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By Paul Madsen, Bade Sozer, Thomas Hennings, Eileen Test

The Rondout Bypass Tunnel in New York has two access shafts. The upper sections of the shafts are lined with steel pipe to resist a substantial net internal water head . Initial design included a ¾-inch-thick cement mortar lining (CML) for all three components. Because of concerns with CML application on large-diameter pipes, the protective lining was redesigned for shotcrete application. This paper discusses the details of that design, mock-ups, and shotcrete application.

Jun 13, 2023

By Raphael Victor

The construction and modification of tunnels brings a requirement for precise measurement of convergence and divergence to safeguard the structure, maintain safety and provide the assurance needed to maintain efficient progress. Established methods include manual measurement using tape extensometers and automated methods using photogrammetry and automated total stations. Drawbacks include the need for frequent access, power supply, cabling, and cost. The paper describes how the development of reliable optical displacement sensors (ODS) has changed the landscape. ODS sensors are connected to a long-range wireless mesh communications network via a solar-powered gateway outside the tunnel, with data instantly transmitted to the internet. A sensor and its reflector target can be installed in 20 minutes and is maintenance free for a decade. Tunnel movement is measured to sub-millimeter precision with repeatability of ±0.15 mm. Integration of a triaxial tilt sensor allows slope distance to be converted to horizontal and vertical changes and allows rotational movement to be determined. Applications include new-build and long-term structural health monitoring. Case studies will be given, including the refurbishment of rail tunnels in Spain where the ODS measured movement during track lowering in a situation where no other automated system was considered viable.

Jun 13, 2023

By Ross Goodman, Jean-Luc des Rivières

The Ohio River Tunnel Project encountered multiple unexpected geotechnical challenges which, continuing to develop over time, hampered excavation completion and impacted the cast-in-place final lining technique and work execution sequence for the entire project. The continued degradation of the excavated hard rock tunnel conditions led to a unique, dynamic, geologic setting that forced the project to innovate new and adaptable measures allowing for a conventional cast-in-place liner to be completed in a safe and timely manner and minimize delay.

Jun 13, 2023

By Robin Dill, Julian Prada, Kathryn Kelly, Brian Hann, Todd Moline

Narragansett Bay Commission’s (NBC) Pawtucket Tunnel Project includes construction of the 11,600-ft long, 30-ft ID, deep rock tunnel. This paper presents insight into the features and benefits of lump-sum, design-build that led NBC to select it as the project delivery method. The use of a design-build contracting process that included proprietary meetings to discuss and obtain feedback on Alternative Technical Concepts as well as to facilitate reaching consensus on modifications to the GBR-B is also described. The discussion includes features and benefits of design-build process that not only addressed NBC’s desired outcomes, but also allowed the Design-Builder to propose several innovative changes to the Base Technical Concepts included in the bid documents, and to develop a GBR-C that was compatible with their proposed means and methods of construction and addressed what they believed to be the more significant subsurface risks on the project.

Jun 13, 2023

By Karin Bäppler

Hydropower produces almost two-thirds of the world’s renewable electricity generation and delivers a major contribution on the ambition of the Paris Agreement and Sustainable Development Goals (SDG) with a range of benefits to society and environment. These include clean and flexible generation and storage in addition to reduced dependence on fossil fuels and avoidance of pollutants. The Limberg III PSP is one of the European projects that addresses the implementation of the UN SDGs. The challenge of the project is the construction of a 770 m long pressure shaft to be excavated with a TBM at an inclination of 42°.

Jun 13, 2023

By Doug Harding

The 3.5 km long Ashbridges Bay Outfall in Toronto, Ontario, Canada was a challenging drive set below Lake Ontario. After a remote machine acceptance due to the global pandemic, an 8 m diameter Single Shield machine launched in March 2021 from an 85 m deep shaft and began its bore in shale with limestone, siltstone and sandstone. During excavation, the TBM and its crew bored a city-wide record of 30 rings in one day, or 47 m of advance. This paper will cover the unique project, from TBM acceptance through to launch, tunneling in difficult conditions, and completion in 2022.

Jun 13, 2023

By Ryan Ward

The Missouri River Intake Screen Structure and Tunnel (MRISST) is one phase of the Red River Valley Water Supply Project (RRVWSP), a vital piece of infrastructure in the state of North Dakota to transport water to drought-laden communities in the eastern half of the state. The scope of work consists of constructing a cofferdam in the Missouri River, mining a 1,600-foot by 74-inch tunnel from a secant pile shaft near the riverbank into a cofferdam, and erecting a 40-foot Y-shaped vertical pipe structure in the cofferdam to support the intake screens. Construction personnel worked in the river through the North Dakota winter to construct the cofferdam and contended with high hydrostatic pressures and raveling sands, gravels, cobbles and boulders while mining the tunnel. Diligent planning and meticulous execution were essential to overcoming the challenges encountered below the Missouri River.

Jun 13, 2023

By Nik Sokol, Eric Sekulski, Leo Weiman-Benitez, Jon Hurt, Shrinidhi Vijayakumar, Phaidra Campbell

The Silicon Valley Clean Water (SVCW) Gravity Pipeline (GP) is the first Progressive Design Build (PDB) tunnel completed in North America. As part of the Regional Environmental Sewer Conveyance Upgrade (RESCU) Program, the tunnel is a key component to replacing and rehabilitating components of the existing conveyance system in San Mateo County, California. The GP consists of a large diameter Fiberglass Reinforced Polymer Mortar (FRPM) pipe installed inside a 4.1 m (13.5 ft) inside diameter, 5.3 km (3.3 mile) long precast concrete segmentally lined tunnel. The tunnel was constructed using a 4.6 m (15.2 ft) diameter Earth Pressure Balance (EPB) Tunnel Boring Machine (TBM) through heterogenous silts, clays and sands. Construction included two separate TBMlaunches from a centrally located access shaft, and a tunnel alignment below but in close proximity to very soft Young Bay Mud. Settlement criteria and mitigation strategies focused on protection of an existing 1.42 m (56 inch) diameter force main and adjoining structures along the alignment. This paper discusses the results of the theoretical settlement analysis versus the actual observed ground movements, while also presenting mitigation measures and adjustments made during tunneling to reduce the risks of adverse settlement.

Jun 13, 2023

By Denis Tepavac, Mark Trim

Structural performance of fiber reinforced concrete (FRC) depends on its ability to carry tensile forces after cracking. Australian Standards AS5100-2017 and AS3600-2018 are the only available design standards that establish a test procedure to determine strength and toughness of an FRC in direct tension. Direct tensile testing of fiber reinforced shotcrete samples was performed to determine if the model and guidelines in AS5100/3600 were applicable to shotcrete; all previous testing was from cast samples. In addition to direct testing, micro CT-scanning was also performed. The paper presents tests performed, results, and how the tests could be used on future projects. In addition, a brief summary is provided of the guiding structural mechanics used for estimating residual tensile strength and test methods utilized to verify those estimates.

Jun 13, 2023

By H. Vigil Fernandez, G. Peach

The Musaimeer pump station and outfall project located in Doha Qatar, was designed to collect and manage ground and stormwater and then discharge the treated waters offshore. The project constructed a long outfall tunnel using an EPB TBM with segmental lining, each tunnel ring being 1.35 m in length with an internal diameter of 3.7 m.. The diffuser structure was a 6-arm structure, measuring 294m by 40 m connected to a central manifold in turn connected to the TBM constructed tunnel via a riser shaft drilled from an off-shore barge. This technical paper will discuss the planning, methodology and construction practices employed to connect the TBM tunnel to the diffuser structure 10.2 km offshore.

Jun 13, 2023

By Jorge Ferrero, Andreas Raedle, Uhland Konrad, Michael Dutton, Keivan Pak Iman, Walter Trisi

Strabag, in partnership with Arup, is constructing the Advance Tunnel for the Scarborough Subway Extension (ATSSE); a project by Metrolinx and Infrastructure Ontario (Sponsors). The 10.7 m internal diameter single bore tunnel represents a significant departure from the traditional arrangement of twin subway tunnels in North America. ATSSE is the first-time steel fibers are used to solely reinforce a tunnel of this size in Eastern Canada. This paper discusses the challenges with design and acceptance of SFRC segments and the state-of-the-art numerical models employed to check the joint performance. The advance procurement approach for TBM and PCTL’s procurement to accelerate the project schedule is also presented.

Jun 13, 2023

By Tatiana Kotrikova, Steven Kolarz, Alan Kolodne, James Parkes, Matthew Goff

The WMATA Yellow Line is the section of steel segmentally lined tunnels that have experienced leakage and significant corrosion in isolated areas. A three part rehabilitation design has been developed for curtain grouting, structural repairs, and corrosion protection to provide continued performance. As WMATA’s first Construction-Manager-at-Risk (CMAR) project, the design development benefitted from collaboration with the Contractor through the final design development process. Rehabilitation work started in Fall 2022 and will be completed by late Spring 2023. Details of the project, the remediation design, and the process and benefits of the CMAR approach in the design development are presented.

Jun 13, 2023

By Enrico Pavese, Tim Kearney, Stefan Lemke

Watertightness is of central importance in hydraulic and underground structures but has always been associated with a risk, as demonstrated by the very high impact that water inflows have on the damage of linings and infrastructure (Howard, 1991; Sandrone and Labiouse, 2011). Concrete is vulnerable to groundwater and chemical contaminants in the soil. These can leach into the pores and cracks of the concrete and degrade its integrity, causing spalling and corroding the reinforcing steel. Moisture migrating into the building can also degrade structural elements over time and lead to mold and other hazards to occupants’ health. In this connection, the demands placed on the setup and detailed design of the seal depending on the negative influence by water on the one hand and on the other hand on the function of a construction in view to its watertightness classification. Thus, the reliable functioning of a seal is of particular significance in the case of traffic tunnels, which are not easily accessible for all subsequent repairs after the construction in seepage water and especially when located in a pressure water zone (risk–cost assessment). Requirements for the long-term efficiency and quality of underground structures have increased in recent decades. Today, the standard lifetime requirement for an underground infrastructure project is 100 to 120 years and, in some cases, even higher. This calls for high increased attention to the durability of the whole structure and of each individual element. Standards, which started as application guidelines given by the manufacturers, are available in the market since the 1980s and are constantly adapted to the current developments in various technical committees. Differentiations are made between: Manufactures application guidelines, case studies or published articles Test standards for the laboratory to guideline the testing procedures (air temperature, type of test equipment, dimensions, test speed, test duration, concentration, type of liquids, monitoring, tolerances, interpretation of results, documentation, etc.), developed by committees based on material and laboratory experts Application standards, which include test standards but also the related minimum performance requirements (values) for material, processing, and quality assurance (practical tolerances), developed by committees based on a wide range of experts (e.g., designers, construction companies, applicators, manufactures, owners, test institutes, quality engineers) and therefore also based on a wide field of experience, different views and up-dated case studies. In the following there are some examples of guidelines and published information’s, ranked according to the year of issue, which are relevant for the development of waterproofing specifications in the tunnel industry:

Jun 13, 2023

By Dan Ifrim, Andre Solecki

Tunneling could be a major challenge to tunneling contractors as tunneling operations can be seriously affected by the Tunnel Boring Machine (TBM) performance. Specifying the appropriate TBM methodology, selection of systems and features, is critical for managing tunnel risks and contribute to successful tunneling project. The paper analyzes tunneling records from the recently completed City of Toronto’s Ashbridges Bay Treatment Outfall tunnel project and underlines the righteous selection of the TBM type and associated TBM systems in achieving good advance rates during tunnelling and managing project risks. The paper intends to draw attention of a few aspects of TBM technical specification importance and highlight the lessons learned from this process.

Jun 13, 2023

By Jon Y. Kaneshiro, Eric Dawson, Pooyan Asadollahi, Steven Hunt

This paper provides updates to the paper published by the lead author at RETC 2011 with a summary of developments in technologies, products, and approaches to corrosion analyses of gravity sewer tunnels and microtunnels. This paper presents approaches in evaluating degradation of reinforced concrete liners. Also, the carbon footprint of conventional concrete liners and alternative “green” liners are compared and their life cycle costs are considered. A few case histories from the past decade are provided indicating the latest and emerging trends in liner protection.

Jun 13, 2023

By Ralf Plinninger, Pafos Busch, Richard Gradnik

This paper presents the details of the Bad Bergzabern tunnel project. This tunnel is the main part of the B427 federal road bypass, intended to improve the regional traffic infrastructure and to reduce the traffic load in the historic city centre of the health resort Bad Bergzabern. Located in the south-western part of Germany, the project area is situated at the eastern margin of the so-called Palatinate Forest, a low mountain region of mainly triassic sediments with a complex and variable geological history. The German federal government, represented by the office of mobility of Rhineland- Palatinate, awarded the contract to BeMo Tunnelling, a specialized Tunnelling company with a long history of innovation and success in NATM tunnelling. The contract includes the construction of two separate tubes with a length of approximately 1,44 km (0.9 mi)—the road (main) tunnel with a cross section of 101 m2 (1,090 sq ft) and a parallel rescue tunnel with a cross section of ca. 23 m2 (250 sq ft.) Both are connected by six cross passages. Tunnels and cross passages are excavated according to the principles of the New Austrian Tunnelling Method (NATM). Due to BeMo Tunnelling’s technical expertise and capabilities, the project team was able to engineer a speed-up concept that saves money and time for the construction team and client. This paper presents the innovative approach BeMo Tunnelling made to optimize the execution of the tunnelling works and the challenges the project team is facing with regard to a complicated geological situation, countermeasures against an increasing effect of climate change and volatile prices for construction materials.

Jun 13, 2023

By Cameron Dunn, Callum Fryer, Carmen Hu, Craig Sewell, Peter Stakne, Andrew Raine

The Woodsmith Project is located in north-eastern England within the North York Moors National Park. The strata contains the world’s largest known high-grade Polyhalite resource of around 2.66 billion tonnes. The Project was initiated by York Potash Limited (YPL), a subsidiary of Sirius Minerals plc., but in March 2020, a takeover was completed by Anglo American, one of the largest mining companies in the world. Polyhalite is an evaporite mineral and contains essential nutrients required for plant growth. The Polyhalite will be extracted via two deep mine shafts and transported underground from the mine site to a Materials Handling Facility on a Mineral Transport System (MTS), which comprises a high-capacity conveyor belt system located within a 4.9 m ID tunnel. In 2018, STRABAG were awarded with the design and construction of the MTS tunnel and associated infrastructure, including the high-capacity conveyor system. The scope of work consists of 300 m of open cut, 100 m SCL tunnel, 36.5 km TBM drive (originally anticipated as three separate TBM drives) along with a network of underground caverns at the Woodsmith Mine. The construction of two 380 m deep intermediate access shafts was later awarded as Amendments to the Contract. The tunnel is constructed using a Herrenknecht Single Shield TBM. As a result of how the various elements of the project have developed over time, the first TBM drive has been extended to ~29 km making it the worlds longest single heading TBM Tunnel when complete. The option of completing the entire tunnel length with a single heading TBM drive is currently being assessed by Anglo American and STRABAG. This unprecedented tunnel length requires two intermediate shafts to provide essential access and services, the first intermediate shaft is at Lockwood beck (LWB) and the second is at Ladycross (LDX). The LWB shaft has been constructed utilising the innovative Blind Boring technique never used before in the UK. This paper will explain the methodology and technical risk management associated with this technique. The authors believe that the collaborative approach between all contract partners is and continues to be the important contributor for the success of this project.

Jun 13, 2023

By Ulf Georg Gwildis

Overexcavation and ground loss events during pressurized-face TBMadvance in soft ground can result in unplanned deformations above the tunnel and damage to existing infrastructure. Successfully managing the risk of this occurring is crucial for any project in an urban area to proceed. Common risk management approaches include a combination of establishing suitable ranges of TBM operational parameters and using geotechnical instrumentation for deformation monitoring. Another risk management tool is material flow reconciliation, which varies depending on the specified mining method and the equipment choices by the contractor. This paper compares recent and ongoing projects in the Pacific Northwest regarding overexcavation risk management.

Jun 13, 2023

By J. Andrew McGlenn, Brian McInnes, Bruce Downing, Murray Gant

The Second Narrows Water Supply Tunnel crossing beneath Burrard Inlet is an important component of the Greater Vancouver Water District’s plans to increase seismic resilience and meet increasing water demands. The project included the 110-meterdeep (350 ft) South TBM Receival Shaft, one of the deepest shafts to date in the sedimentary rock unit underlying much of Metro Vancouver. The shaft encountered varied sedimentary rock types, including fractured rock, with accompanying high groundwater inflows. This paper discusses the design and construction challenges associated with this shaft and the necessary means to complete the shaft in time for TBM arrival.

Jun 13, 2023

By Reinhard Gertl, Maximilian Weithaler, Harald Kammerer, Juan Pablo Muñoz, Juan-Carlos Rueda

The Guillermo Gaviria Echeverri tunnel and its access roads project in Antioquia, Colombia is a mega infrastructure project that includes a road network with the longest tunnel in Latin America and several short tunnels, the latter being the focus of this study. The design of the project required careful consideration of several special factors, such as the tunnels’ steep slopes of up to 5%, high fire load of 100 MW, bidirectional operation, and short lengths that make it difficult to place ventilation equipment. The combination of all these parameters cause a challenging design problem for the ventilation systems and smoke control of the short tunnels. To address this challenge, a risk assessment study was conducted to support the design of a new and innovative ventilation strategy that deviates from relevant guidelines and standards, like the Austrian RVS [1][5][6] or the German EABT [8] in order to provide a customized solution for this particular project. This strategy resulted a cost-effective solution, that allowed a reduction in the number of required jet fans and at the same time reaches or reduces the risk level compared to traditional ventilation strategies.

Jun 13, 2023