INTERNATIONAL SEMINARLONG TUNNELS

17, 18 y 19 de Octubre 2012Santiago, Chile

Challenges for Design, Construction and Operation

PIARC CHILE

Martin Knights

HALCROW a CH2MHill company

& The International Tunnelling Association

11 November 201022 An introduction to Halcrow

Thank you

Sustaining and improving thequality of people’s lives

HalcrowA CH2MHill company

Perspective

Brazil,Chile,Argentina,Panama

International Tunnelling & UndergroundSpace Association

Our goals are :

To encourage new uses of underground space

To encourage studies of underground alternatives tosurface construction

To have resilient infrastructure ~

To encourage the development of guidelines.~

To better procurement and contracts ~To encourage & stimulate innovation .

To improve training

To arrange international exchange

To network

To be the global leader influencing use of

underground space

Thru our Exco,GA,WGs,Committees,WTC,Seminars,Foundation,training& education

In future our urban areas need to incorporate more sustainable underground solutions

ITA

Always Act Safely

All of you here today have a role to play in the managament and commitment to safety

• Client• Government• Designers• Coordinators for H&S• Contractors• TBM Manufacturers• Workforce• Professional Organisations• Regulators and Standards makers• Insurers

HALCROWA CH2MHill Company

The most vital contribution to safety in any tunnel is

………………………….. a trained and disciplined workforce

Safety is the responsibility of every person on site,the office,& off site supply chain

China—Taiwan

Hong Kong –Macau—China Link

Reality

Dream?

Dream?

Reality

Technology and Innovation are realising dreams

Moscow to New York bytrain?

Proposed tunnel between Siberia and AlaskaDream ?

LOCATIONS OF MAIN NORWEGIAN SUB SEATUNNELS

Grov

•@30 tunnels built /range= 1km>20km

CERN GENEVA

Brazils` High Speed Rail Project• 6 years to plan and constuct• +90km tunnels--@50km >1km long(4>7km long)• TBM and Conventional tunnelling• Logistics and planning challenge• Soft and Hard Ground• Tunnelling= >30% of total construction cost

Halcrow

London 2012 Olympics

2006>>2022Turin--Beijing-- Vancouver—London—Sochi—Rio—Moscow--Qatar/Doha

Its official--Tunnelling is now an Olympic and World Cup Sport!!>>“Synchronised tunnelling”

Qatar 2022 World Cup

S

Rio de Janeiro

Metro Line 4

Extension west from to(Olympics site) @16km

<Copacabana

<Ipanema

Ipanema/

Barra Tujuca

Ipanema

<Rio centro

<Sugar Loaf

<Leblon

Halcrow

Busan Geoje immersed tunnel, South Korea Halcrow

Foster + Partners / Halcrow www.thameshub.co.uk

The London Hub Dream?

Dubrovnik,Croatia

Innovation in Tunnelling

Innovation in Tunnelling,Hydro ,Water Supply& Dams

Global TunnellingMore powerful Hydro energy ,Rail and Road tunnel schemes in the Himalayas

The global challengesSustainable

development

Urbanisation

Energy

Water scarcity

Populationgrowth

Climate change

Transport

Civil Engineering infrastructure & use of underground space will provide solutions

Demographic Trend

source: SustainableUrban Infrastructure

– Siemens

21

February 2012

The Singapore URA SustainableUrban Living R&D Programme

1 Create more underground space and optimise theuse of underground space to expand Singapore`sland resources

2 Hong Kong Strategic Cavern StorageProgramme >>>>>>>>>>>>>>>>>>>>>

ITACUS Committee for use ofunderground space

• Formed @ 5 years ago• Promotes use of underground space• Leading the debate at ITA WTC`s• Networking with global non governmental

agencies eg UN,• Working with local and national

government planners• Meeting in Singapore November this year

New technical committee 2011

ITA will be more Industry driven in future

Innovation in tunnelling technology

Halcrow and Cambridge University

BAM VINCI

Sprayed Concrete

Hindhead-A3 Road Tunnel, England

Immediate flash coatapplication of SprayedConcreteOn the newly excavated faceand profileSprayed waterproofmembrane

<<<<

<

Startdate Country Project TBM

manufacturer Diameter

1994 Japan Trans Tokyo BayHighway Tunnel

8 machines3 Kawasaki, 3Mitsubishi, 1Hitachi, 1 IHI

14.14m

1997 GermanyHamburg 4th

Elbe RiverHighway Tunnel

1 HerrenknechtMixshield 14.2m

2000 The NetherlandsGroenehartdouble-track railtunnel

1 NFMTechnologies 14.87m

2001 RussiaMoscowLefortovoHighway Tunnel

1 HerrenknechtMixshieldEx-Elbe projectmachine

14.2m

2004 Japan Tokyo Metro 1 IHI EPBM 14.18m

2004 China

ShangzhongRoadSubacqueousTunnel,Shanghai

1 NFMTechnologiesEx-Groenehartmachine

14.87m

2004 RussiaMoscowSilberwaldHighway Tunnel

1 HerrenknechtMixshieldEx-Elbe projectmachine

14.2m

2005 Spain Madrid Calle 30Highway Tunnels

2 machines1Herrenknecht,1 Mitsubishi

15.2m15.0m

2006 CanadaNiagara WaterDiversionTunnel*

1 Robbins hardrock gripperTBMRebuiltManapouritailrace tunnelmachine

14.4m

2006 ChinaShanghaiYangtze RiverTunnel

2 HerrenknechtMixshields 15.43m

2006 China

Jungong RoadSubaqueousTunnel,Shanghai

1 NFM slurryshield Ex-Groenehartmachine

14.87m

Bund Tunnel, 1 Mitsubishi

2008 China Nanjing YangtzeRiver Tunnel*

2 HerrenknechtMixshields 14.93m

2009 ChinaYingbinsan RoadTunnel,Shanghai

1 MitsubishiEPBM Ex-BundTunnel machine

14.27m

2010 China

QianjiangSubaqueousTunnel,HangzhouSecond tubecurrently underconstruction

1 HerrenknechtMixshield Ex-ShanghaiYangtze RiverTunnel machine

15.43m

2010 SpainSeville SE-40HighwayTunnels*

2 NFMTechnologiesEPBMs

14.00m

2011 Italy A1 highwaytunnel*

1 HerrenknechtEPBM 15.55m

2011 China Hong Mei Road,Shanghai

1 HerrenknechtMixshield 14.9m

2011 China Weisan RoadTunnel, Nanjing*

2IHI/Mitsubishi/CCCC slurryTBMs

14.93m

2011 USA

Alaskan Wayelevatedhighwayreplacementtunnel*

1 HitachiZosen EPBM(Letter ofintent)

Approx 17.6m(58ft)

2011 RussiaOrlovskyTunnel, SaintPetersburg*

1HerrenknechtMixshieldEngineeringstarted 2009,orderconfirmed2011

19.25m

2011 New Zealand

Waterviewmotorwayconnectiontunnel,Auckland*

1 EPBM to beordered Approx 14m

Masters of the Universe?

Size of TBMs

Tunnel talk

?

Traditional Delivery

The traditional TBM factory assembly

JIN PING II – CHINAOPEN, HARD ROCK HP-TBM

JinPing Mountain (4420m) viewed towards the west

Yalong River ValleyDeep & narrow canyons with very steepwalls

• Job Site

• Shipmentsfrom Shanghai

• Shipmentsfrom Dalian

• Shipmentsfrom Chengdu

• Imported parts

JIN PING IIINTERNATIONAL SOURCES

USA

Oth

erLo

catio

nEu

rope

JIN PING IION SITE, FIRST TIME ASSEMBLY (OFTA)

Cutterhead WeldingCutterhead must be welded at site.This is required even for factoryassembled machines

Presentation to World Bank 13th June 2012, Washington DCWorld Bank Group Hydropower Community of Practice - Working Group on Tunneling & Underground Works

Martin Knights

Procurement ,risks &contracts

12th june `12International Tunnelling Association

Halcrow GroupA CH2MH Company

Aims of the International Tunnelling &Underground Space Association

One of ITA goals include:

better procurement and contracts ~

In future our urban areas need to incorporate more sustainable underground solutions

Current Global HEP MarketHydro Schemes are unique in thatthey carry their own inherent risksby nature of the project.

These risks can be grouped into 4 mainheadings:-

Technical- Internal water pressure- External Water Pressure- Ground Conditions- Durability including quality ofmaterials- ground water migrationpermeation under dam- access to site normally remote- cfd analysis to avoid turbulence insystem- turbine(s) & turbine hall design- Associated tunnels & shafts

Commercial- return on investment-contract--programme-Conditions of contract\type

- Socio EconomicDiversion of water coursesDam water land take

Political

Market now growing again

Political interference slows progress

Procurement is slow & needs overhaul

Procurement typified by phases ofintermittment surge`s of activityfollowed by long interim phases of no action

Interim Gap being filled by thermal power

Procurement & Contracts need to be appropriate

Funders need to address,benchmark& influence….now.

Need to agree consistent approachto procurement of HEP underground works…now

Long term planning /less politics/ more enlightened

Intention of Seminar 1

• discuss issues of procurement incontracting and try to see how to resolvesome of the challenges in deliveringsustainable hydropower projects……….

Intention of Seminar 2

• …..collectively discuss issues of procurement incontracting and try to see how to resolve someof the challenges in delivering sustainablehydropower projects. risk management & risksharing mechanism, use of standard biddingdocuments, EPC versus traditional methods ofcontracting and capacity building, do theprocurement rules of the Banks provideflexibility? for efficient contracts.

•

World Bank SeminarThemes

• EPC v Traditional• Risk ownership and management• Competitive bidding v Strategic Partners• Eligibility & prequalification• Training and capacity building• Least cost v Value for money• What WB needs to do in future

Risk Management!!

Contractor

Client

Training Session in Vancouver on May 14-15, 2010

Managing Risk!!

Risk…….=

Lawyer?>>Consultant?>> The Contract

The Procurement vehicle>>

Structure Level ofGeologicalUncertainty

Dam

SurfaceSurface PowerHouse

Underground Cavern

Shafts

Long tunnels

Level of geological Risk

Hydro ProjectsPerceptions levels of Geological Risk?

Ghopal

So…..Is tunnelling `risky`?

Tunnelling is not risky!The risks just need to be removed, mitigated planned for &

managed….

….methodically by experienced and competent companies & peopleusing the right equipment AND PROCUREMENT .

Well not always!

Simple!?

No!

No construction project is risk free.Risk can be managed, minimised,shared, transferred or accepted.

It cannot be ignored

`Codes`

www.britishtunneling.org www.imia.com (Being updatednow by ITA & ITIG )

`?

Basic message of Risk Ownership

• The party who ‘owns’ a risk will pay for it if itmaterialises

• ‘Who Pays’ for risk is a contractual issue• Who Manages’ a risk is non-contractual – and is

determined by who is best to manage.• Risks should not be `dumped `onto party least

able to manage the risk• Usually - risks should be owned by party with

best ability to influence the outcome

• ‘

on potential for opportunity)

• The contract must define ‘riskownership’

Hydro SchemesAs geotechnical information can be sparse due to cost of drilling boreholes inmountainous terrain the Client can manage ground & other risks by 3 options.

1) Passing all ground risks over to contractor – this will increase cost of project &generate an adversarial approach & you get what you deserve!

2) Preparing a Geotechnical Baseline Report & asking the contractor to price withinpredefined limits. These need to be narrow. This will help to share risk through anEngineer’s design with alternatives allowed or a Design & Build approach to areference design

3) Engaging the contractor at an early stage & jointly manage the risks from theoutset of the project. This should lead to the most economical solution through atarget cost approach. This is not always appreciated by Clients.

Prof Evert Hoek:pragmatic observations

• Difficult to apply traditional Sl`s for long deep tunnels• Justified expenditure on sophisticated SI for Large

Underground Power Houses• Seldom can either party agree on interpretation of ground as

tunnelling proceeds .• Sees increased use of TBMs long tunnels• Success of an underground project is less to do with the

Contract and more to do with Client and Contractorrelationship and objective ,non confrontational & competentbehaviour of engineers.

• Flexible procurement needed• Baselining of ground condidtions

Athens Conference April `12

KISHANGANGAHYDROELECTRIC PROJECT

Jammu & Kashmir,India

Risk Management Approach

Special Measures Criteria for Critical Conditions(Long TBM driven tunnel)

Summary information

Squeeze control !

PROJECT DETAILS•s

53

Started : January 2009Completion :January 2016Client :National Hydropower Commission NHPCGenerated Power 330MW

Contractor: HCCDesigner /Engineer : Halcrow

Location Map

Kishanganga HEP54 March 2011

TBM ADIT

March 2011 Kishanganga HEP59

PROJECT LAYOUT

60Headrace Tunnel @24km ( > 70% by Double Shield TBM)

General geological conditionsAdit 1 TBM

Portal

AndesiteHasthoji FmRazdhan Fm

0 10 20 30 40 50 60 70 80 90 100

GSI

Thinly bedded meta-siltstones

Meta-sandstones, withinterbedded siltstone

Folded siltstone with phyllite

Very thinly to thinly bedded shales withinterbeds of meta-sitlstone

faulting

Thinly bedded meta-siltstones

fault zone withPanjal Volcanics

HAFKHALAN FORMATION

HASTHOJI FORMATION

RAZDHAN FORMATION

Typical Fair conditions based on Ref 1,circle represent value used in TN

Poor to Very Poor conditions based on Ref 1

Hafkhalan Fm

The formations where squeezing may besignificant are:Tragbal and Hafkhalan FormationsHasthoji Formationparts of the Razdhan Formation.

Squeezing and critical conditions

The occurrence and extent of squeezing isrelated primarily to parameters to bemonitored:

• rock mass quality, GSI• unconfined compressive strength (UCS) of

intact rock pieces• in situ stress ratio (ko) in the plane of the

tunnel cross section• depth and rock density.

TBM for the Headrace tunnel

63

SELI Double Shield with Honeycomb pcc tunnel segments

What is squeezing?• significant time dependent deformations

resulting from tunnel excavation

St Martin Access Tunnel(Lyon-Turin Base Tunnel, Alps)

Nathpa Jhakri HEP(India, Himalayas)

Why is squeezing important tothe TBM tunnel?

• great depth (up to1400m)

• weak rock in places• stresses concentrate

around tunnel• rock is overstressed• rock fails – becomes

‘plastic’

Long term loads

• initial segment load increases withtime

• creep mechanisms superimpose onrock failure

• long-term loads may be 2 to 3 timesthe initial loads

What are critical conditions?TBM:• geological conditions – particularly squeezing - which

might impair or prevent forward progress of the TBMand/or compromise the structural capacity of thesegmental lining

Segmental lining:• geological conditions – particularly squeezing - which

might compromise the structural capacity of thesegmental lining

A risk management approach to design and construction is needed

What are ultimate contingencymeasures?

• measures that may have to be taken in the ultimate caseof critical conditions in which the TBM becomesentrappedand/or

• the lining becomes, or is predicted to become,overstressed

In these ultimate conditions, it may not be feasible to construct sections ofthe tunnel using the TBM - the method of tunnel construction may need tobe changed temporarily.

Contingency plans need to be made.

Halcrow wanted to provide guidance tosite personnel on:

• the severity of squeezing to be anticipated alongthe length of the TBM tunnel

• monitoring requirements• criteria to be followed during construction• special measures to be implemented

in order to allow the TBM to be used to construct as much of the plannedlength of the tunnel as possible - with minimum risk to the project

Risks to the TBM andsegmental lining

Risk to the TBM:• collapse of the rock face• significant groundwater inflow, possibly forming

mudflows• squeezing of the ground onto the TBM shield

with sufficient pressure to prevent TBM progresswithout special measures being taken

Risk to the segmental lining:• squeezing of the ground onto the segmental

lining with sufficient pressure to exceed thestructural capacity before special measures canbe taken

• particularly severe squeezing conditions in whichthe structural capacity of the segmental lining ispredicted to be exceeded even if the full range ofspecial measures was to be implemented

Special measures (risk to TBM)

• more cutterhead motors• 43MN thrust• conical shields with increasing clearances to rock• over-cutting• operational special measures• forward probing• pre-excavation grouting• access to outside of shield• external grout plant

Special measures (risk to segments)

• over-cutting• early consolidation grouting• pre-excavation grouting• instrumented segments

Ultimate contingency measures (1)

TBM cannot be used or becomes entrapped:• ‘park’ TBM and proceed with hand mining/drill-and-blast

methods• oversize tunnel with deformable temporary support• when conditions improve, move TBM through the mined

tunnel• re-start TBM

• permanent lining with segments backfilled with concreteor

• permanent cast concrete lining

Ultimate contingency measures (2)

Segmental lining cannot be used in these circumstances:• critical conditions are detected ahead of the TBM and indicate

that the segmental lining cannot be used through a section oftunnel without an unacceptably high risk of overstressing beforeother mitigating measures can be implemented, i.e. the liningmay become overstressed over the length of the back-up trainIn this case the TBM and segmental lining method should notbe used; change to drill-and-blast with deformable temporarysupport

• the critical conditions are not detected and the lining is used,but becomes, or is predicted to become, overstressed beforeother mitigating measures can be implemented at the rear ofthe back-up trainIn this case install instrumented segments to monitor loaddevelopment to ensure tunnel remains safe as TBM movesforward

Squeezing and criticalconditions

Results of the time dependent numerical modelling based on specialistlaboratory testing (Turin, Italy)

Some key conclusions from time dependent (visco-plastic) modelling:• effects of squeezing are greater at slower advance rates• over-cutting is an effective special measure, and most likely to be needed

to prevent squeezing of the TBM, but pre-excavation grouting may also berequired

• pre-excavation grouting will affect advance rates and therefore squeezing• consolidation grouting behind the back up train is generally too late to be

effective in preventing squeezing, but it limits further development ofsqueezing pressures

Ko = 1.5

Chainage 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500 12000 12500 13000 13500 14000 14500 15000 15500 16000 16500 17000 17500 18000 18500 19000 19500 20000 20500 21000 21500 22000 22500 23000Invert 2357 2356 2355 2353 2352 2351 2350 2348 2347 2346 2344 2343 2342 2341 2339 2338 2337 2335 2334 2333 2331 2330 2329 2328 2326 2325 2324 2322 2321 2320 2319 2317 2316GL 3200 3000 2800 2800 2900 3100 3350 3500 3400 3550 3550 3750 3650 3500 3400 3400 3200 3000 2800 3000 2850 2750 2950 3150 3300 3100 2850 2800 2700 2650 2800 2750 2500Depth 843 644 445 447 548 749 1000 1152 1053 1204 1206 1407 1308 1159 1061 1062 863 665 466 667 519 420 621 822 974 775 526 478 379 330 481 433 184

HAL04 / HAL05 Report 10m per dayUCS GSI40 40 N O O M M M Z Z Z Z M M M PO O N O O N O PO PO O O N N N N60 40 N N O PO PO PO M M M M M PO PO O O N O N N O O PO O N N N N N80 40 N N O O PO PO PO PO PO PO PO PO PO O N N N N N N O O O N N N N N

40 50 N N O M M M Z Z Z Z M M M O O N O N N O O O O N N N N N60 50 N N N O O O M M M M M O O O N N N N N N O O N N N N N N80 50 N N N N N N O O O O O N N N N N N N N N N N N N N N N N

40 60 N N N O O O M or Z M or Z Z Z O O O O N N N N N N N O N N N N N N60 60 N N N N N N N N O O N N N N N N N N N N N N N N N N N N80 60 N N N N N N N N N N N N N N N N N N N N N N N N N N N N

HAL04 / HAL05 Report 1m per day40 40 O O PO M Z Z Z Z Z Z Z Z Z M PO O PO O O O PO M PO O O N N O - -60 40 N O O M M M M M M M M M M PO O N O O N O PO PO PO O O N N N - -80 40 N N O PO PO PO PO PO PO PO PO PO PO O O N O N N O O PO O N N N N N - -

40 50 N O O M Z Z Z Z Z Z Z Z Z M O N O N N O O M O N N N N N - -60 50 N N O M M M M M M M M M M O N N N N N N O O O N N N N N - -80 50 N N N O O O O O O O O O O N N N N N N N N N N N N N N N - -

40 60 N N N O M M M M M M M M M O N N N N N N O O N N N N N N - -60 60 N N N N N N N N O N N N N N N N N N N N N N N N N N N N - -80 60 N N N N N N N N N N N N N N N N N N N N N N N N N N N N - -

N Over-cutting not requiredO Over-cutting required

PO Pre-excavation grouting and over-cutting requiredM TBM may be stuck based on sliding friction co-efficient of 0.25 and/or the segmental lining is overloaded in the long term - pre-excavation grouting and over-cutting may not resolve the problem, monitoring of the lining requiredZ TBM may be stuck based on sliding friction co-efficient of 0.25 and/or the segmental lining is overloaded in the long term - pre-excavation grouting and over-cutting are unlikely to resolve the problem

Drill And Blast TBMRazdhan Formation

85% meta-sandstone, 10% thinly bedded meta-siltstone, 5% siltstone with phylliteRazdhan Formation

70% meta-sandstone, 20% thinly bedded meta-siltstone, 10% siltstone with phylliteHasthoji Formation Panjal VolcanicsHafkhalan and Tragbal Formation

D & B

Special Measures

P+O / D & B

noneO

P+O

20002200240026002800300032003400360038004000

7000 9000 11000 13000 15000 17000 19000 21000 23000Chainage

Ele

vatio

n

GL Tunnel

Behaviour of the rock mass and special measures required

Consolidation grouting requirements

Ko = 1.5

Chainage 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500 12000 12500 13000 13500 14000 14500 15000 15500 16000 16500 17000 17500 18000 18500 19000 19500 20000 20500 21000 21500 22000 22500 23000Invert 2357 2356 2355 2353 2352 2351 2350 2348 2347 2346 2344 2343 2342 2341 2339 2338 2337 2335 2334 2333 2331 2330 2329 2328 2326 2325 2324 2322 2321 2320 2319 2317 2316GL 3200 3000 2800 2800 2900 3100 3350 3500 3400 3550 3550 3750 3650 3500 3400 3400 3200 3000 2800 3000 2850 2750 2950 3150 3300 3100 2850 2800 2700 2650 2800 2750 2500Depth 843 644 445 447 548 749 1000 1152 1053 1204 1206 1407 1308 1159 1061 1062 863 665 466 667 519 420 621 822 974 775 526 478 379 330 481 433 184

Consolidation Grouting40 40 R R E E E E E E E E E E E E R R R R R R E E E R R R R R R R60 40 R R E E E E E E E E E E E E R R R R R R E E E R R R R R R R80 40 R R E E E E E E E E E E E E R R R R R R E E E R R R R R R R

40 50 - - E E E E E E E E E E E E - - - - - - E E E - - - - - - -60 50 - - E E E E E E E E E E E E - - - - - - E E E - - - - - - -80 50 - - E E E E E E E E E E E E - - - - - - E E E - - - - - - -

40 60 - - E E E E E E E E E E E E - - - - - - E E E - - - - - - -60 60 - - E* E* E* E* E* E* E* E* E* E* E* E* - - - - - - E* E* E* - - - - - - -80 60 - - E* E* E* E* E* E* E* E* E* E* E* E* - - - - - - E* E* E* - - - - - - -

- Consolidation grouting not requiredR Routine consolidation grouting (i.e. location to suit the Contractor's operations and programme)E Early consolidation grouting required (i.e. grouting to be undertaken at the rear of the TBM back-up train)E* Early consolidation grouting required, but requirement may be reviewed on referral to Halcrow

Consolidation Grouting

Drill And Blast TBMRazdhan Formation

85% meta-sandstone, 10% thinly bedded meta-siltstone, 5% siltstone with phylliteRazdhan Formation

70% meta-sandstone, 20% thinly bedded meta-siltstone, 10% siltstone with phylliteHasthoji Formation Panjal VolcanicsHafkhalan and Tragbal Formation

20002200240026002800300032003400360038004000

7000 9000 11000 13000 15000 17000 19000 21000 23000Chainage

Ele

vatio

n

GL Tunnel

Halcrow & ITAtechGovt Clients:NHPC/CBIP/JKSPDC

March April September 2012

3 Workshops

Colourful meetings!

Finally some overall summary thoughts

• Get procurement strategy sorted out early ie what arethe owners key requirements?

• Consider the appropriate Contract Document• Manage the interfaces• Do not over specify ie allow market to `add value`.• Management of Risk , Quality and Safety are key

considerations in deciding procurement route.• Procurement is the weakest link in Global HEP• Got to change.

Thank you

Thank you from Halcrow and ITA!