An infrastructure modernisation project with a vision.

The initial situation.

The Federal Roads Office is preparing the operational infrastructure of the Bubenholz tunnel for the planned comprehensive refurbishment in 2030. The lighting system was the top priority. Rather than waiting, the project management decided to begin with an advance modernisation measure as early as 2025.

The goal: install new lighting technology with minimal interruptions, test it in parallel, and build an architecture that seamlessly prepares for the future comprehensive refurbishment.

The strategy: parallel installation under live conditions.

Intelligent renewal of lighting in the Bubenholz tunnel

The core concept is simple — but highly complex in implementation: the modern lighting grows alongside the old system during controlled night closures. Only after a complete functional check and system integration is the old system shut down and subsequently dismantled. The final switchover takes place without any operational interruption — in a single closure period.

This approach avoids the risks associated with lengthy road traffic disruptions and creates a buffer for thorough quality assurance.

Technical components and partnership:

cablex works with leading specialists.

Siteco Switzerland AG supplies LED luminaires with dimmable technology. They enable drivers to quickly adapt their eyes to the brightness inside the tunnel — a critical safety function.

Officine Rigamonti (Switzerland) contributes emergency lighting and escape route signalling systems. Essential in the event of an evacuation.

Studer Cables supplies specialised armoured cables with optimised cross-sections. The cable ducts are made of stainless steel — a material that lasts for decades under tunnel conditions.

DALI control.

The DALI system (Digital Addressable Lighting Interface) enables remote dimming and switching functions, groupings for different zones and real-time monitoring. Future expansions are also possible without rewiring.

Redundancy and risk management.

A major project in an active tunnel requires multi-layered safety concepts:

Network-alternating installation

The lighting is distributed across different phases. If one phase fails, the tunnel remains adequately illuminated.

Dual power supply

Transit lighting runs on both the normal grid and the emergency grid — operational continuity even in the event of power outages.

Logistical safety net

A cablex warehouse in Dielsdorf (10 km from the tunnel) guarantees rapid supply of materials and spare parts. This proximity is crucial in tunnel operations.

On-site quality management

A Safety Leader reviews all project phases. Special deployment checklists ensure that every installation team follows precise specifications — from clearance profile measurements to correct bolt torque. All installations are photographically documented.

Migration without operational interruption.

Project manager Humberto De Sousa Pires and site manager Marco Rütti have developed a detailed plan for the "migration phase":

Phase 1: Preparation

Kick-off with FEDRO, engineers and subcontractors. Coordination of technical details.

Phase 2 — Parallel installation:

During night closures, the following steps are carried out sequentially:

Cable duct replacement and new installation (two coordinated teams)
Cable pulling and laying (subcontractor Zumak AG)
Installation of adaptation and transit luminaires
Connections and measurements

Phase 3 – Testing

Complete functional check according to the test plan with individual, combined and overall tests.

Phase 4 – Go-Live

After remediation of any defects, the switchover takes place in one closure period. The old components are dismantled and professionally disposed of.

Expertise and references.

cablex acts as a strategic partner of FEDRO with:

200 employees in infrastructure installation and operations
Tunnel Soliwald BSA (2019–2021): reference project of similar complexity, parallel installation under traffic, successful acceptance
Proven subcontractors: Spina Montagen GmbH for efficient, safe cable duct installation; Zumak AG with decades of experience in road infrastructure

Conclusion.

The project N11/60 TBUB IS BSA demonstrates how strategic infrastructure management works:

Planned, not improvised: advance modernisation with FEDRO project management
Risks minimised: parallel installation, redundancy, quality assurance
Operations not interrupted: well-thought-out migration
Future-proof: preparation for the 2030 refurbishment already integrated
Partnership in practice: specialist suppliers, proven subcontractors, close FEDRO coordination

For road users: a safer and more reliable tunnel — without road users being affected by traffic jams.

For infrastructure managers: a flagship project for strategic lifecycle management.

Project information

Client: Federal Roads Office FEDRO, Winterthur branch

Contractor: cablex AG, Zurich

Project manager: Humberto De Sousa Pires

Site manager: Marco Rütti

Duration: Q2 2025 – Q1 2026

Maintenance section: N11/60, kilometre 1.470–2.070

Municipality: Opfikon, Canton of Zurich

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