Number Extension

Presentation to Presentation to

PMIPMINJ ChapterNJ Chapter

January 15, 2013

7

Project Overview

Contract 1 – Running Tunnels

Methods of Excavation and Construction

Concrete Work

AGENDA

PROJECT OVERVIEW

No. Project Context7

34th StreetStation

No. Alignment7

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

No. 7 and Development Sites

Site A

Site L

Site JSite P

Site K

34th Street Station

34th Street StationPlatform

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

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)

CONTRACT 1 RUNNING TUNNELS

34th StreetStation

No. Alignment7

11th Avenue - 25th to 31st Streets

Site A

26th

Stre

et

26th St.30th St.

Eleventh Avenue

11th Avenue – 31st to 39th Streets

34th St. 38th St.

Site P Site K

Jacob JavitsConvention Center

34th

Stre

et

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

41st Street – 9th to 8th AvenuesPort Authority Bus Terminal

9thA

venu

e

9th Ave8th Ave

8thA

venu

e

Eighth Avenue Section

No. 7 Flushing Line

Tail Tracks

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)

METHODS OF EXCAVATION/CONSTRUCTION

LOOKING WEST FROM SITE A

Muck Pile

Adit Mucking

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.

TBM Operations

TUNNEL CC1 HOLEDecember 28, 2009

TUNNEL CC2 TBM CRADLE

TBM CC2 TRAILING GEAR

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

“Conceptual” Cross SectionGround Freeze Area

11th Avenue

GROUND FREEZE AREA GROUND FREEZE HEADER PIPING

GROUND FREEZE AREA REPAVED

Eighth Avenue Section

No. 7 Flushing Line

Tail Tracks

TIMES SQUARE TAIL TRACKS LOOKING WEST

TIMES SQUARE UNDERPINNING

CONCRETE

• Precast Tunnel Liners• Grout• Shotcrete• Cast-in-place

Concrete Work

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

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

HANDLING OF SEGMENT IN PLANT

SEGMENTAL LINING RINGS

Segmental Tunnel Lining Rings

PRECAST SEGMENT CONTROL NUMBERS

TRANSPORT OF ONE RING

LINED TUNNEL

41

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

41

• Cost Management

• Schedule Management

• Quality Management

• Safety Management

PROJECT MANAGEMENT AND CONTROLS

42

43

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

44

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)

45

46

Number 7 Line Project Budget

• Subway Related Cost : $2,100 Million• Non-Subway Related Cost: $266 Million

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

47

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

48

49

34th

St. S

tatio

n

Site A

Site L

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)

51

52

SCHEDULE MANAGEMENT

53

Schedule Management (Cont’d)

Vision

• Revenue Service by June 2014

• Dignitary Train by December 2013

• Achieve Project Completion by June 2016

54

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

Integrated Project Schedule

56

57

58

59

60

61

62

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

63

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

64

QUALITY MANAGEMENT

65

Quality Control

Phase QC Performed By

Design Engineer of Record

Construction Each Respective Contractor

66

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

SAFETY MANAGEMENT

68

69

Thank you