appendix d tbm tunnel assumptions and cost estimating output · • 300mm thick concrete secondary...

Appendix D TBM Tunnel Assumptions and Cost Estimating Output

Appendix D TBM Tunnel Assumptions and Cost Estimating Output

Discussion:

The tunnel costs were estimated using TBM cost estimating software and cost database developed by Hatch Mott MacDonald. Appendix D contains output from the software for each TBM type and tunnel diameter. Please note the following about the output:

1. ‘Rock Types’ are called ‘TBM Types’ in the main body of the report.

2. ‘Rock Type A/B’ is called ‘TBM Type B’ in the main body of the report.

3. The costs for concrete inverts were not included in the output in the appendices. These were added in the CNA cost estimating spreadsheet. The inverts are needed to provide a flat working surface. Inverts were added to TBM Types A and C only because it was assumed that the TBM Type B cast-in-place liner could be formed with a flat bottom.

4. The costs of grouting for water control were not included in the appendices. These were added in the CNA cost estimating spreadsheet. Grouting was added to TBM Types A and B only. TBM Type C is a sealed system that does not allow water to enter the tunnel so grouting is not required.

List of Abbreviations:

CIP Cast-in-place

H Hour

m2 Square meters of tunnel face

Nr Number (equivalent to ‘Each’)

W Week

mW per meter per week

kWh Kilowatt hour

l Liter

m Meter

m3 Cubic meter

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Fermilab Tunnels

Cost Estimates

Assumptions

General

The following assumptions apply to all tunnel drives:

• 4800 metres of tunnel from shaft to shaft

• 2 ten hours shifts undertaken daily, 5 days per week

• Tunnels excavated using 3.66 metre or 4.88 metre finished diameter rock TBM

• 75 percent of TBM cost written off in first drive, 15 percent in second drive, 10 percent in third drive, and 0 percent in fourth and fifth drives

• Labour rates based on Minneapolis Project for Year 2001. (Similar to Illinois)

Specific

Assumptions used for 3.66m (12ft) diameter tunnel in Rock Type A as follows:

• No areas of difficult excavation

• A total of 400 3 metre long rockbolts installed sporadically in the tunnel crown in jointed or potentially weak zones

• Average tunnel advance rate of 225 metres per week

• No secondary lining required

Assumptions used for 3.66m (12ft) diameter tunnel in Rock Type A/B (requiring CIP liner) as follows:

• No areas of difficult excavation

• Three rockbolts, 3 metres in length, installed in each 6 metre length of tunnel

• Average tunnel advance rate of 211 metres per week

• Secondary cast-in-place concrete lining installed to prevent long term degradation of the rock

Assumptions used for 3.66m (12ft) diameter tunnel in Rock Type C as follows:

• Areas of difficult excavation encountered, slowing normal advance rate by 20 percent, over 20 percent of the tunnel length

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• No primary support provided with a 200mm thick segmental concrete lining installed immediately behind the TBM following each excavation cycle

• Average tunnel advance rate of 102 metres per week

Assumptions used for 4.88m (16ft) diameter tunnel in Rock Type A as follows:

• No areas of difficult excavation

• A total of 400 3 metre long rockbolts installed sporadically in the tunnel crown in jointed or potentially weak zones

• Average tunnel advance rate of 225 metres per week

• No secondary lining required

Assumptions used for 4.88m (16ft) diameter tunnel in Rock Type A/B (requiring CIP liner) as follows:

• No areas of difficult excavation

• Three rockbolts, 3 metres in length, installed in each 4.5 metre length of tunnel

• Average tunnel advance rate of 195 metres per week

• Secondary cast-in-place concrete lining installed to prevent long term degradation of the rock

Assumptions used for 4.88m (16ft) diameter tunnel in Rock Type C as follows:

• Areas of difficult excavation encountered, slowing normal advance rate by 20 percent, over 20 percent of the tunnel length

• No primary support provided with a 225mm thick segmental concrete lining installed immediately behind the TBM following each excavation cycle

• Average tunnel advance rate of 102 metres per week

Fermilab Tunnels

Estimate Summary

12 ft dia tunnel (3.66 m)

Rock Type Tunnel Drive Tunnel Length Drive Cost TBM setup Total(m)

A First 4800 8,160,000 400,000 8,560,000A Second 4800 6,070,000 200,000 6,270,000A Third 4800 5,910,000 200,000 6,110,000A Fourth 4800 5,600,000 200,000 5,800,000A Fifth 4800 5,600,000 200,000 5,800,000

A/B with CIP First 4800 18,930,000 400,000 19,330,000A/B with CIP Second 4800 16,350,000 200,000 16,550,000A/B with CIP Third 4800 16,140,000 200,000 16,340,000A/B with CIP Fourth 4800 15,710,000 200,000 15,910,000A/B with CIP Fifth 4800 15,710,000 200,000 15,910,000

C First 4800 26,630,000 400,000 27,030,000C Second 4800 23,190,000 200,000 23,390,000C Third 4800 22,940,000 200,000 23,140,000C Fourth 4800 22,430,000 200,000 22,630,000C Fifth 4800 22,430,000 200,000 22,630,000

16 ft dia tunnel (4.88 m)

Rock Type Tunnel Drive Tunnel Length Drive Cost TBM setup Total(m)

A First 4800 10,930,000 400,000 11,330,000A Second 4800 7,360,000 200,000 7,560,000A Third 4800 7,080,000 200,000 7,280,000A Fourth 4800 6,520,000 200,000 6,720,000A Fifth 4800 6,520,000 200,000 6,720,000

A/B with CIP First 4800 24,410,000 400,000 24,810,000A/B with CIP Second 4800 20,160,000 200,000 20,360,000A/B with CIP Third 4800 19,810,000 200,000 20,010,000A/B with CIP Fourth 4800 19,100,000 200,000 19,300,000A/B with CIP Fifth 4800 19,100,000 200,000 19,300,000

C First 4800 33,360,000 400,000 33,760,000C Second 4800 27,830,000 200,000 28,030,000C Third 4800 27,400,000 200,000 27,600,000C Fourth 4800 26,550,000 200,000 26,750,000C Fifth 4800 26,550,000 200,000 26,750,000

Appendix E TBM Tunnel Assumptions and Cost Estimating Output (Not

Used)

Appendix E TBM Tunnel Assumptions and Cost Estimating Output (Not Used)

Discussion:

The tunnel costs were estimated using TBM cost estimating software and cost database developed by Hatch Mott MacDonald. Appendix E contains output from the software for TBM types and tunnel diameters not used in the final estimate, but is included here for completeness. Please note the following about the output:

1. ‘Rock Types’ are called ‘TBM Types’ in the main body of the report.

2. Appendix E contains Rock Types B and B+, which are not used in the final estimate.

List of Abbreviations:

CIP Cast-in-place

H Hour

m2 Square meters of tunnel face

Nr Number (equivalent to ‘Each’)

W Week

mW per meter per week

kWh Kilowatt hour

l Liter

m Meter

m3 Cubic meter

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Fermilab Tunnels

Cost Estimates

Assumptions

General

The following assumptions apply to all tunnel drives:

• 4800 metres of tunnel from shaft to shaft

• 2 ten hours shifts undertaken daily, 5 days per week

• Tunnels excavated using 3.66 metre or 4.88 metre finished diameter rock TBM

• 75 percent of TBM cost written off in first drive, 15 percent in second drive, 10 percent in third drive, and 0 percent in fourth and fifth drives

• Labour rates based on Minneapolis Project for Year 2001. (Similar to Illinois)

Specific

Assumptions used for 3.66m (12ft) diameter tunnel in Rock Type B as follows:

• Areas of difficult excavation encountered, slowing normal advance rate by 35 percent, over 20 percent of the tunnel length

• Tunnel support consists of 3 metre long rockbolts with steel straps, installed in sets of 3 in the tunnel crown, with each set spaced at 3 metre centres. Additional support in the form of 2 sq.m. of timber laggings per metre of tunnel and associated ribs over 50 percent of the tunnel length.

• Average tunnel advance rate of 122 metres per week

• No secondary lining required

Assumptions used for 3.66m (12ft) diameter tunnel in Rock Type B+ as follows:

• Areas of difficult excavation encountered, slowing normal advance rate by 35 percent, over 20 percent of the tunnel length

• Tunnel support consists of 3 metre long rockbolts with steel straps, installed in sets of 3 in the tunnel crown, with each set spaced at 3 metre centres. Additional support in the form of 2 sq.m. of timber laggings per metre of tunnel and associated ribs over 50 percent of the tunnel length.

• Average tunnel advance rate of 122 metres per week

• 300mm thick concrete secondary lining installed on completion of tunnel boring

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• Average lining installation rate of 225 metres per week

Assumptions used for 4.88m (16ft) diameter tunnel in Rock Type B as follows:

• Areas of difficult excavation encountered, slowing normal advance rate by 40 percent, over 20 percent of the tunnel length

• Tunnel support consists of 3 metre long rockbolts with steel straps, installed in sets of 3 in the tunnel crown, with each set spaced at 3 metre centres. Additional support in the form of 3 sq.m. of timber laggings per metre of tunnel and associated ribs over 50 percent of the tunnel length.

• Average tunnel advance rate of 114 metres per week

• No secondary lining required

Assumptions used for 4.88m (16ft) diameter tunnel in Rock Type B+ as follows:

• Areas of difficult excavation encountered, slowing normal advance rate by 40 percent, over 20 percent of the tunnel length

• Tunnel support consists of 3 metre long rockbolts with steel straps, installed in sets of 3 in the tunnel crown, with each set spaced at 3 metre centres. Additional support in the form of 3 sq.m. of timber laggings per metre of tunnel and associated ribs over 50 percent of the tunnel length.

• Average tunnel advance rate of 114 metres per week

• 300mm thick concrete secondary lining installed on completion of tunnel boring

• Average lining installation rate of 225 metres per week

Fermilab Tunnels

Estimate Summary

12 ft dia tunnel (3.66 m)

Rock Type Tunnel Drive Tunnel Length Drive Cost TBM setup Total(m)

B First 4800 13,900,000 400,000 14,300,000B Second 4800 11,570,000 200,000 11,770,000B Third 4800 11,390,000 200,000 11,590,000B Fourth 4800 11,030,000 200,000 11,230,000B Fifth 4800 11,030,000 200,000 11,230,000

B+ First 4800 23,380,000 400,000 23,780,000B+ Second 4800 20,610,000 200,000 20,810,000B+ Third 4800 20,400,000 200,000 20,600,000B+ Fourth 4800 19,970,000 200,000 20,170,000B+ Fifth 4800 19,970,000 200,000 20,170,000

16 ft dia tunnel (4.88 m)

Rock Type Tunnel Drive Tunnel Length Drive Cost TBM setup Total(m)

B First 4800 17,740,000 400,000 18,140,000B Second 4800 13,560,000 200,000 13,760,000B Third 4800 13,250,000 200,000 13,450,000B Fourth 4800 12,610,000 200,000 12,810,000B Fifth 4800 12,610,000 200,000 12,810,000

B+ First 4800 29,000,000 400,000 19,031,000B+ Second 4800 24,380,000 200,000 14,206,000B+ Third 4800 24,020,000 200,000 13,852,000B+ Fourth 4800 23,320,000 200,000 13,144,000B+ Fifth 4800 23,320,000 200,000 13,144,000