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Appendix DTBM Tunnel Assumptions and Cost Estimating Output


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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 eachTBM 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 toprovide a flat working surface. Inverts were added to TBM Types A and C only becauseit 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 TypesA 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 inthird 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) asfollows:


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


Secondary cast-in-place concrete lining installed to prevent long term degradation of therock

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 installedimmediately behind the TBM following each excavation cycle


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


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



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


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


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 installedimmediately behind the TBM following each excavation cycle



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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 8,560,000

A Second 4800 6,070,000 200,000 6,270,000

A Third 4800 5,910,000 200,000 6,110,000

A Fourth 4800 5,600,000 200,000 5,800,000

A Fifth 4800 5,600,000 200,000 5,800,000

A/B with CIP First 4800 18,930,000 400,000 19,330,000

A/B with CIP Second 4800 16,350,000 200,000 16,550,000

A/B with CIP Third 4800 16,140,000 200,000 16,340,000

A/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 27,030,000

C Second 4800 23,190,000 200,000 23,390,000

C Third 4800 22,940,000 200,000 23,140,000

C Fourth 4800 22,430,000 200,000 22,630,000

C Fifth 4800 22,430,000 200,000 22,630,000



(m)

A First 4800 10,930,000 400,000 11,330,000

A Second 4800 7,360,000 200,000 7,560,000

A Third 4800 7,080,000 200,000 7,280,000

A Fourth 4800 6,520,000 200,000 6,720,000

A Fifth 4800 6,520,000 200,000 6,720,000

A/B with CIP First 4800 24,410,000 400,000 24,810,000

A/B with CIP Second 4800 20,160,000 200,000 20,360,000

A/B with CIP Third 4800 19,810,000 200,000 20,010,000

A/B with CIP Fourth 4800 19,100,000 200,000 19,300,000

A/B with CIP Fifth 4800 19,100,000 200,000 19,300,000

C First 4800 33,360,000 400,000 33,760,000

C Second 4800 27,830,000 200,000 28,030,000

C Third 4800 27,400,000 200,000 27,600,000

C Fourth 4800 26,550,000 200,000 26,750,000

C Fifth 4800 26,550,000 200,000 26,750,000


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Appendix ETBM Tunnel Assumptions and Cost Estimating Output (Not

Used)


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Appendix E TBM Tunnel Assumptions and Cost Estimating Output (NotUsed)

Discussion:

The tunnel costs were estimated using TBM cost estimating software and cost databasedeveloped 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 forcompleteness. 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 Meterm3 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 inthird 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:



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



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





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:





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


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 theform of 3 sq.m. of timber laggings per metre of tunnel and associated ribs over 50percent of the tunnel length.


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

Average lining installation rate of 225 metres per week


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Fermilab Tunnels

Estimate Summary



(m)

B First 4800 13,900,000 400,000 14,300,000

B Second 4800 11,570,000 200,000 11,770,000

B Third 4800 11,390,000 200,000 11,590,000

B Fourth 4800 11,030,000 200,000 11,230,000

B 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 20,810,000

B+ Third 4800 20,400,000 200,000 20,600,000

B+ Fourth 4800 19,970,000 200,000 20,170,000

B+ Fifth 4800 19,970,000 200,000 20,170,000



(m)

B First 4800 17,740,000 400,000 18,140,000B Second 4800 13,560,000 200,000 13,760,000

B Third 4800 13,250,000 200,000 13,450,000

B Fourth 4800 12,610,000 200,000 12,810,000

B Fifth 4800 12,610,000 200,000 12,810,000

B+ First 4800 29,000,000 400,000 19,031,000

B+ Second 4800 24,380,000 200,000 14,206,000

B+ Third 4800 24,020,000 200,000 13,852,000

B+ Fourth 4800 23,320,000 200,000 13,144,000

B+ Fifth 4800 23,320,000 200,000 13,144,000


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