number 7 extension presentation to pmi nj chapter · presentation to pmi nj chapter january 15,...
TRANSCRIPT
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Number Extension
Presentation to Presentation to
PMIPMINJ ChapterNJ Chapter
January 15, 2013
7
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Project Overview
Contract 1 – Running Tunnels
Methods of Excavation and Construction
Concrete Work
AGENDA
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PROJECT OVERVIEW
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No. Project Context7
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34th StreetStation
No. Alignment7
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PABTPABTPABT
JJJJJJCCCCCC
414141ststst St.St.St.
424242ndndnd St.St.St.
Site K
Site P
34th Street Station Cavern Length: 1,212’34th Street Station
Cavern Length: 1,212’
Tunnel1.5 mile extension from Times
Square Station
Tunnel1.5 mile extension from Times
Square Station
Tail Track ModificationLength: 275’
Tail Track ModificationLength: 275’
Site J
Site A
Site L
8THA
ve.
9THA
ve.
Dye
r Ave
.
10TH
Ave
.
26th St.
36th St.35th St.
11TH
Ave
.
34th St.
41st St.
Legend:Project SiteStationStation Entrance
Number Subway Line
Extension
Project Scope
Key Plan
7
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No. 7 and Development Sites
Site A
Site L
Site JSite P
Site K
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34th Street Station
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34th Street StationPlatform
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Project FactsLength: 1.5 mile extension34th Street Station: 1,212 ftProject cost: $2.366BCompletion Date: June 2014
City Representative: Hudson Yards Development Corp.
Funding: Hudson Yards Infrastructure Corp.
Design Consultant: PB Team
Consultant Construction Management (CCM):
HLH7Hill International, Inc.LiRo Engineers, Incl.HDR| Daniel Frankfurt
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34th
St.
Sta
tion
Site A
Site L
Site K
Site P
Site J
Construction Contracts
- Running Tunnels (Contract 1)
- Site L Ventilation Building
- Site J Ventilation Building & Station Entrance
- Site K Ventilation Building
- Systems & Finishes
- Secondary Station Entrance(Site P)
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CONTRACT 1 RUNNING TUNNELS
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34th StreetStation
No. Alignment7
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11th Avenue - 25th to 31st Streets
Site A
26th
Stre
et
26th St.30th St.
Eleventh Avenue
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11th Avenue – 31st to 39th Streets
34th St. 38th St.
Site P Site K
Jacob JavitsConvention Center
34th
Stre
et
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41st Street – 11th to 9th Avenues
10th
Ave
nue
Dye
r Ave
.
9thA
venu
e
Site L
41st Street
10th Ave.9th Ave
Site M
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41st Street – 9th to 8th AvenuesPort Authority Bus Terminal
9thA
venu
e
9th Ave8th Ave
8thA
venu
e
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Eighth Avenue Section
No. 7 Flushing Line
Tail Tracks
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11th
AVE
NU
E
10th
AVE
NU
E
DYE
R A
VEN
UE
9thA
VEN
UE
8thA
VEN
UE
41st STREET
SITE ‘L’
RECEIVING PIT
TBM Locations (April 19, 2010)
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METHODS OF EXCAVATION/CONSTRUCTION
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LOOKING WEST FROM SITE A
Muck Pile
Adit Mucking
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Tunnel Boring Machines (TBMs)
Manufactured in Germany by Herrenknecht.
Two TBM’s arrived job site January/ February 2009.
Lowering of first TBM Cutterhead February 2009.
Assembled in starter tunnels April 2009.
Commenced boring May 2009.
Complete boring June 2010.
Disassembly and removal from site August 2010.
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TBM Operations
TUNNEL CC1 HOLEDecember 28, 2009
TUNNEL CC2 TBM CRADLE
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TBM CC2 TRAILING GEAR
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Ground Freezing11th Avenue between 26th and 28th Streets
26th St. 30th St. 34th St.
Amtrak Tunnel
No. 7 Tunnel 34th Street StationSite A Adit
Amtrak Tunnel
40’
Approx. Rock Line
Top of Ground
11th Avenue Viaduct
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“Conceptual” Cross SectionGround Freeze Area
11th Avenue
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GROUND FREEZE AREA GROUND FREEZE HEADER PIPING
GROUND FREEZE AREA REPAVED
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Eighth Avenue Section
No. 7 Flushing Line
Tail Tracks
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TIMES SQUARE TAIL TRACKS LOOKING WEST
TIMES SQUARE UNDERPINNING
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CONCRETE
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• Precast Tunnel Liners• Grout• Shotcrete• Cast-in-place
Concrete Work
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Precast Tunnel LinersManufacturer Technopref Industries
Royersford, PATotal estimated liners: 9,388 LFDimensions:
Number of planned precast rings: ~1,900Ring width: 5 ftInside diameter: 22.5 ftOne ring: 5 segment + 1 “key” pieceSegment thickness 1 ftWeight: ~ 4-5 tons/piece
~ 2 tons/ “key” pieceConcrete: ~ 12 yds3/ring, or 22,800 yd3 total
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Precast Tunnel Liners – Cont’dStrength
Design mix:
Actual:
8,000 psi (28 days)
8,000 psi (7 days)10,000-12,000 (28 days)
Formwork: Black steel rebarsPolypropylene fibersStripped after 8 hours; 2,500 psi
Gaskets: EDPM – applied 12 hours after initial casting
Hydrophylic – applied with epoxy-like glue within 7 days of tunnel installation
Unique ring and segment identification codeProduction rate: 5 rings/shaft @ 2 shifts/day = 10 rings/dayCareful procedures for each ring segment:
HandlingStorageTransportPlacement
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HANDLING OF SEGMENT IN PLANT
SEGMENTAL LINING RINGS
Segmental Tunnel Lining Rings
PRECAST SEGMENT CONTROL NUMBERS
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TRANSPORT OF ONE RING
LINED TUNNEL
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Construction Management Association of America (CMAA)
• Metro NY/NJ Chapter - Honorable Mention Project of the Year
2012
• National - 2012 Project Achievement Award
Colorado School of Mines• Tunnel Achievement Award for Project Excellence
( Best National & International Tunneling Project - 2012)
Engineering News Record New York• Award of Merit (Transportation)
Recognition Awards to Date
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• Cost Management
• Schedule Management
• Quality Management
• Safety Management
PROJECT MANAGEMENT AND CONTROLS
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Cost Management (Cont’d)
Establish Budget
• $2.1 Billion Subway Program established by MOU
• Breakdown Budget into major categories• Design• Construction• Construction Management • Contingencies
• Further broken down to measurable sub categories.
• Detail bottom up estimation for each budgeted line item
• Categories to remain valid for life of project
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Cost Management (Cont’d)Breakdown of Budget
• Construction cost - per contract
• Design cost –- Preliminary Engineering (PE)- Final Design (FD)- Design Support During Construction (DSDC)
• Construction Management (CM) Cost
– In-house CM cost (MTA’s Project team)
– CM Consultant cost (CCM)
– Transit Authority Costo Transit Authority Labor (TA Labor)o Engineering Force Account cost (EFA)
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Number 7 Line Project Budget
• Subway Related Cost : $2,100 Million• Non-Subway Related Cost: $266 Million
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Cost Management (Cont’d)Monitor Expenditures
•To date Administered $1.5 billion total disbursement
•Timely and prompt payment for every invoice
•Peak monthly payment - $50 millions to Contractors
•Negotiated Changes of total $10.5 million, includes several
millions in credits
•Tunnel contract ($1.1 billion) was completed below budget
•Developed Baseline Budget and Baseline Cash Flow for
each line item separately.
•Track Actual against Plan each month and review trend
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Cost Management (Cont’d)
Cost Control
• Perform Trend Analysis• Based on the trend, revise budget allocation, i.e. Re-
baseline• Forecast “Estimate-At-Completion” (EAC)• Look for Opportunities
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34th
St. S
tatio
n
Site A
Site L
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Cost Performance To-Date
• Project Budget ………………. $2,366 million
• Construction Contracts…….. $1,972 million
• Construction Completed …... $1,535 million (78%)
• Remaining Construction …... $437 million (22%)
• Contingency Budget ……….. $100 million• Contingency Spent …………. $10.5 million
(0.53% of Construction Cost)
• Number of Contracts Completed...………..........3 out of 6
• Contingency spent on Completed Contracts ….0.22%
• Estimate-At-Completion (EAC)………………….$2,366 million
Cost Management (Cont’d)
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SCHEDULE MANAGEMENT
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Schedule Management (Cont’d)
Vision
• Revenue Service by June 2014
• Dignitary Train by December 2013
• Achieve Project Completion by June 2016
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Schedule Management (Cont’d)
• Overall Integrated Project Schedule (IPS)
• Include all aspects of work
• Detailed schedule for each construction contract
• Each Detailed schedules has more than 1000 activities
• Largest schedule has more than 7000 activities
• Update the schedule on monthly basis, review/analyze
• Identify Critical path and near critical paths
• Identify delays and potential delays, discuss mitigation
measures and implement
• Identify Opportunities and Implement55
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Integrated Project Schedule
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Some unique steps taken for this project
• Implementing Guaranteed Maximum Price (GMP) Contract
for Design Support During Construction services.
• Added Bonus sharing feature for accelerated completion.
• Transferred Scope among Contracts, to expedite the work
• Ensured follow-on Systems and Finishes Contractor had
on-time or early access.
• Minimized changes
• Dispute Resolution Board (DRB) for Tunnel Contract.
• Developed “What-if” contracting and construction scenarios
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Impact Due To Hurricane Sandy
Short Term• Impact on material supply chain• Time lost in review of Submittals due to 2 Broadway
closing
Long Term• Industry wide shortage of construction materials
• Potential damages to materials on hand
• Diversion of TA resources
• Availability of resources for Testing & Commissioning
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QUALITY MANAGEMENT
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Quality Control
Phase QC Performed By
Design Engineer of Record
Construction Each Respective Contractor
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Quality Assurance
Phase QA Performed By
Design MTACCe.g., Semi-annual Performance EvaluationsMTACC and Consultant Construction Manager (CCM)e.g., Spot Check Programs (applicable design standards, Co-ordination of drawings, etc.)
Construction MTACC and Consultant Construction Management (CCM)e.g., Semi-annual Performance EvaluationsConsultant Construction Managere.g., Quarterly Quality Audits and Spot Check
Programs (i.e., Material Certifications, Witness Tests, Tunnel Leaks, etc.) 67
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SAFETY MANAGEMENT
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Thank you