Professional Documents
Culture Documents
WT0712
WT0712
Equipment
Underground support vehicles
Guidance
www.world-tunnelling.com
CovIWT0712.indd 1
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BREAKTHROUGH
SOLUTIONS
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1
COMMENT
contacts
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ISSN 0026-5225
World Tunnelling is published ten times
annually by Mining Communications Ltd,
Albert House, 1 Singer Street, London,
EC2A 4BQ, UK
Mining Communications Ltd 2007
A member of BPA
Worldwide
A member of the Periodical
Publishers Association
Continental Conveyors.co.uk
www.continental-conveyor.co.uk
Hunter Personnel
www.hunterpersonnel.com
Lovat
www.lovat.com
CONTENTS
advertisers
Atlas Copco Rock Drills
www.atlascopco.com
5
25
4
Cov II
Regulars
FRONT COVER
1 Comment
2-9 Global news and STUVA
30-31 Innovation
www.msd-dresden.de
12
Mining Equipment
www.miningequipmentltd.com
17
Parsons Brinckerhoff
www.pb.com.au
15
Features
Prime Horizontal
www.prime-horizontal.com
14
Propex
www.bermesh.com
28
Robbins
www.TheRobbinsCompany.com
A large-scale programme will help meet the sewage demands of North Seattle
Cov III
RocTest
www.roctest.com
19
Sandvik
www.sandvik.com
Steam Engineering
www.steamengineering.ca
Tunnel Engineering
www.tesuk.co.uk
11
VMT
www.vmt-gmbh.de
Wyo-Ben
www.wyoben.com
16
26
December 2007
01WT0712.indd 1
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NEWS
Copenhagen, Denmark
New York, US
Skanska bags
US$400m
subway project
SKANSKA has announced that
it recently signed a contract
with MTA New York City Transit
for the extension of the No 7
Subway Line.
Skanska will receive a 35%
share of the US$1.4 billion
contract, which involves the
extension of the No 7 line
between Times Square and
West Side of Manhattan,
including 3.6 km of new 6.5 mdiameter tunnel constructed at
depths of around 40 m.
Also included is the
construction of an underground
station at 34th Street and the
lowering by about 2 m of
existing track at the Times
Square Station to allow
connectivity with the new
tunnels. Extensive underpinning
of the existing 8th Avenue
Subway Line will also be
required. The project is
scheduled for completion in
about 57 months.
Skanska USA Civil signed
the contract as part of the
S3tunnel Constructors JV that
also features JF Shea Construct
ion (35%) and the Schiavone
Construction Company (30%).
The news follows on from
the award earlier this year
when Skanska won the contract
to build the first stage of the
Second Avenue Subway line on
the east side of Manhattan.
Athens, Greece
December 2007
02,04,06-08WT0712.indd 2
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Sandvik.indd 1
31/8/07 12:19:28
NEWS
New York, US
Extra funding
for Hudson
A FURTHER US$1 billion will
be provided by the Port
Authority of New York and New
Jersey to construct the
US$7.5billion Hudson River
rail tunnel project. This is in
addition to the US$2 billion
pledged by the Authority.
The tunnel aims to almost
double the train capacity into
Manhattan during rush-hours.
Rising petrol prices and
increasingly crowded highways
are forcing more onto New
Yorks public transport and it is
hoped the tunnel will ease the
situation. The project is due for
completion by 2017.
The Port Authority of New
York and New Jersey is
responsible for operating the
airports, bridges and tunnels
carrying car traffic between
New Jersey and New York.
Delhi, India
Pittsburgh, US
02,04,06-08WT0712.indd 4
December 2007
6/12/07 21:09:48
2007-11-26 13:51:01
NEWS
Antwerp, Belgium
Brisbane, Australia
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02,04,06-08WT0712.indd 6
Tunnel has a
cloudy lining
www.vmt-gmbh.de
12.09.2007 12:55:51 Uhr
6/12/07 21:10:20
NEWS
Munich, Germany
Sheffield, UK
Hydrogen cars
driving rethink
HYDROGEN cars may be the
panacea for reducing CO2
emissions, but recent research
highlights their potential danger
should they explode in a tunnel.
Unlike a crash with a
conventional car, where petrol
would collect on the ground
and ignite, the scenario with a
hydrogen car is more
hazardous, according to recent
research by Yajue Wu of
Sheffield University, England.
Wus computer simulation is
reported to have shown that in
a serious collision, escaping
hydrogen would form a giant,
high-velocity, 2,000C jet flame
that would stretch high enough
to cause serious damage to the
tunnel roof. The findings could
cause a rethink on ceiling
design if the hydrogen
economy starts to take off.
Instant Steam
Generator
Curing concrete
tunnel segments.
curing pipelinings.
02,04,06-08WT0712.indd 7
6/12/07 21:10:25
NEWS
Dushanbe, Tajikistan
Hindhead, UK
to 20 m. Lovat also
designed and supplied
the segmental tunnel
lining. Tunnel
excavation is set to
begin by the end of
this year.
In Sydney, Australia,
contractor Theiss Pty recently
signed a contract with Lovat to
deliver a 3.7m-diameter
RMP147SE 22001 TBM, en
route to Australia for use in the
construction of Sydneys City
West Cable tunnel.
Sandvik
jumbos
primed for
construction
on the
Hindhead
project in
January
Newcastle, UK
December 2007
02,04,06-08WT0712.indd 8
6/12/07 21:10:39
EXHIBITIONS & CONFERENCES: Germany
STUVA prize
CONFERENCE
After the official opening and welcome
speeches, Prof Dr Ing Alfred Haack, managing
director of STUVA, gave the keynote lecture on
Trend-setting Development in Tunnel Construct
ion and Operation. After a brief summary of the
historic development of transport tunnels in Germany and the need for new tunnels in Europe
and worldwide, Prof Haack stressed the need for
technological developments in the building and
operation of transport tunnels.
The session on international projects included:
The 3km-long Grouft twin road tunnels in
Luxembourg.
An update on the development of the Alp
Transit Gotthard twin tunnels.
The construction of the 1.2 km length of the
Gotthard Base Tunnel in squeezing ground.
The progress on the Ceneri Base Tunnel of the
Alp Transit.
The planning and construction of the twin
Carmel Tunnels in Israel.
The special environmental protection
measures required during the construction of
the Malmo City Tunnel in Sweden.
Mechanised tunnelling was the subject of the
second session. The first paper by Martin
Herrenknecht, discussed his companys 40-plus
TBMs made for Chinese metro and road tunnel
projects, including the worlds largest two TBMs
of 15.43m in diameter, currently working on
the 7.5 km-long tunnels to Chongming Island,
Shanghai.
Other presentations in this session included:
recent developments in mechanised tunnelling;
gasket systems under high water pressure at
launch and reception shafts; high shove loads
due to TBM steering problems; studies of shield
tail deformation during boring; and a paper on
The Betuweroute:
the Netherlands
link to the Trans
European Networks
Trans European
Freight Rail
Network
December 2007
09WT0712.indd 9
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10
FOCUS: North America
Brightwater on track
for North Seattle
A major large-scale tunnel and treatment programme will go a long way to
meet the sewerage demands of North Seattle. Jack Burke reports
Structure (IS) for mining 22.5m deep and 24.3m diameter, with 39.6m-deep slurry
diaphragm walls, tremie slab and final concrete wall lining.
One Influent Pump Station shell (IPS) 25.3m deep, twin 25.6m (inside diameter) cells, with
48.8m-deep slurry diaphragm walls, tremie slab, and final lining.
Two short 3.66m-diameter connector tunnels.
One extraction shaft 12m deep x 12m wide and 42.6 m long for connection to treatment
plant piping.
Aerial view of the Brightwater site,
May 2007
Geological Setting
The Brightwater Conveyance System lies
within the Puget Trough, a structural basin
between the Olympia Mountains and the
Cascade Mountains, formed by the Juan de Fuca
oceanic plate being thrust beneath the North
American Continental plate. A north-south
compressional regional stress component
caused by the northward movement of the Sierra
Nevada tectonic block has created a series of
smaller blocks and basins within the volcanic
bedrock. Depth to bedrock in the project area
(122-457m) will not be encountered during
construction. The bedrock is overlain by glacial
and non-glacial sediments, through which the
Brightwater Conveyance System will be built.
Puget Troughs geological history is
dominated by a succession of at least six
continental glaciations. As glaciers advanced,
large lakes were formed where silt and clay
were deposited. As the ice sheets advanced
further to the south, the supply of sediment to
the lake coarsened and sand and gravel filled
the lowland. When the ice reached about the
latitude of the project, sub-glacial melt water
Groundwater
A sequence of aquifers and aquitards varying in
thickness and lateral continuity have been
formed by this depositional environment.
Aquifers comprise granular water-bearing
sediments and the aquitards contain finergrained sediments reducing water flow. In the
project area, six deposits were identified as
aquifers or aquitards. Groundwater flow through
the area is initiated by recharge infiltrating the
ground in uplands and moving down until
reaching the uppermost regional aquifer.
Construction
In January 2006, the contractor mobilised on
site, installing utilities and screen/sound wall,
followed by placing the guide walls for the (IS)
shaft, 39.6m deep, and the (IPS) Shaft, 48.76 mdeep.
Bencor, the slurry wall subcontractor, started
actual slurry-wall excavation in June 2006 on
the (IS) shaft but finished in early fall after a sixweek delay due to an operators strike against
the ready-mix concrete suppliers in King County.
This was followed by the 27 m deep IS shaft
excavation in the wet and the pouring of the
4.1m steel reinforced tremie plug. After
dewatering, a cast-in-place final lining of the
shaft was achieved in two three-pour lifts,
including portals for launching the BrightwaterEast tunnel, the receiving portal of the
December 2007
10,12WT0712.indd 10
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10/12/07 11:49:43
12
FOCUS: North America
Brightwater-Central tunnel and three more
Boring pipe 96 in the micro tunnel, view west. Above right: TBM for Brightwater-East
launch pad was placed across the IS shaft in line
with the tunnel and affixed with launching rails
to assemble the 5.9m Lovat EPB TBM. A critical
delay in manufacturing the Lovat EPB TBM was
due to the late delivery of the cutterhead drive
bearing made by Rotek, Ohio, which was due to
increased government priority orders for the Iraq
war. A request for a time extension is under
review by owner King County.
On July 17 and 18, TBM tests took place in
Toronto, with non-production bearing and
disassembly starting the same week. Delivery of
the TBM started in early August and the
production bearing installed in the motor plate
at Lovat and delivered to site on August 31. TBM
assembly took place on the launch block, but
suffered problems associated with the front and
rear articulation seals. These have been replaced
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Before the
Brightwater-East
tunnel could
start, the 1.8mdiameter micro
tunnel had to be
finished
December 2007
6/12/07 21:01:31
13
FOCUS: North America
Arrowhead on target in
the Sunshine State
PROJECT HISTORY
Following the award of the rst contract to
Shank/Balfour Beatty in January 1997 for
US$88.4 million, the project was mobilised and
work started at the city portal. The plan was to
drive westwards to daylight at Strawberry Creek
Canyon Portal in Waterman Canyon.
Shank/Balfour Beatty opted for support by
December 2007
13,15-19WT0712.indd 13
10/12/07 10:46:11
Prime Horizontal
primehorizontal.indd 1
prime horiz.indd 1
5/12/07 10:28:02
30/4/07 14:26:04
15
FOCUS: North America
cover in the
Controlling
water inows
was key
ADVANCE RATES
The more water encountered at the face, the
slower the overall mining advance rates. This was
due to the need to perform more pre-excavation
drilling, grouting and water handling, as well as
the presence of excess quantities of ne material
often found with the muck. Fault, gouge and shear
zones have also contributed to slower advance
rates, as well as to highly altered rock.
13,15-19WT0712.indd 15
Reduce ground-
Pre-excavation grouting
was initially performed, as
directed by the owner, to
reduce groundwater inows
to typically 16 litres/s in the
30 m interval from the tunnel
face back to the portal.
However, the extent and
potential for improvement in
ground stability could not be
quantied directly by more
grouting. Furthermore, it was
always uncertain whether
probe drilling would be
10/12/07 10:46:18
16
FOCUS: North America
rock, gouge, weathered and altered rock.
13,15-19WT0712.indd 16
Description
Pre-excavation grouting
Water Ground Voids
CEMENTITIOUS PRODUCTS
Portland cement Type II
Portland cement Type III
Rapidset cement
Micro-ne cement
Fly ash
CHEMICAL PRODUCTS
Polyurethane grout
Sodium silicate
Colloidal silica
Minova Celbex 802
Annular grouting
Stage I
Stage II
= Primary grouting material; = Secondary grouting material; = Trial & test grouting material
GROUND BEHAVIOUR
The contract documents described the
subsurface conditions and behaviour anticipated
during construction of the East and West
10/12/07 10:46:19
17
FOCUS: North America
Checking
water
ingress
the segmental tunnel lining with a sand-cement (Type II) grout. Various anti-dispersion agents
and grout accelerators were also used on an experimental basis.
Stage II contact grouting: Injected periodically as the TBM advanced and completed the
lling of the annular void surrounding the tunnel liner with neat cement (Type II) grout.
Drainage holes: Installed at 20 through the segmental tunnel lining to relieve excess
hydrostatic pressure and inows into the cutterhead plenum and to assist with ground
stabilisation and pre-excavation grouting procedures.
13,15-19WT0712.indd 17
Several grouting materials have been used to control inows and ground improvement. Some
are still in use depending on mining conditions at the heading (See Table 1). Other materials are
under test and may be used later for water and ground control needs.
Micro-ne cement: Used for most rock and rock-like conditions to curtail water inows and
improve structural properties of the rock mass for mining. Various mix designs and pressures
were routinely used.
Types II and III cement: Used for most rock conditions to curtail water inows and improve
properties of the rock mass for mining, following the completion of grout injection with
micro-ne cement.
Colloidal silica grout: Used in strata that while producing water inows, resisted penetration
from micro-ne cement grouts even in diluted concentrations. This material was successful
in reducing water inows.
Polyurethane grout: Used in the tunnels with limited success to control groundwater inows
and lling voids. Based on experience, this material did not work well under high water
pressures when injected in to bore holes.
Chemical grout: Sodium silicate grout was used in the tunnels and portals to consolidate
loose and brecciated rock and to control groundwater. This material had limited success in
tight rock formations and where clay was present.
10/12/07 10:46:27
18
FOCUS: North America
operations and then backlling. On occasions to
December 2007
13,15-19WT0712.indd 18
10/12/07 10:46:30
19
FOCUS: North America
Probe ows
measure water
inows
Slurry medium
System or capacity
54 litres/s
41 litres/s
Screens, clarier and centrifuge
<6% nominal to a 15% maximum
(by volume) and dependent on
ow character
Water in a closed re-circulation circuit
with additives injected at the plant
Primary equipment
Habermann slurry pump
Habermann slurry pump
Brandt Equipment at the portal
An effective
pre-excavation
drilling and
grouting
programme
was absolutely
essential
December 2007
13,15-19WT0712.indd 19
NORTH AMERICA
www.roctest.com
1-877-ROCTEST
REPRESENTATIVES
WORLDWIDE
+1-450-465-1113
EUROPE
www.telemac.fr
+33.1.64.06.40.80
ISO 9001:2000
10/12/07 10:46:40
20
TECHNOLOGY: TBM guidance systems
December 2007
20-21WT0712.indd 20
6/12/07 20:49:47
21
TECHNOLOGY: TBM guidance systems
Irrespective
of the type of
guidance system
to be used on
a tunnelling
machine, a
suitable survey
window must
be available
to enable
periodic precise
measurement of
the machines
position to take
place
Guidance system
configuration on TBM
December 2007
20-21WT0712.indd 21
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22
FOCUS: North America
The project
TBM Tunnel
Connecting the two shafts is a TBM-bored,
3,276 m-long rock tunnel, 7m in diameter, with
a finished diameter of 6.4m. The Hampton Shaft
site will have an extension of the tunnel 45 m
south from the shaft and a 3 m diameter, 2.4 m
finished diameter hand-mined tunnel to connect
the new storage tunnel with an existing ISS. The
entire tunnel and connection will be lined with
305mm of cast in-place concrete.
With the contract award, the joint venture
erected extra trailers for the crew and office
personnel on the office complex they had
furnished for the Siphons Project but with some
of the Affholder employees continuing their
positions.
To refurbish the Robbins main beam hardrock TBM, the main frame from the previous
Milwaukee Project recently completed was used
and a new rebuilt cutterhead previously used on
the Buckskin Mountain job in Arizona added.
Shop facilities near the project to rebuild the
TBM and trailing gear were also from the recent
Milwaukee Project.
The components are arriving at the shop and
the contractor personnel under the direction of
Norm Hutchins will turn out the TBM in as nearnew condition. The unit should be ready to go
down the shaft as soon as the access shaft
excavation and lining is completed.
Geology
The tunnel will be bored through bed rock
consisting of dolomite clays. The major
formations are the Racine and Waukesha
Formations, (Niagaran Group, Upper Silurian),
with overburden mainly comprising glacial tills.
The following personnel are on site for the ISS Project: Danny Martz, project manager; Len Postregna, project Engineer; Norm Hutchins, TBM superintendent; Keith Walters, master mechanic; Bonnie Senkowski, office manager; Randy Britton, safety; Dutch Vliegenthart, vice-president
December 2007
22WT0712.indd 22
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23
TECHNOLOGY: Muck-flow handling
OUTLINE OF MUCK-FLOW
CONTROL TECHNOLOGY
Appropriate flow
Blowing
INTRODUCTION
Solid
Clogging
Velocity of muck flow
0.75 1.3
Chamber
Cutter face
December 2007
23-24WT0712.indd 23
6/12/07 21:50:47
24
TECHNOLOGY: Muck-flow handling
Velocity(m/sec)
Velocity(m/sec)
Velocity(m/sec)
(m/sec)
December 2007
23-24WT0712.indd 24
6/12/07 21:51:06
26
EQUIPMENT: Underground support vehicles
The underground
understudies
A huge range of
underground support
vehicles exist for
tunnelling, all designed
to perform a specic
post-excavation task.
Here are some options
BENEFITS
The investment required for one locomotive
with tandem is much lower than for two
locomotives operating in double traction.
Forming a supply train with one locomotive and
one or two tandems will generally incur lower
capital costs than using larger locos operating in
double traction. When a conventional system is
installed, larger locos will be needed for steeper
gradients. More engine power is required to
achieve the same speeds because the locos
weight is just dead weight.
Clearly, the higher the
December 2007
26-28WT0712.indd 26
10/12/07 09:40:50
27
EQUIPMENT: Underground support vehicles
Clayton trolley locomotive
engine power, the greater the fuel consumption and of course, the higher the exhaust
emissions. A wear-free braking system reduces
the consumption of brake pads and lowers
maintenance costs.
One solution has been to design a platform
car driven by the locomotive that can carry
a muck container, mortar container and other
parts of the payload.
CLAYTON
Originally a general engineering company that
subsequently supplied narrow-gauge locomotives to the coal-mining industry, UK-based
Clayton (www.claytonequipment.co.uk) looked
for other markets when coal faced a sharp
decline by the 1990s. As a result, it turned to
non-coal and export markets. This included
tunnelling, to which the company today supplies
a range of products that include battery
locomotives from between 1.75 and 40 t.
In 2006, the company supplied four small
battery locomotives to the London Underground
designed to haul materials and equipment in
narrow tunnels with steep gradients and tight
curves. Trolley locomotives (3-40 t) are also
made by the company, as are diesel (5-40 t) and
ame-proof variants.
IRWIN CAR
When it comes to the transportation
of underground personnel, Irwin Car
(www.irwincar.com) makes various rubber-tyred,
SCHARF
With an international presence, Scharf
(www.smtscharf.com) is well-known for its
rail-bound transportation systems in underground construction. This includes the design,
manufacture, delivery, installation and
maintenance for the transport of personnel,
equipment and material, including for tunnel
applications with small cross-section or steep
GIA INDUSTRI AB
GIA (www.gia.se) states its ambition is to
become a complete supplier of mining and
tunnelling equipment worldwide. Based in
Grangeberg, Sweden,
December 2007
26-28WT0712.indd 27
10/12/07 09:41:00
28
EQUIPMENT: Underground support vehicles
gradients. In particular, the company can tailor
products for the tunnelling industry, including
tunnel monorails and loading equipment.
Earlier this year, Scharf supplied a monorail
for the recently-completed 6.3 km-long cable
tunnel that is designed to replace overhead
electricity pylons on Londons Olympic 2012
site at Stratford. Included in the contract were all
the rails for the tunnel and its three shafts, as
well as two trains. The monorail is equipped
with cameras and can be operated by remote
control from the surface. It can transport up to
ve people and works independently in both
directions with remote operation.
Since the 1940s, Michigan-based
Construction Equipment Company
(www.constructionequipmentcompany.com )
has been supplying the tunnelling and mining
industry with equipment and other services. Its
huge range of equipment supplied includes
tunnel cars and muck cars, rail equipment,
ventilation equipment, tunnel-boring machines.
A wide range of vehicles can be seen during
the construction phase of a tunnel, including
locomotives, dumper trucks, mini excavators
and personnel carriers. But from Atlas Copco
(www.atlascopco.com), you might also see the
following the worlds largest mobile grouting
rig combining mixing, pumping and recording of
26-28WT0712.indd 28
Mini excavators
USED EQUIPMENT
If it is used equipment you are after, a look at
Mining Equipments website will reveal a host of
used equipment for tunnelling and mining. This
ranges from compressors and conveyor belts to
hoists, locomotives, service trucks and scoops.
And you never know, you might nd a bargain
(www.miningequipment.com) .
10/12/07 09:41:02
The UKs biggest and best drilling, piling and trenchless construction show, GeoDrilling 2008
will provide a superb opportunity for manufacturers, contractors, buyers and specifiers of
trenchless construction and drilling services to gather in one place, to assess the current
developments in the market, and to develop leads and contacts for new business and future
projects.
GeoDrilling 2008 will exceed all your expectations by providing an exhibition containing the
top names in the industry, international delegates with the credentials to make all the right
buying decisions, and a seminar programme packed with the best speakers covering the
issues which matter to you.
GeoDrilling 2008 will attract more than 150 exhibitors and some 2,000 visitors and we very
much hope you will be one of them.
If you are in the construction and piling industry, then GeoDrilling 2008 must not be missed.
If you would like further information about GeoDrilling 2008,
contact Eileen Smith on +44 (0) 20 7216 6077 or at
eileen.smith@mining-journal.com
Supported by:
GDIshow2008ad.indd 1
10/12/07 11:33:22
30
TECHNOLOGY: Innovation
White geomembrane
is a reector
December 2007
30-31WT0712.indd 30
6/12/07 21:23:54
31
TECHNOLOGY: Innovation
of CIVILS 2007
Reverse osmosis
does the trick
Corrosion prevention
association SPURS R&D
CONTRACTORS, consultants and
manufacturers working in the field of
corrosion prevention for concrete and
masonry encased steel are all represented by
the Corrosion Prevention Association (CPA).
An authority on cathodic protection and
other corrosion techniques, the CPA
encourages research in a wide range of
concrete-corrosion related fields, in addition
to a range of publications.
www.corrosionprevention.org.uk
the company than these core products. From an
organisational point of view, DSI divides its
activities into Construction and Underground.
Falling clearly into the latter category, the
recently established tunnelling division
combines all the tunnelling activities of the
newly-acquired companies of Alwag in Austria,
DSI-Soprofint in Chile and American Commercial in the US.
One of the companys ongoing projects is a
2.6 m diameter, 615 m-long water, power and
communication tunnel that will run beneath the
runways at Indianapolis airport. Because the
airport needs to be in continuous operation, it is
vital that no settlement occurs beneath the
runways. Due to the geology and its location
beneath the groundwater table, an EPB TBM is
being used to drive the tunnel which, in place of
concrete segments, is being lined with sealed,
heavy steel liner plates due to engineering
requirements. It is the longest-ever EPB-driven
tunnel to make use of steel liner plates.
www.dywidag-international.com
December 2007
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32
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Capacity up to 14" diameter
Length up to 10 metres
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equipment
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and accessories
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December 2007
32WT0712.indd 32
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Innovation.
or 50 years, nobodys
broken more new
ground than Robbins.
Robbins invented the first
successful tunnel boring
machine. That was only the
beginning of a long line of
rsts: The rst Main Beam
TBMs. Hard Rock disc cutters.
Floating grippers. Double
Shield TBMs. Nineteen-inch
cutters. Wedgelock cutter
mounting. All major innovations that have driven the
industry.
And while others try to copy
these innovations, they cant
duplicate our results. Thats
because Robbins innovations
arent mere imitations. Theyre
continuous improvements in
TBM design, driven by real
challenges and lessons
learned on more than 700
projects worldwide. Learn more.
www.TheRobbinsCompany.com.
Robbins Innovations.indd 1
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