stormwater management and road tunnel - ita-aites

ITA2009 BudapestGus Klados

BKV-DBR Metro ITA-AITES WTC 2009

MMC-GAMUDA JV 11

Construction of the SMART Project in MALAYSIA

Presentation for theITA-AITES WTC 2009 BUDAPEST

23d- 28th May 2009

SMARTStormwater Management

and Road Tunnel

ITA-AITES WTC2009BUDAPEST by Gus

BKV – DBR Metro ITA-AITES WTC 2009 Budapest Gus Klados

MMC-GAMUDA JV 22

FLOODED AREAS IN KUALA LUMPUR

24th October 2007, GSM by Gus

MMC-GAMUDA JV ITA-AITES WTC 2009

MMC-GAMUDA JV 33

Flood Level on 26 April 2001

TUN PERAK BRIDGEFlow Capacity: 180 m³/s only



MMC-GAMUDA JV 44

THE SMART IDEA

PROVIDE FLOOD RELIEF BY:BORING A 13.26/11.83m DIAMETRE 9KM LONG TUNNEL TO PROVIDE FLOW OF 291m3/sec

MAKE IT CHEAPER TO THE PUBLIC BY:

BUILDING A TWIN LEVEL 2 LANE MOTORWAY IN THE CENTRAL 3KM TO RELIVE TRAFFIC CONGESTION AVAILABLE MOST OF THE TIME TO THE PUBLIC

MAIN ELEMENTS:PONDSINTAKE & OUTLET STRUCTUREGATE STRUCTURESVENTILATION SHAFTSTUNNEL ROAD DECKS & ESCAPE PASSAGES



MMC-GAMUDA JV 55

RO

W

R OW

RO

W

OFFTAKE

RO

W

RO

W

RO

W

FLOATING

ROW

RL=38m Flood Level

RL=30.7m Standing Water Level

Bypass Tunnel

SG

. KLA

NG

SG

. A

MP

AN

G

SG

. KLA

NG

DIVERSION WEIR

BOOM

19.5024.50

Twin Box Culvert Kerayong

18.05

8.20

Storage Reservoir

28.00 Flood Level

OutfallIntake gated

-0.80

20.00 Standing Water Level

(TAMAN DESA POND) (2 nos. 5.1m H x 5.5m W)

25.70 Flood Level


0

5

10

15

20

25

30

35

4040

35

30

25

20

15

10

5

0

28.70

33.35

21.55

Sg Klang

Holding Pond

Bypass Tunnel(Diameter 11.8m)

38.50 Flood Level

31.3

38.00 Flood Level31.80 Standing Water Level structure

Offtake gatedstructure

STRUCTURE

BELL MOUTHSTRUCTURE AREA = 119028m

TAMAN DESA POND

RL 20mNEW POND SIZE

TO SEREMBAN

TO KL

2

TWIN BOX CULVERT(2 nos. 5.1m H x 5.5m W)

SG. BESI AIRFIELD

BY

PA

SS

TU

NN

EL

KL - SEREMBAN HIGHWAY

AREA = 216594m

ORIGINAL POND SIZERL 28m

2

RESTAURANTDESA

WATER PARK

THEME PARKDESA

WATER PARK

INTAKE GATEDSTRUCTURE

OUTFALLSTRUCTURE

OUTFALLSTRUCTURE

structureSg

RO

W

ROW

RO

W

OFFTAKE

RO

W

ROW

RO

W

FLOATING

ROW

RL=38m Flood Level

RL=30.7m Standing Water Level

Bypass Tunnel

SG

. KLA

NG

SG

. A

MP

AN

G

SG

. KL

AN

G

DIVERSION WEIR

BOOM

19.5024.50

Twin Box Culvert Kerayong

18.05

8.20

Storage Reservoir

28.00 Flood Level

OutfallIntake gated

-0.80


(TAMAN DESA POND) (2 nos. 5.1m H x 5.5m W)

25.70 Flood Level


0

5

10

15

20

25

30

35

4040

35

30

25

20

15

10

5

0

28.70

33.35

21.55

Sg Klang

Holding Pond

Bypass Tunnel(Diameter 11.8m)

38.50 Flood Level

31.3

38.00 Flood Level31.80 Standing Water Level structure

Offtake gatedstructure

STRUCTURE

BELL MOUTHSTRUCTURE AREA = 119028m

TAMAN DESA POND

RL 20mNEW POND SIZE

TO SEREMBAN

TO KL

2

TWIN BOX CULVERT(2 nos. 5.1m H x 5.5m W)

SG. BESI AIRFIELD

BY

PA

SS

TU

NN

EL

KL - SEREMBAN HIGHW

AY

AREA = 216594m

ORIGINAL POND SIZERL 28m

2

RESTAURANTDESA

WATER PARK

THEME PARKDESA

WATER PARK

INTAKE GATEDSTRUCTURE

OUTFALLSTRUCTURE

OUTFALLSTRUCTURE

structureSg

THE FLOOD DIVERSION SYSTEMFloodgates divert storm-water from Klang river to Holding Pond

Water flows through Intake Tower and tunnel gravitationally to Storage Reservoir at Taman Desa

Max. flow: 280m³/sec

Water flows through Twin Box Culvert to the Kerayong river

Low section of tunnel pumped dry



MMC-GAMUDA JV 66

THREE MODES OF OPERATION



MMC-GAMUDA JV 77

THE SMART PROJECT ORGANISATION

After 2,2km the North Drive contract was terminated, the remaining 2.8km was completed by MMC-GAMUDA JV in 11 months.


MMC-GAMUDA JV 24th October 2007, GSM by Gus

MMC-GAMUDA JV 88

GROUND CONDITIONS

-10.00m

0.00m

KERAYONG

SUBSURFACE CONDITIONS FOR SMART

10.00m

20.00m

30.00m

40.00m

1 : 650

1 : 1000

LEGEND:-OVER BURDENROCK BED

STORAGEPOND

SG.SG.Klang JALAN DESA PANDAN

FROM SG. KLANG TOKPG. PANDANALONG JALAN

ALONG JALAN TUN RAZAK CHAN SOW LINAL0NG JALAN KL - SEREMBAN

HIGHWAYSALAK

I/C

KUALA LUMPUR LIMESTONE FORMATION o DEEPLY FISSUREDo ERRATIC ROCKHEAD WITH RELIEF OF >30Mo SINK HOLESo KARST SOLUTION CHANNELS, MOSTLY FILLED SOMETIMES

OPEN

OVERBURDENo SILTS & SANDSo ALLUVIAL TIN DEPOSITSo MINE TAILINGSo SLUMP ZONES OVER THE KARSTIC ROCKHEAD



MMC-GAMUDA JV 99

KARSTIC ROCKHEAD EXPOSED DURING TIN MINING



MMC-GAMUDA JV 1010

KARST MORPHOLOGYkIV - KOMPLEX KARST

K IV is typical in tropical climate, rare in temperate climate.

(from Waltham és Fookes)



MMC-GAMUDA JV 1111

KARST MORPHOLOGYk V - EXTREME, COVERED KARST

k V is typical in Peninsular Malaysia. Climatic conditions accelerate solution.

(from Waltham és Fookes )



MMC-GAMUDA JV 1212

KARST FEATURES 3D IMAGE OF THE NORTH VENTILATION & TBM’S LAUNCH SHAFT

The widening at the ends are the two TBM launch areas.

‘L’ shaped walls used at ‘normal depth’ rockhead tied back secant pile walls keyed into the rock at karstic features.

300m³ of grout was used to stem 4000l/min water inflow at the south end (LHS).

South

North North



MMC-GAMUDA JV 1313

KARST FEATURESSUDDEN DROP OF ROCKHEAD

Tied back bored pile wall temporary support next to the generally used ‘L’ shaped walls



MMC-GAMUDA JV 1414

KARST FEATURES POTHOLE or BURIED SINKHOLE

AS SHOWN BY WALTHAM & FOOKES

AS FOUND ON SITEAS FOUND ON SITE



MMC-GAMUDA JV 1515

KARST FEATURES POTHOLE AT THE NORTH JUNCTION BOX



MMC-GAMUDA JV 1616

RESISTIVITY TOMOGRAPHY

Successfully used in the South Drive to detect anomalies in the karst well ahead of the TBM. The suspect areas were investigated by drilling from the surface and treteated if necessary. Probing from the machine was abandoned.



MMC-GAMUDA JV 1717

KARST FEATURESAS MAPPED AT AN EGRESS RAMP

From SSP’s Lee & Tan Oct 2008



MMC-GAMUDA JV 1818

RCC LININGExternal diametre: 12,83mInternal diametre: 11,83mRing length: 1,70mRing split: 8 + 1Ring weight: 82tNormal segment weight: 10tReinforcement ratio: 82kg/m3Concrete: Grade 50



MMC-GAMUDA JV 1919

GATES AT THE NORTH JUNCTION BOX

TO JLN S

ULTAN ISM

AIL

WATER FLOW

TO KL-SEREMBAN HIGHWAY

TO STORAGE POND

NORTH JUNCTION

SOUTH JUNCTION

MOTORWAY TUNNELGATE

VENTILATION ANDEMERGENCY ESCAPE SHAFT


UPPER DECKSERVICE GATE

GRID GATESERVICE GATE

EMERGENCY GATE


MOTORWAY TUNNEL GATE

SERVICE GATEEMERGENCY GATE

GATE SHAFT

GATE SHAFT

KEY PLAN

EMERGENCY GATE

AIR RELEASE SHAFTS

DIRECTION OF WATER FLOW

GROUND LEVEL

UPPER DECK SERVICE GATE SHAFTSERVICE & EMERGENCY GATE SHAFT

Upstream Stormwater Tunnel Flood GatesLONGITUDINAL SECTION

UPPER DECK SERVICE GATE

LOWER DECK SERVICE GATE



MMC-GAMUDA JV 2020

UPSTREAM MOTORWAY TUNNEL GATE SHAFT

MOTOR ROOM ACCESS

GROUND LEVEL

FL

OO

DG

AT

E

GATE MOTOR ROOM

HYDRAULIC RAM

HYDRAULIC RAM

TYPICAL MOTORWAY TUNNEL SHAFT DETAIL 1 - OPERATION OF TYPICAL ROAD GATE

PLAN SHOWING ROAD GATE ASSEMBLY

Traffic

Traffic

See Detail 1

ROAD CLOSURE/FLOOD GATES

Prevents vehicle acces during flood diversionPrevents flooding of ramps and reduces cleaning time

TO JLN SULTAN IS

MAIL

WATER FLOW

TO KL-SEREMBAN HIGHWAY

TO STORAGE POND

NORTH JUNCTION

SOUTH JUNCTION

MOTORWAY TUNNELGATE




GRID GATE

SERVICE GATE

EMERGENCY GATE


MOTORWAY TUNNEL GATE

SERVICE GATEEMERGENCY GATE

GATE SHAFT

GATE SHAFT

KEY PLAN



MMC-GAMUDA JV 2121

ESCAPE ARRANGEMENTS

ROAD DECK

CROSS PASSAGE AT 250m INTERVALSESCAPE SHAFTS AT 1 km INTERVALS

UPPER

ROAD DECKLOWER

CHANNELLOWER

ROAD DECKUPPER

ROAD DECKLOWER

CHANNELLOWER



MMC-GAMUDA JV 2222

VENTILATION LOWER ROAD DECK

LOWER

INVERT

ROAD DECK

UPPERROAD DECK

EXHAUST SUPPLY

EXHAUST SUPPLY

ESCAPE STAIR

AIR DEFLECTORSIN VENT DUCT

PLAN

SECTION



MMC-GAMUDA JV 2323

REVISION OF PLANNED EXCAVATION METHODS

Drill & Blasto Difficult to prevent groundwater

drawdown, triggering sinkholes away from the alignment

o Risk of inundation if major open karstic system is encountered

o Major noise and vibration problems while blasting

o Erratic rockhead forces frequent excavation method changes

o Many sections require partial face excavations

o Difficult to support soft overburden in mixed faces while blasting rock

Cut & Covero Major disruption in an urban

environmento Difficult to prevent groundwater

drawdown, triggering sinkholes away from the alignment

o Major noise and vibration problems while blasting over 1million m3 rock in the city

o Difficult temporary sidewall supporto Risk in passing under sensitive

railway structures (ERL, KTM, LRT)o Costly utilities diversions

Planned Drill & Blast with shotcrete temp. support tunnelling method and Cut & Cover method in South Drive revised, changed to closed TBM drive for:

THIS RISK MANAGEMENT DECISION INTRODUCED A NEW RISK; SLURRY SHIELD TUNNELLING WAS TO BE PERFORMED BY FIRMS WITH NO EXPERIENCE IN TUNNELLING. THE NEW RISK WAS PROVED TO BE EMINENTLY MANAGEABLE BY EMPLOYING A PROFESSIONAL TEAM.



MMC-GAMUDA JV 2424

METHOD SELECTION DEVELOPMENTSOUTH SECTION



MMC-GAMUDA JV 2525

METHOD SELECTION DEVELOPMENT NORTH SECTION



MMC-GAMUDA JV 2626

SHAFT EXCAVATIONVentilation and TBM launch shaft

‘Y’ shaped junction box



MMC-GAMUDA JV 2727

TBM SELECTION CRITERIAGENERALo Short, one year delivery time to satisfy tight concession

contract programo Design and build to high standards to survive long drive

and difficult geologyo Large, 13,25m excavation diametreo Able to negotiate tight R=200m curves; tunnel design

R=250m curveso Low overburden

o Minimum 0.9Do Maximum 1.5D

o Urban tunnelling environmento Restricted access to alignment at 2/3d of the cases for

ground treatment



MMC-GAMUDA JV 2828

TBM SELECTION CRITERIAGEOTECHNICALo ~70% of tunnel in the KL Limestone Formation (marble)o ~25% of tunnel in full face mine tailings at the North endo ~5% of the tunnel in Kenny Hill formation (stiff soils of

granitic origin)o Karstic rock with solution features such as channels and

interconnected cavitieso Highly variable, pinnacled rockhead causing frequent mixed

face conditionso Alluvial or mine tailing overburden with low SPT ‘N’ valueso High groundwater table close to surface o Slump zones in the overburden above rockheado Solution channels, cavities mostly filled with slumped soilo Extremely high permeability at open karsic solution channelso Naturally occurring sinkholes caused by cyclical water table

changes or during earthquakes



MMC-GAMUDA JV 2929

TBM SELECTION BASED ON SOIL PARTICLE SIZE DISTRIBUTION

Herrenknecht brochure



MMC-GAMUDA JV 3030

TBM SELECTION BASED ON GROUND PERMEABILITY

The answer depends on placing the following foreseen situations in this table.

1.Fractured rock

2.Karstic rock with partly filled solution channels

3.Karstic rock with completely filled solution channels

4.Mixed face of soil and rock with all the above as possible combinationHerrenknecht

brochure



MMC-GAMUDA JV 3131

STM SCHEMATICS

Herrenknecht brochure



MMC-GAMUDA JV 3232

TBM SELECTIONTECHNICAL COMPARISON POINTS

Description Herrenknecht Hitachi Kawasaki Mitsubishi NFM

General 25 14 13 6 24

Cutterhead 85 53 57 33 72

Cutterhead Drive 65 63 50 43 62

Shield 44 30 27 21 29

Segment Handling 35 22 24 20 35

Probe drilling 10 7 7 6 12

Manlocks 17 16 8 8 24

Trailer 26 18 18 12 26

Guidance & Monitoring 44 28 31 27 42

Services 75 53 40 41 78

Slurry System 49 41 43 37 55

Total 475 345 318 254 459



MMC-GAMUDA JV 3333

TBM SELECTIONCOMMERCIAL COMPARISON

The prices were adjusted by:

o Cost of items not included in the offer but considered necessary and included by others

o Delivery time impact on scheduleo Finance costs

Herrenknecht Hitachi Kawasaki Mitsubishi NFM

Price ratio

1.00 1.41 1.28 1.21 1.01



MMC-GAMUDA JV 3434

SELECTED TBMSS 252 & S 253

Cutterhead dia.: 13.260mmDrive: 4.000kW hydraulicTorque: 24.400kNmRotation: 0-3 rpmDisplacement thrust force: 28.900kNLength of machine: 71mTwo trailer cars on haunch railsWeight of machine: 2.500t

Length of shield : 10.245mmWeight of shield : ~1.500tThrust cylinders: 3x16=48NosMax. thrust: 94.500kNGrout lines: 8Nos Guidance: VMT SLS T-APDTailseal: 3 rows, wire brushesDisc cutters: 17”; 76 Nos

TWO HERRENKNECHT MIXSHIEDS



MMC-GAMUDA JV 3535

SPECIAL FEATURES

o Spherical main bearing to negotiate tight, min. R200m curves (tunnel min. radius R250m)

o Cutterhead retraction of 400mm by axial displacement through main bearing without shield movement for easier cutter replacement

o Articulated tailskin to negotiate the tight curves (at the time of manufacturing the largest in the world)

o Cutterhead tilt moment indicator to detect karstic features and mixed face conditions

o Two probe drilling rigs in fixed downward looking position, mounted on the erector the rig could drill through any port in the skin

o Inflatable “pig” (obdurator) for slurry pipe extensionso SSP Sonic device mounted on the cutterhead to detect

cavities and rock/soil interfaces (did not survive the mixed face environment)



MMC-GAMUDA JV 3636

THE TWO SEPARATION PLANTS

New plant of at the factory yard in Műhlheim

Capacity:4x600=2400m³/óra

Refurbished plant used to build the Elbe tunnel in Hamburg

Capacity:3x800=2400m³/óra



MMC-GAMUDA JV 3737

THE TBMs IN SCHWANAU AT THE HERRENKNECHT FACTORY

S 252S 253

S 253

in winter



MMC-GAMUDA JV 3838

LIFTING OF THE 160t ARTICULATED TAIL SKIN



MMC-GAMUDA JV 3939

LIFTING THE S 252 CUTTERHEAD

The head segments were weldeded together by 8t of electrodes

Lifted load 295t



MMC-GAMUDA JV 4040

BREAKTHROUGH, NORTH DRIVE



MMC-GAMUDA JV 4141

MOVING THROUGH THE NORTH JUNCTION BOX



MMC-GAMUDA JV 4242

ASSEMBLY OF THE SOUTH TBM



MMC-GAMUDA JV 4343

THE SOUTH TUNNEL

The end of the trailer with the escape container

1xΦ2000mm ventduct

2Φ500mm slurry pipes

2xΦ200mm cooling water

2xΦ200mm compressed air



MMC-GAMUDA JV 4444

PASSING THROUGH A VENT SHAFT



MMC-GAMUDA JV 4545

BREAKTHROUGHS IN ROCK IN SOFT GROUND

TAMAN DESA

NORTH TEMP SHAFT



MMC-GAMUDA JV 4646

PREPARATIONS TO RELAUNCH

Fixing of the starting seal ring in the eye.

Excvation of the road ramp during the relaunch of the TBM



MMC-GAMUDA JV 4747

RELAUNCH AT THE SOUTH DRIVE



MMC-GAMUDA JV 4848

SOUTH DRIVE PRODUCTION SUMMARY



MMC-GAMUDA JV 4949

Figure 3.11 : Cross Section For The Motorway

NOTE: INTERNAL TUNNEL DIAMETER IS 11.8 M OR EQUIVALENT SECTION

Appendix 3Concession AgreementStormwater Management And Road Tunnel

SMART Page 30 of 56

2550

Traffic LaneTraffic LaneEmergency

Lane

2550

2000 3350 3350150

LOWER CHANNEL

LOWER DECK

UPPER DECK

RAHSIA

RAHSIA

MOTORWAY TUNNEL CROSS SECTION



MMC-GAMUDA JV 5050

ANALYSIS OF ROAD DECK

LOAD TRANSFER TO SEGMENTS (TENSION AND SHEAR)

RESULTANT FORCE UP

WATER UPLIFT



MMC-GAMUDA JV 5151

TESTING THE THIN SLABS OF THE ROAD DECK

350

175 175175

350

175175

350

175175

350

175175

350

175175

350

175175

350

175175

350

175175

350

175175

350

175175

350

175 175

350

175 175

350

175 175

350

175 175

350

175 175

350

175 175

350

175 175

350

175

350 175175

A

A

250 12

512

5

PLAN

LONGITUDINAL SECTIONSCALE 1:12.5

SCALE 1:12.5

G40N (Slump 150+/-25mm)

40

T12 Links

2T16 Links2T16 Links

B

B

100

1625

1625

125 125 1025

6550

6550

125

125

125

125

125

125

125

125

125

125

125

125

8600 (T25)

1025

8600

25mm Coupler (Lower Main Bars Only) 25mm Coupler (Lower Main Bars Only)

Ø25

SECTION A-ASCALE 1:5

Ø25

Ø32

Ø25

250 375 250 375 250

12Ø

40

12Ø

Ø25

12Ø12Ø

Ø32

12Ø12Ø

2T16 2T16 2T16

25

2525

25

TOP SURFACE TO HAVE ROUGHENED & EXPOSED AGGREGATES

441.5

125

625

100

1625

510

Ø25

SECTION B-BSCALE 1:5

Ø25

Ø25

250 375 250 375 250

Ø12 12Ø40

100

12Ø

2525

25

25

TOP SURFACE TO HAVE ROUGHENED & EXPOSED AGGREGATES

Ø32

Ø12 12Ø

12Ø

Ø32

Ø12 12Ø

12Ø

441.5

625

1625

510

FILIGRI SLAB UPPER DECK (STANDARD)GRIDER REINFORCEMENTKenny Lim Yeoh HK

25 August 2004 25 August 2004 SMART/MGJV/TUNNEL/FILIGRI SLAB /0002A

A23/8/04 1. Height of girder bars extended to 441.5mm c/c 2. Top middle main bar change from T32 to T25 3. Bottom main bar length 8.6m 4. Top main bars (T32 & T25) extended to 8.6m 5. Lower Main Bars Fitted 25mm Coupler A



MMC-GAMUDA JV 5252

ROAD DECK CONSTRUCTION



MMC-GAMUDA JV 5353

ROAD DECK CONSTRUCTION



MMC-GAMUDA JV 5454

CROSS or ESCAPE PASSAGES AT 25OM INTERVALSProvide escape to smoke free environment between road decks



MMC-GAMUDA JV 5555

CROSS PASSAGE CONSTRUCTION



MMC-GAMUDA JV 5656

HOLDING POND & FOUNDATION OF THE WATER INTAKE TOWER



MMC-GAMUDA JV 5757

TWIN BOX CULVERT AT TAMAN DESA



MMC-GAMUDA JV 5858

TIME-CHAINAGE DIAGRAM SOUTH TUNNEL



MMC-GAMUDA JV 5959

TIME CHAINAGE DIAGRAMNORTH TUNNEL



MMC-GAMUDA JV 6060

THE UPPER ROAD DECK BEFORE OPENING



ex. MMC-GAMUDA JV.BKV-DBR Metro

6161

THANK YOU

FOR YOUR PATIENCE

stormwater management and road tunnel - ita-aites

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