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Resurfacing the carriageway inside the tunnel

Working in the tunnel: the foreground shows the paved surface course, whilst in the background, several workers can be seen standing next to the Vögele SUPER 1803-5 X wheeled paver.

July 2026 | Reading time: 6 min

New wheeled paver proves its worth inside Mont Blanc tunnel

SUPER 1803-5 X scores points with its “Dash 5” technologies

It’s a mammoth project: Mont Blanc tunnel, almost 12 km long, is to be completely resurfaced and modernised by 2042. Taking part in the project are two Vögele wheeled pavers - a new-generation SUPER 1803-5 X and a SUPER 1303-3i.

Modernisation in sections

Some two million vehicles a year travel through Mont Blanc tunnel. Since the 1960s, the tunnel has linked Chamonix in France to Courmayeur in Italy, making it one of the most important North/South axes in the European road network. Over the next almost two decades, the infrastructure is to be modernised in sections and the safety technology brought up to date. The tunnel is of key significance, not least for tourism, on both the French and the Italian sides, so it can only be closed for a few weeks - and countless nights - at a time.

A lot to do, but only one night to do it

As part of this project, contractor Cogeis SpA was commissioned to carry out extensive resurfacing work on a 400 m section of the tunnel. This was a challenge, as tunnel sites mean confined space, darkness, restricted visibility, enhanced safety requirements and a tight project plan. In just one night, the aim was to pave the whole section with a 5 cm-thick surface course across a width of 6.5 m. Cases like this depend on efficient machine technology, so the contractor selected a new-generation wheeled paver from Vögele, the SUPER 1803-5 X.

The SUPER 1803-5 X is Vögele’s most powerful wheeled paver, fitted with numerous new technical features.

Efficient interaction between Vögele wheeled pavers and the Hamm roller.

SUPER 1803-5 X paving the surface course inside Mont Blanc tunnel

In the tunnel: a Hamm roller in the foreground and the great manœuvrability and power of the SUPER 1803-5 X

Paver offering high manœuvrability and performance

With a laydown rate of up to 700 t/h, this Universal Class representative is Vögele’s most powerful wheeled paver and covers pave widths of up to 8.25 m. This allowed the paving crew to use the SUPER 1803-5 X to pave both carriageways without joints in a single pass. Its manœuvrability also played an important role, its Pivot Steer steering brake reduces its turning circle to just 4.2 m, enabling it to manœuvre with ease, even in the cramped tunnel. It was supported by its “little brother”, the SUPER 1303-3i: this Compact Class paver allowed the paving crew to pave a total of three emergency breakdown bays with a total length of 150 m and a width of 2.8 m in parallel with the two-lane carriageway.

“The SUPER 1803-5 X is manœuvrable, quiet and state of the art. New automatic functions or features like the integrated Light Package Plus were particularly helpful here in the tunnel.”

Lori Bibe, paver operator

New touch panel for digital applications: the ErgoPlus 5 paver operator’s console has more functions and at the same time, is very clearly arranged.

The steering wheel of the paver operator’s console is smaller than before, making it even easier to operate the buttons.

Bird’s eye view of the ErgoPlus 5 paver operator’s console of the SUPER 1803-5 X

Operator using the steering wheel of the paver operator’s console

Start-up at the touch of a button increases efficiency

The technologies of the new “Dash 5” generation were an advantage in this tunnel project, including, among other things, the new automatic and comfort functions of the SUPER 1803-5 X. Convenient Paver Access Control (PAC) supported the crew when starting up and shutting down the paver, for example. The team was used the control unit on the screed to control all the initial steps from the ground just by pressing of a button: turning on the lights and the engine, putting up the hardtop, lowering the screed and booting up the paver control unit. It enabled operators to switch on the integrated lighting in the dark tunnel and start preparing for work at once.

Integrated lighting saves both time and effort

The optional Light Package Plus of the “Dash 5” paver assisted in Mont Blanc tunnel in more ways than one: aside from simple activation (no assembly effort and no time spent setting up), the new feature delivered optimum illumination - the package comprises of additional integrated LED lights in the hardtop and in the cross-member of the control panel, illumination of the tow point rams, headlights which can be freely positioned and a special hardtop extension with powerful LEDs. These illuminate the working area evenly to a width of up to 10 m and a range of up to 4 m behind the screed. “As a result, we were able to set up and prepare the paver quickly without the need for additional lighting and then work in perfect lighting conditions,” says Lori Bibe, paver operator at Cogeis SpA.

Light Package Plus: integrated LEDs illuminate the working area evenly to a width of up to 10 m and a range of up to 4 m behind the screed.

Reduced noise and emissions

Another benefit inside Mont Blanc tunnel: the SUPER 1803-5 X has a drive concept which significantly reduces both consumption and emissions of CO₂ and noise, the primary contributor here being the optimised EcoPlus low-emissions package. This reduces consumption and, in combination with other measures, also cuts noise emissions. The latest-generation AB 500 TV Extending Screed also works with less noise than before. “These factors are critical, especially in cramped, enclosed job sites like the one in this tunnel,” says foreman Antonio Lachi. The new installation aid for attaching bolt-on extensions for screeds and the efficient heating up of the compacting systems also minimise set-up time. “The new extending screed is very user friendly and saved us a lot of time here,” says Lachi.

The new-generation AB 500 TV Extending Screed makes less noise in operation and minimises set-up times.

The Power Tunnel ensures an optimum head of material in front of the screed and thus consistent paving.

Focus on the extending screed of the SUPER 1803-5 X

SUPER 1803-5 X working in the tunnel, two workers standing to one side.

Successful stress test

In combination with the optimised material handling system, which ensured a consistent supply of material and an optimum head of material in front of the screed, the paving crew achieved a high standard of paving quality. All this in spite of the huge time pressure and the asphalt having to travel for around two hours in winter temperatures. So the Mont Blanc tunnel just shows what the “Dash 5” generation can achieve in day-to-day situations: more convenience, simple operation and greater efficiency when paving.

Job details

Replacing the surface course inside Mont Blanc tunnel between Chamonix-Mont-Blanc (France) and Courmayeur (Italy)

Paved distance: