractors. Since the start of these projects, the Group has collaborated with 4,300 partner companies.

Bovino's facility represents a major technological advancement in the production of prefabricated segments. It includes high-level automation processes and uses robotics and Artificial Intelligence to achieve top-tier safety and green productivity goals. Every 7 minutes, two segments will be produced, bringing the plant’s overall production capacity to 48 rings per day. This will enable the supply of over 1 million cubic meters of segments for the six Tunnel Boring Machines (TBMs) planned for the excavation of the Hirpinia and Orsara tunnels on the Naples-Bari line.

Equipped with two independent automated production lines, Bovino's facility will operate with the highest safety standards while accelerating the delivery of prefabricated segments to construction sites. The plant is expected to boost overall productivity by 30% and reduce its environmental impact, especially by cutting out the need for long-distance segment transportation. Additionally, its energy-efficient design will prevent the emission of around 140 tonnes of CO2 annually.

With these factories, Webuild further strengthens its global leadership in underground tunnelling. The Group currently boasts one of the largest TBM fleets in the world, with approximately 60 machines, including those already in operation, under assembly, ordered, and those yet to be ordered for ongoing projects. Of these, approximately 40 TBMs are planned for projects in Italy, with 30 of them dedicated to the South. Meanwhile, in the South, Webuild is also advancing its training and employment activities through the “Cantiere Lavoro Italia” programme, which aims to hire 10,000 people in Italy by 2026, with 80% of those positions based in the South.