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Cut&Cover Excavation in Hyperbaric Condition: An Innovative Solution Applied For Napoli/Cancello High Speed Railway
Cut&Cover Excavation in Hyperbaric Condition: An Innovative Solution Applied For Napoli/Cancello High Speed Railway
G. Lunardia
G. Cassania
A. Bellocchioa
C. Nardonea*
M. Cafarob
G. Ghivarellob
R. Sorgec
F. Carrieroc
a
Rocksoil S.p.A., Milano, Italy
b
Salini Impregilo S.p.A., Milano, Italy
c
Astaldi S.p.A., Roma, Italy
In the frame of the high-speed railway line Napoli-Bari, it is foreseen the realization of a cut crossing seven different Member States:
and cover tunnel which partially develops below water table level. The top down construction Finland, Sweden, Denmark, Germany, Aus-
will be performed using the compressed air in order to achieve a dry base during the soil tria, Italy and Malta. The development of
excavation and the cast of the internal structures. This method was abandoned in Italy a the Naples-Bari route, falling within the
long time ago due to the high risks to workers’ health, but to-day, with the latest technology Corridor 5 Helsinki - Valletta, has been
and with a careful control of all the health implications, can be safely applied to prevent identified as a priority.
ground water inflow, where the required lowering of the water table does not exceed 10 m. Referring to the national point of view the
This is the first time that such technology is applied in Italy and the paper describes its construction of the high capacity railway
general principles focusing on the construction phases and the safety and health procedures line Naples-Bari, together with the ac-
to be strictly followed for this innovative tunnelling approach. tivation of the Rome-Naples high-speed
Key words: Cut&Cover, Compressed air, Hyperbaric Chamber, Construction Phases, railway system, will favour the integration
Connection Detail of the railway infrastructure of the South-
East with the Connecting Directories to
northern Italy. This upgrade will have a
paramount impact for the socio-economic
development of the South, reconnecting
1. Introduction multimodal transport network allowing two areas, Campania and Puglia.
people and goods to move quickly and eas- The variant in the stretch between Naples
The Naples-Bari route is part of the Scan- ily across the EU (Fig.1). This is intended and Cancello, particularly strategic in the
dinavia - Mediterranean Corridor of the to support the development of the internal overall arrangement of metropolitan, re-
Trans-European Network (TEN). Its re- market and reinforce economic and social gional and long-distance connections, al-
qualification and development aim to im- cohesion. lows bringing the tracks of the line to the
prove the competitiveness of rail transport, The Scandinavian-Mediterrean Corridor new station of Naples Afragola, which in
integrate the south - east railway network (5) is the longest of the TEN-T Core Net- the future will become the station for pas-
with the high-speed service, and increase work Corridors and is partially based on a senger interchange between regional and
the share of goods transported by rail [1]. series of former Priority Projects. It links the high-speed services increasing overall ac-
The Trans-European Transport Network major urban centres in Germany and Italy to cessibility to the railway transport in the
(TEN-T) aims to develop an integrated Scandinavia and the Mediterranean whilst Naples hub.
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G. LUNARDI - G. CASSANI - A. BELLOCCHIO - C. NARDONE - M. CAFARO - G. GHIVARELLO - R. SORGE - F. CARRIERO
a) b)
Fig. 2 – Railway section Napoli-Cancello: (a) general layout and intersection with the historical line (dashed white line define the limit of section detail); (b) section detail of the cut and
cover tunnel “Casalnuovo”.
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CUT&COVER EXCAVATION IN HYPERBARIC CONDITION: AN INNOVATIVE SOLUTION APPLIED FOR NAPOLI/CANCELLO HIGH SPEED RAILWAY
petitors to study an original technical so- struction process and on how the latter SE, filled with sedimentary and volcanic
lution that could solve the interference of influenced the design phase. deposits of the plio-quaternary age. The
the tunnel with the groundwater (from its northern, southern and eastern margins are
beginning till chainage 1+600), analysing 1.2. Geological Overview constituted by Mesozoic carbonate soils
the working phases with the aim of getting and by Miocene, calcareous and siliciclas-
an easy management from a construction The vast flat area, between the Tyrrhenian tic soils between the Burdigalian and the
point of view. For this purpose, NACAV Sea, the Massico Mountain, the mountains Upper Tortonian (Miocene). These soils
s.c.p.a. company, a JV between Salini Im- of Caserta and the Vesuvius, is called Piana derive from the deformation of the west-
pregilo S.p.A. and Astaldi S.p.A., decided Campana. In this area, in historical times ernmost areas characterized by carbonate
to choose an original technical solution, and in particular during the recent Quater- sediments.
successfully used abroad in the recent pe- nary, volcanic phenomena occurred which The Piana has been progressively filled by
riod (i.e. Allmend Tunnel in Luzern, Swit- contributed to define the current morpho- marine deposits, alluvial and marsh, by the
zerland and Audi Tunnel in Igolstadt [2]), logical structure. products of Campi Flegrei and those of the
consisting in using pressurized air dig for From the structural geological point of view Somma-Vesuvio complex. The thicknesses
the tunnel excavation between diaphragm of the region, the area affected by the pro- of these deposits have been estimated to
walls. Such choice allowed NACAV s.c.p.a. ject alignment is entirely located in the so- be at least 4500 m based on geophysical
company to get the job. called “Piana Campana”. and gravimetric analyses. The thickness of
The scope of the paper is to describe this The Piana Campana is a structural depres- the vulcanoclastic and debris cover gradu-
specific technique focusing on the con- sion stretched in the direction of NO/ ally increases from the carbonate slopes
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G. LUNARDI - G. CASSANI - A. BELLOCCHIO - C. NARDONE - M. CAFARO - G. GHIVARELLO - R. SORGE - F. CARRIERO
a) b)
Fig. 5 – (a) Pyroclastic deposits (DI); (b) 2. Pyroclastic units of recent age (PO).
towards west, with thicknesses of about – soil Cover (R); The average permeability ranges from 10-3
2000 m in the central and southern part – pyroclastic deposits (DI); to 10-6 m/s.
of the plain. Geologically the lands of the – pyroclastic units of recent age (PO); The tunnel stretch interfering with the
Piana Campana are young, no more than – litoid tuff (TL); ground-water is mainly excavated in DI (Fig.
30000 - 39000 years. – loose Tuff (Ts); 5a) and PO (Fig. 5b) units which can be
Among the pyroclastic events for the con- – base pyroclastics (Pb). classified respectively as silty-clayey sands
stitution of the plain, the most important is - clayey/silty sands and medium to coarse
represented by the event that marked the In the area of interest, the main aquifer is sands with silt and gravel derived from
“putting in place” of the Ignimbrite Campa- located in the Base Pyroclastics which are volcanic deposits. The soil nature thence
na, erupted from the Campi Flegrei volcanic confined at the top level by the Ingnim- requires a specific intervention in order to
complex, about 37000 - 39000 years ago. brite Campana (Litoid and Loose Tuff). In avoid the water inflow and the likely conse-
The lithostratigraphic units that are found the upper layer, where the tunnel will be quent fine transportation.
along the alignment (Fig. 4) of the cut and excavated, it is located a superficial aquifer
cover tunnel are listed below: punctually connected with the deeper one.
2. The proposed solution
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CUT&COVER EXCAVATION IN HYPERBARIC CONDITION: AN INNOVATIVE SOLUTION APPLIED FOR NAPOLI/CANCELLO HIGH SPEED RAILWAY
dangerous for the workers who, working 3. General Construction Method foreseen to monitor the ground water table
at high pressures, were subjected to a high during the excavation it is possible to adapt
health risk. This is the reason why it was The tunnel will be constructed following the pressure to the required value.
abandoned in Italy, but today, with the lat- the top down method (see Fig. 7) which After the internal structures are casted and
est technology and with a careful control of foresees the following phases: sealed it is possible to deactivate the inter-
all the health implications, can be safely ap- 1. Excavation to the diaphragm wall exe- nal air pressure.
plied to prevent ground water inflow, where cution level and realization of the dia-
the required lowering of the water table is phragm walls; 3.1. Design Compliance
limited. 2. Cast of the reinforced concrete roof slab
In order to perform all the excavation and and backfilling above the roof slab; The application of the compressed air in
construction activities in dry condition tra- 3. Excavation below the roof slab, between the tunnel construction should be taken
ditionally it is foreseen the execution of a the diaphragm walls, to the foundation into account in order to consider all the
jet grouting plug, which compared to the level and cast of the bottom slab; relevant load cases and global equilibrium
use of compressed air presents various dis- 4. Cast of the lining walls and finishes in- scenarios.
advantages: stallation. The internal pressure is an additional load
difficulty in controlling the design require- In order to perform the excavation and the acting on the structure in the temporary
ments have been actually fulfilled; cast of internal structures in dry condition, phase that should be considered in the
a lower flexibility of the system in order to a pressure higher than the atmospheric one structural analyses. It has to be remarked
adapt to ground water level fluctuation; is applied in the tunnel after the execution that in general the air pressure acts in the
possible impact on the environment due of the backfilling, before the start of dig- opposite direction of the most demand-
to the contamination of the groundwater, ging operations. The pressure value to be ing loads: for both the retaining walls and
which frequently serves as a reservoir for applied is equal to the corresponding value the top slab the internal pressure partially
the water supply. of hydrostatic pressure acting on the exca- counteracts the earth and water pressure
The Table 1 compares the alternative solu- vation bottom due to the water head at that acting inward the tunnel. In other words,
tions. time: by means of piezometers specifically this methodology does not require a
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G. LUNARDI - G. CASSANI - A. BELLOCCHIO - C. NARDONE - M. CAFARO - G. GHIVARELLO - R. SORGE - F. CARRIERO
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CUT&COVER EXCAVATION IN HYPERBARIC CONDITION: AN INNOVATIVE SOLUTION APPLIED FOR NAPOLI/CANCELLO HIGH SPEED RAILWAY
Compartment 1
tained during the whole excavation process,
it reduces the internal actions associated to
the temporary phase.
While the compressed air system is active
the global equilibrium toward the possi-
ble uplift should be checked: the inter- • After the construction of the hyperbaric chamber, demolition of the compartment diaphragm walls and excavation under top slab of the
nal pressure, determined to counteract soil volume above GWL at atmospheric pressure;
• Well point installation for GWL lowering and excavation completion at atmospheric pressure;
the water pressure at the bottom of the • Waterproofing system installation and casting of internal structures;
excavation, can lead to a structure uplift • Installation of production plant and air pressure management facilities in the hyperbaric chamber (including the conveyor belt for muck
transport).
in case of low backfilling. This condition
should be taken into account performing
a specific check, which should consider
Compartment 2-6
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G. LUNARDI - G. CASSANI - A. BELLOCCHIO - C. NARDONE - M. CAFARO - G. GHIVARELLO - R. SORGE - F. CARRIERO
ber of passages. In particular, to manage in the stretch individuated by the compart- In Fig. 10 the solution adopted for the foun-
the muck transport, it is envisaged the use ment) and fixed volume. dation joint is described in detail, showing
of a hanged extensible conveyor belt, which Fig. 9 summarises the work phases applied also the construction phases foreseen to
will discharge the material coming from the in the case of the Casalnuovo Tunnel. actually realize the connection between the
front on a reversible belt feeding two shut- two structures. The same concept has been
tle belts. The shuttle belts will store the applied to the connection in correspond-
muck alternatively in one of the two com- 4. Connection with existing ence of the lining walls.
partments addressed to this specific func- structures At the end of the last compartment, the
tion (Compartments A and B). waterproofing layer is mechanically fixed
The pressure value to be applied for the The tunnel stretch to be excavated with to the partition diaphragm: the fixing is lo-
excavation, depending on the water-head the application of compressed air ends at cated below the design level of the extrados
has to be adapted while the excavation chainage 1+337.65 that corresponds to of foundation slab in order to maintain the
proceeds. In the case of study, the maxi- the start section of a tunnel portion already water-tightness also after the partition dia-
mum excavation level varies along the existing. Between chainages 1+337.65 and phragm demolition. A Styrofoam layer 10
alignment and the excavation section wid- 1+448.35 the tunnel alignment under- mm thick is placed between the foundation
ens for the STI exits, for the wastewater passes an existing railway embankment: slab and the partition diaphragm in order
lifting plants and the relative inspection since the project in object was already to protect the structure during the demoli-
chambers and for the niches (air losses scheduled at the moment of the embank- tion works.
evaluation through Schenck & Wagner ment construction, the construction of in- Once the structure is completely sealed,
formula [5]). terfering portion of tunnel was anticipated the air pressure is lowered to the atmos-
This configuration would require the in order not to cause subsidence to the pheric value and it is possible to proceed
adjustment of the air pressure of com- surface railway line in the future. realizing the connection with the existing
pressed air at each advance, not appli- With the aim of getting a continuous entity structure. The execution phases are de-
cable in practice. For logistic purpose both from a structural and water-tightness scribed in Fig. 11.
and to avoid excessive air losses at the point of view, a specific construction detail
tunnel face, the tunnel has been divided has been studied at the end of compart-
into compartments (n.14) limited on the ment 12. In correspondence of the contact Conclusions
sides and on the top by the tunnel struc- section, in fact, it is necessary on the one
tures and at the front by specific partition hand to seal the new structure, so as not to Casalnuovo Tunnel, part of the high-speed
diaphragm walls. have any water inflow at the deactivation of railway line Napoli-Bari, will be excavated
At each of the 14 compartments will cor- the air pressure, and on the other hand, to with the use of compressed air: the air is
respond a uniform design value of the air allow for the connection of waterproofing pressurized at the tunnel face in order
pressure (maximum value of the water head layers and structural elements. to lower the water head and perform all
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CUT&COVER EXCAVATION IN HYPERBARIC CONDITION: AN INNOVATIVE SOLUTION APPLIED FOR NAPOLI/CANCELLO HIGH SPEED RAILWAY
• Chemical injection realized through the partition diaphragm in order to reduce the soil
permeability in the volume adjacent to the structural joint;
• Demolition of the partition diaphragm walls: in the lower portion, close to the founda-
tion slab of compartment 12 the demolition should be executed from the existing
stretch in order to preserve the recently casted structures.
• Additional chemical injection in order to extend the volume of treated soil to all the
intervention area;
• Partial demolition of the foundation slab of the existing stretch trying not to damage
the waterproofing layer.
• Cleaning of the waterproofing layer uncovered in the first portion of the existing struc-
ture;
• Installation of the new waterproofing layer welded to the existing one: in corresponden-
ce of the future structural joint between the two stretches the waterproofing layer is fol-
ded in order to guarantee the water-tightness also in case of differential displacements.
An injection pipe is set up to repair the waterproofing layer as a redundancy measure;
• At the connection with the already casted portion of compartment 12 another mechani-
cal fixing is provided.
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G. LUNARDI - G. CASSANI - A. BELLOCCHIO - C. NARDONE - M. CAFARO - G. GHIVARELLO - R. SORGE - F. CARRIERO
the operations in a dry environment. Al- tion process focusing on the operative References
though this technology finds its origin in phases for the ingress and egress of per-
the 1th century, its application nowadays sonnel, machinery and muck through the [1] Regulation (EU) No. 1315/2013. Council of
can be considered innovative due to all hyperbaric chamber and on the advance 11 December 2013, European Parliament.
the constraints related to worker health phases related to the particular stretch [2] SCHWARZ J., HEHENBERGER F. (2004) – Com-
and safety. geometry. For a successful application of pressed air for top down. In Tunnels & Tunnelling
The construction process has been deep- this excavation method, all the construc- International, 36 (2).
ly studied in the design phase with the aim tion details should be meticulously ana- [3] EN 12110. Tunnelling machines - Air locks -
Safety requirements.
of reducing air losses and adapting to the lysed: in particular the waterproof layer
[4] ITA-AITES WG5, 2015. Guidelines for good
variable water head always guaranteeing fixing at the extremities of the stretch working practice in high pressure compressed air.
the worker safety and the instantaneous has been studied considering the need [5] JARDINE F.M., MCCALLUM R.I. (1992) – Engi-
implementation of the emergency proce- of connecting to the adjacent existing neering and Health in Compressed Air Work. Pro-
dures. The paper describes the construc- structures. ceedings of the International Conference. Oxford.
Sommario di:
Cut&Cover in condizioni iperbariche: una soluzione
innovativa applicata all’alta velocità ferroviaria nella
tratta Napoli/Cancello
G. Lunardia
G. Cassania
A. Bellocchioa
C. Nardonea*
M. Cafarob
G. Ghivarellob
R. Sorgec
F. Carrieroc
a
Rocksoil S.p.A., Milano, Italy
b
Salini Impregilo S.p.A., Milano, Italy
c
Astaldi S.p.A., Roma, Italy verrà eseguito con l’applicazione dell’aria per prevenire l’ingresso di acqua durante
compressa in modo da garantire un fon- lo scavo nei casi in cui l’abbassamento di
* corresponding author: chiara.nardone@rocksoil.com
do scavo asciutto durante le operazioni di falda necessario non eccede i 10 m. Que-
smarino e il getto delle strutture interne. sta è la prima volta che una tecnologia del
Questo metodo venne abbandonato mol- genere viene applicata in Italia; nell’articolo
to tempo fa a causa dell’alto rischio per la si descrivono i principi generali di funzio-
Lungo la linea di alta velocità ferroviaria salute dei lavoratori, ma oggi con le recen- namento focalizzando l’attenzione sulle fasi
Napoli-Bari, è prevista la realizzazione di ti tecnologie e un attento controllo delle costruttive e sulle procedure di sicurezza
una galleria artificiale che si sviluppa par- possibili ripercussioni in termini di sicu- che devono essere seguite secondo questo
zialmente sotto falda. Lo scavo, top-down, rezza può essere applicato in modo sicuro approccio innovativo.
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