Road Deck Resurfacing in 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 delivers impressive performance in the Mont Blanc Tunnel

The SUPER 1803-5 X scores top marks with its “Dash 5” technologies

It’s a mammoth project: current plans foresee the complete renovation and modernization of the Mont Blanc Tunnel over its full length of almost 12 km by 2042. Working on the project are: two wheeled pavers from Vögele – a latest-generation SUPER 1803-5 X and a SUPER 1303-3i.

Modernization in Stages

Around two million vehicles a year travel through the 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 corridors in the European road network. Over almost the next two decades, the infrastructure is to be modernized in stages and the safety technology will be brought up to date. However, since the tunnel is of the utmost importance for tourism on both the French and Italian sides, it can be closed only for a few weeks – and countless nights – at a time.

Tolles Produkt

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 spaces, darkness, restricted visibility, strict safety requirements and a tightly scheduled project timeline. In just one night, the aim was to pave the entire section with a 5 cm surface course across a width of 6.5 m. In cases like this, everything depends on efficient machine technology, so the contractor chose to use a latest-generation wheeled paver from Vögele, the SUPER 1803-5 X.

The SUPER 1803-5 X is Vögele’s most powerful wheeled paver, and features numerous new technologies.

Efficient interaction between Vögele wheeled pavers and the Hamm roller.

SUPER 1803-5 X paving the surface course in the Mont Blanc Tunnel
In the tunnel: a Hamm roller in the foreground and the highly maneuverable and powerful SUPER 1803-5 X

paver in the background

With a laydown rate of up to 700 t/h, this representative of the Universal Class is Vögele’s most powerful wheeled paver and can pave widths of up to 8.25 m. This enabled the paving crew to use the SUPER 1803-5 X for the seamless paving of both carriageways in a single pass. Its particular agility also played an important role, its Pivot Steer steering brake reduces its turning circle to just 4.2 m, enabling it to maneuver with ease, even in the narrow tunnel. It was backed up by its “little brother”, the SUPER 1303-3i: this Compact Class paver allowed the paving crew to pave a total of three emergency parking and breakdown bays with a total length of 150 m and a width of 2.8 m parallel to the two-lane carriageway.

“The SUPER 1803-5 X is agile and quiet, and features cutting edge technology. 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 offers more functions and a very clear and logical layout.

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

View of the ErgoPlus 5 paver operator’s console of the SUPER 1803-5 X from above
Operator using the steering wheel of the paver operator’s console

Start-Up at the Press of a Button Increases Efficiency

The technologies of the new “Dash 5” generation brought a number of advantages on this tunnel project, among other things, the new automatic and comfort functions of the SUPER 1803-5 X. The convenient Paver Access Control (PAC), for example, was a great help to the crew when starting up and shutting down the paver. The crew was able to use the control unit on the screed to control all initial steps from the ground just by pressing a series of buttons: turning on the lights and starting the engine, putting up the hardtop, lowering the screed, and booting up the machine control system. 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 was a great help in the Mont Blanc Tunnel in more ways than one. Apart from being easy to activate without any installation effort or setup time, the new lighting system also provided optimal illumination: the package contains additional integrated LED lights in the hardtop and in the cross-member of the control panel, illumination of the tow point rams, freely-positionable headlights, and a special hardtop extension with powerful LEDs. These evenly illuminate the working area to a width of up to 10 m and a distance of up to 4 m behind the screed. “This enabled us to set up and prepare the paver quickly without the need for additional lighting and then work in ideal 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 to a distance of up to 4 m behind the screed.

Lower Noise levels and Reduced Emissions

Another benefit in the Mont Blanc Tunnel: the SUPER 1803-5 X has a drive concept that significantly reduces both fuel consumption, carbon emissions, and noise. The major role here is played by the improved EcoPlus low-emissions package. This reduces fuel consumption and, in combination with other measures, also cuts noise emissions. The latest-generation AB 500 TV extending screed also works with lower noise levels than before. “These factors are critical, especially in narrow, enclosed spaces like the construction site here in the tunnel,” says foreman Antonio Lachi. The new installation aid for bolt-on screed extensions and the efficient heating of the compacting systems also help to minimize the 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 is less noisy in operation and minimizes set-up times.

The Power Tunnel provides a consistently high head of material in front of the screed and ensures even 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 optimized material management, which ensured a consistent supply of material and an ideal head of material in front of the screed, the paving crew achieved a high standard of paving quality. All this despite the tight deadlines and the asphalt having to travel for around two hours in winter temperatures. The Mont Blanc Tunnel shows just what the “Dash 5” generation can achieve in day-to-day situations: more convenience, simple operation and greater efficiency when paving.

Project Details

Surface course rehabilitation in the Mont Blanc Tunnel between Chamonix-Mont-Blanc (France) and Courmayeur (Italy)

Paved distance:

  • 400 m with SUPER 1803-5 X – pave width 6.5 m
  • 150 m with SUPER 1303-3i – pave width 2.8 m

Pave width:

  • 6.5 m

Layer thickness:

  • 5 cm

Machines deployed:

  • 1 Vögele SUPER 1803-5i / AB 500-5 TV
  • 1 Vögele SUPER 1303-3i / AB 340-3 TV
  • 1 Hamm HX 90i roller

Mountain scenery, dusk

Please visit our product pages for details and further information.

Universal Class

Universal Class