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High suspense

High suspense

At 85m above ground, the Filstal Bridge is a high-speed railway and Germany's third-tallest bridge – powered by Bosch Professional.

Building the Filstal Bridge

It will take seven years to build the Filstal Bridge. And it will take seven seconds to cross it. One of the most anticipated construction projects in Germany, the Filstal Bridge (or "Filstalbrücke" in German) is a new high-speed ICE railway bridge that stands 85m tall and stretches 500m across the Fils Valley. Due to its unique tunnel-bridge-tunnel design, the construction has been pushing architecture, engineering, and power tools to new heights. To make tough work easier, we gave the builders of the Filstal Bridge our latest 18V cordless angle grinders with X-LOCK.

Building at new heights is tough work – but it's easier with Bosch Professional.

A construction worker shortens steel bars with a Bosch Professional 18V angle grinder on the Filstal Bridge.

Pioneering engineering

FILS VALLEY – "When we complete this 500m bridge, it will be a pioneering piece of engineering,” says Manfred May, construction manager at Max Bögl Group. It's the dead of winter and May is standing 85m above ground on a railway bridge still under construction. Below, cars speed along the Autobahn through the frost-covered valley. An ice-cold wind rushes around us as May looks across the Fils Valley toward the next tunnel. There's still quite a distance to go. Due to its unique structure, this one stretch of the new high-speed Stuttgart-Ulm ICE railway will take seven years to build. "And soon, high-speed trains will rush across this bridge in just seven seconds," May smiles.


Long way to go: At this stage, only three out of ten sections of the Filstal Bridge have been built.

Tough factors

What makes the Filstalbrücke so challenging? To begin with, it isn't technically one, but two bridges: A pair of single tracks run parallel across the valley, 30m apart, held up by slender Y-shaped pillars. "The two tracks are due to the separate tunnels,” May explains. And that's not all: "The high speed of the trains will exert great force on the bridge and its slim pillars. Even the tunnel entrances have to be supported by the bridge. And last but not least – the height! All of these factors present daily challenges.” To help make tough work at new heights easier, we gave the team a range of Bosch Professional cordless tools for more flexibility.


Manfred May, Construction Manager, Max Bögl Group
When we complete this 500m bridge, it will be a pioneering piece of engineering.

Manfred May, Construction Manager, Max Bögl Group

The Filstal Bridge is wrapped in a moving steel scaffolding that allows the team to grow the bridge across the valley.

"Growing" the bridge

In total, the Filstalbrücke will use up an estimated 770 tonnes of steel and 55,000 cubic metres of concrete – a lot of material for the crew to handle at such heights. The challenge was so big that bridge-building specialists Max Bögl and Porr joined forces to form the Arge EÜ Filstal working group. Together, they're using a special technique to "grow" the bridge across the valley. “We're working with a moving steel scaffolding, which wraps the newest section of the bridge from above," explains May. "When concreting is done, we release the bottom of the steel scaffolding and move it forward to the next section. This is how we're 'growing' the bridge across the valley."


The GWX 18V-10 SC Professional angle grinder and matching X-LOCK discs lie on steel reinforcement bars at the Filstal Bridge jobsite.

No time to lose

At these heights, you can't afford to drop a tool. "We need to have the right tools and accessories ready to go at anytime," says Martin Mayer, a foreman. "If anything is missing, it's a long way from up here to the tool depot. And that costs us time.” Today, the team needs to lay 160 tonnes of steel as soon as possible so that the concrete can be poured. Part of the job is to trim the bars to length so that they line up perfectly. Mayer reaches for the GWX 18V-10 SC Professional cordless angle grinder. It's still missing a disc, so he picks up an X-LOCK metal-cutting disc and "clicks" it onto the tool in one easy movement. You wouldn't know it, but this is his first time trying out the X-LOCK switching system.


Martin Mayer, Foreman at Max Bögl Group
We need to have the right tools and accessories ready to go at anytime. If anything is missing, it's a long way from up here to the tool depot. And that costs us time.

Martin Mayer, Foreman at Max Bögl Group

Bosch GWX 18V-10 SC Professional angle grinder with X-LOCK metal-cutter disc slicing through a steel bar.

Seconds to switch

Mayer looks impressed. “The X-LOCK system is really fast. You can change discs in a few seconds without even needing a key.” He takes a closer look at the GWX 18V-10 SC Professional. “With most angle grinders, you're always searching for the key," he says. "And it's a huge waste of time when the disc jams and the clamping nut gets stuck. Sometimes it's so tough to loosen the nut that you have to reach for a hammer...” Thanks to the X-LOCK mount on the GWX 18V-10 SC Professional, Mayer can now easily "click" the grinder disc into place. To switch accessories, he simply unlocks the disc by using the lever on the tool. After switching discs a few times, he grins: “I don’t even need to take off my gloves!”


The X-LOCK switching system is available with most Bosch Professional angle grinders.

Huge range of applications

The X-LOCK mount is available with most Bosch Professional angle grinders and compatible with over 130 accessories – even from different brands. Mayer can choose any X-LOCK accessory from Bosch Professional or even from Pferd, Austromex, Berner, and more. For metal processing alone, Mayer can choose from a wide selection of accessories, including cutting, roughing, fibre, SCM and flap discs, as well as cup and round brushes. And that's not all: The X-LOCK discs are backward-compatible. “The new X-LOCK discs even fit on our older Bosch Professional angle grinders," says Mayer. "That's a huge advantage, because we can upgrade our accessories without having to buy brand new tools.”


Martin Mayer, Foreman at Max Bögl Group
The X-LOCK system is really fast. You can change grinder discs in a few seconds without needing a key. I don't even have to take off my gloves!

Martin Mayer, Foreman at Max Bögl Group

Manfred May and Martin Mayer from the Max Bögl Group stand proudly at the Filstal Bridge jobsite with a Bosch Professional angle grinder in hand.

Proud to build

May comes over to join Mayer and together they glance across the valley to the distance ahead of them. “Every construction project is unique. You can always be proud to have been involved right from the start," says Mayer. "One day, when passengers speed across this bridge in seven seconds in a high-speed ICE train, when they emerge from the dark tunnel into sudden light, they will only be able to guess the challenges we had to overcome to build them this route.” As a bridge-builder, Mayer is proud to work on major landmarks. “When you finally see the end product, you know how much you've achieved. You can proudly tell your children one day: That was my construction site.”


Martin Mayer, Foreman at Max Bögl Group
Every construction project is unique. You can always be proud to be involved right from the start... One day, you can proudly tell your children: That was my construction site.

Martin Mayer, Foreman at Max Bögl Group

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