TRANSPORTATION RESEARCH BOARD Tunnel Operations Practices Featuring the Hampton Roads Bridge-Tunnel
Wednesday, October 16, 2019 2:00-3:30 PM ET The Transportation Research Board has met the standards and requirements of the Registered Continuing Education Providers Program. Credit earned on completion of this program will be reported to RCEP. A certificate of completion will be issued to participants that have registered and attended the entire session. As such, it does not include content that may be deemed or construed to be an approval or endorsement by RCEP. Purpose To discuss recent developments in tunnel management practices and provide announcements from tunnel-related organizations.
Learning Objectives At the end of this webinar, you will be able to: • Describe how to structure design-build procurement to maximize value-generating innovation PDH Certificate Information
• This webinar is valued at 1.5 Professional Development Hours (PDH) • Instructions on retrieving your certificate will be found in your webinar reminder and follow-up emails • You must register and attend as an individual to receive a PDH certificate • Certificates of Completion will be issued only to individuals who register for and attend the entire webinar session • Q&A counts as part of the session • TRB will report your hours within one week • Questions? Contact Reggie Gillum at [email protected].
4 Louis J Ruzzi, PE PennDOT, AASHTO COBS T 20 Tunnel Committee Chair October 16,2019 Thank you/Purpose of Webinar
• Thank you to Bill Bergeson at FHWA for coming up with the tunnel webinar idea and Elaine Ferrell at TRB for helping us put together and run this webinar series • Purpose of the Webinar-to help build/ develop the Tunnel Community. A strong tunnel community is important for raising awareness and integrating the diverse roles of our stakeholders to include planners, decision makers, regulators, tunnel owners, designers, contractors, inspectors, operators, suppliers, public sector users, and industry trade organizations. • The tunnel community needs to be more than just work being done by AASHTO COBS T 20 Tunnel Committee , TRB AFF6O Underground Structures Committees the states and FHWA and their research projects. But should include transit, other agencies like PIARC-the World Road Association, IRF-International Road Federation, Dept of Energy, TSA, COE and Colleges /Universities, etc. T 20 Purpose/current make up
• T20 was created back in 2006 because Tunnels never had a home at AASHTO. Mal Kerley, the Chairman of SCOBS( Subcommittee on Bridges and Structures -now called COBS) , thought is was best for Tunnels to be under Bridge, because bridge engineers typically got calls to handle structural problems at Tunnels anyway. • T20 meets as a group( 10 members from different states, 2 toll agencies and FHWA Liaison) twice a year. Once at the COBS Annual meeting in June and at TRB in mid-January of each year • T 20’s Mid -Year meeting is tentatively scheduled for January 14, 2020 at Marriott Marquis next to Washington DC convention center. Current research submissions and new research ideas, Alternate Fuel vehicles, Pittsburgh’s tunnel emergency exercise, tunnel rehab/new projects and robotic inspections will be discussed. T 20 Continued
• It is at this meeting that T20’s chair and AFF60’s Chair give each group an update on each group’s work and generate new prioritized research ideas with input from members of both groups • Over the last 14 years, the committee has completed an International Tunnel Scan in 2005, a Domestic Tunnel Scan in 2009, completed research which resulted in a new LRFD Design spec for tunnels, methods for rehabbing tunnels and guidelines for Emergency Exit signs and Marking Systems to name a few .Other projects can be found on AASHTOs website at https://bridges.transportation.org/technical-committees/t-20-tunnels/. • This website also lists our current research for LED lighting and potential future research tunnel linings and calibration of load factors for tunnels and FHWA s research Fixed Fire Suppression Systems T 20 Continued
• T20 also partners with FHWA and other industry stakeholders to develop products that benefit the tunneling community, a sampling, of current technical products, includes: • Load rating guidelines • TBM tunnel liner design guidelines • Integrated FFFS-EVS design guidelines T 20 Continued
• As part of our effort to engage industry stakeholders in the development process, workshops are being planned for each of these guidelines. • Please note that you’re always welcome to learn more about these technical products and the things that the T20 committee does at the public portion of the T20 Midyear and AASHTO COBS Annual meetings. • If you are interested in becoming a friend of the committee, or else simply contributing your research ideas, please feel free to send your contact information to me at: Ruzzi, Louis
Conrad W. Felice, PhD. P.E., F. ASCE
Chair, AFF60 – Tunnels and Underground Structures About TRB
• Part of the National Academies of Sciences, Engineering, and Medicine
• Private, non-profit institution
• Independent, non-partisan, objective
Research – Convene – Advise
Strategic Issues
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• Transformational technology
• Public health and transportation Research Goal: Ensure that competitive research programs address the most pressing transportation needs of the sponsors
Multidisciplinary topics: Make connections with stakeholders in other disciplines
Transformative Resiliency Public Safety AFF60
Committee Scope
This committee is concerned with the planning, design, construction, inspection, operations/systems, and maintenance of underground structures and their components. AFF60: Research Needs
AFF60 - RNS Tunnel Induced Deformation using Modern Tunneling Equipment Connect with Us
• Theme for 2020: A Century of Progress: Foundation for the Future Volunteer for TRB
• Become a member or friend of TRB standing committees
• Join a Cooperative Research Program panel Thank You
For More Information Visit: www.TRB.org [email protected] VIRGINIA TUNNEL PROGRAM VDOT Prasad Nallapaneni, PE; Vice Chair - T20 Tunnels, AASHTO 1 Big Walker Mountain Tunnel Tunnels in Virginia 2 East River Mountain Tunnel 3 Hampton Roads Bridge Tunnel (2 tunnels) 4 Monitor Merrimac Memorial Bridge Tunnel 5 Downtown Tunnel (2 tunnels) – ERC Maintained 7 36 Midtown Tunnel (2 tunnels) – ERC Maintained 14 7 Rosslyn Tunnel
8 Thimble Shoal Tunnel – Entity Owned
9 Chesapeake Channel Tunnel – Entity Owned Roanoke Airport Tunnel – Entity Owned 10 12 98 11 I-564 Runway Tunnel 2 13 10 3 9 1 4 12 Bluff Mountain Tunnel – Federally Owned 8 11 6 13 Williamsburg Tunnel – Federally Owned 5
14 Mary’s Rock Tunnel – Federally Owned Tunnels in Virginia (excluding Federally Owned) Name Type Length Year Built Big Walker Mountain Tunnel Twin Rock Bore (NATM) 4228’ 1972 East River Mountain Tunnel Twin Rock Bore (NATM) 5661’ 1974 Immersed Tube 7479’ 1957 Hampton Roads Bridge Tunnel Immersed Tube 7315’ 1976 Monitor Merrimac Memorial Bridge Tunnel Immersed Tube 4860’ 1992 Immersed Tube 3350’ 1952 Elizabeth River Downtown Tunnel Immersed Tube 3814’ 1987 Immersed Tube 4192’ 1962 Elizabeth River Midtown Tunnel Immersed Tube 4198’ 2016 I-564 Runway Tunnel Cut and Cover 662’ 1972 Thimble Shoal Tunnel Immersed Tube 5738’ 1964 Chesapeake Channel Tunnel Immersed Tube 5424’ 1964 Rosslyn Tunnel Cut and Cover 900’ 1983
Roanoke Airport Tunnel Cut and Cover 951’ 1985 Tunnel Criticality • Multi-Billion Dollar Investment
• Used by over 400,000 Vehicles per Day
• Limited Detour Routes
• Over 20,000 events logged each year that require operator response Statewide Tunnels Oversight Committee (STOC) • Formed in 2010 to provide direction and guidance for all of the tunnels across the state • Executive Leadership • Regional Operations Managers • Operations Division • Tunnel Managers • Recently VDOT designated all tunnels, movable bridges and few large fixed span bridges as Special structures • Currently working on the needs of these structures • Will lead to special funding – General Assembly established fund in 2019 Tunnel Activity • Midtown Tunnel • Opened in 2016 – Immersed tube
• Parallel Thimble Shoal Tunnel Chesapeake Bay Bridge Authority (CBBT) • 2023 - Construction Completion
• New Hampton Roads Bridge Tunnel (HRBT) • 2025 - Construction Completion Parallel Thimble Shoal Tunnel CBBT – Statistics 2018 – Existing Tunnels • 3,999,228 vehicles crossed the facility • ADT approx. 11,000 • Peak Weekend Days traffic exceeds 25,000 • 9% Heavy Trucks • 67% use EZ Pass • Tunnel Lane Closures – over 900 hours of lane closures • Nighttime Work Details • Oversized loads • Disabled vehicles Project Overview • D-B contract value: $756m • Length of Tunnel: 6,525-ft Portal-to-Portal • Diameter of Tunnel: 43-ft Outside Diameter • TBM: Herrenknecht EPB machine • Segment Ring: 9+1 universal ring • Roadway Depth: 134-ft below MLLW • Contractor: Chesapeake Tunnel JV (Dragados USA and Schiavone Construction Co.) • Engineer of Record: Mott MacDonald • Owner’s Engineer: Jacobs • Construction Manager: HNTB Sources of Funding New Hampton Roads Bridge Tunnel (HRBT)
Project Priorities • To provide mobility enhancements and travel-time reliability along the project corridor • To minimize project impacts on adjacent communities • To improve transportation operations and safety throughout the project corridor • To develop public infrastructure in a financially responsible manner HRBT - Public-Private Partnerships Design-Build procured under PPTA • Unique Funding • Hampton Roads Transportation Accountability Commission (HRTAC) is primary funding agent • HRTAC funds to be provided through the Hampton Roads Transportation Fund (HRTF) from regional sales and gas taxes HRBT – Design Build Selection Process Initial bidders during RFQ • Hampton Roads Capacity Constructors, • Hampton Roads Connector Partners • Skanska Kiewit Best Value Proposer • Contract awarded to Hampton Roads Connector Partners (HRCP) • A consortium of Dragados, Vinci, Flatiron, and Dodin Campenon Bernard. HRBT – Benefits to Commonwealth Benefits • Direct Impact within Hampton Roads - ~$3 B • Direct cumulative jobs – ~16,000 (through construction) • Indirect impact within Hampton Roads - ~$900 M • Indirect cumulative jobs – ~5,700 • Architecture, engineering services, maintenance, truck transportation NTIS – Inspections Since the roll out of the SNTI and NTIS • Completed initial inspections of all 11 VDOT owned tunnels • Reviewed initial inspections performed by agency entities • Chesapeake Bay Bridge Tunnel (CBBT) • Elizabeth River Crossings (ERC) • Roanoke Airport Authority (ROA)
• Second cycle of inspections has been completed
NTIS – National Tunnel Inspection Standards SNTI – Specifications for National Tunnel Inventory Tunnel Inspection Manuals
Inspections Manauls are developed for each tunnel • Description of element configuration and components • Pre-inspection preparation and review • Tools and Equipment • Personal Protective Equipment • Field Inspection Procedures • Reporting and Rating Procedures Inspection Updates - Improvements Developing two Instructional and Informational Memorandums (IIM) • Draft IIM for Inventory and Inspection Requirements for Tunnels • Contains definitions, roles and responsibilities, frequencies, level of inspections, report requirements, inspection forms, critical findings and recommendations, Load rating analysis and posting/restriction guidelines (per CFR 23- Part 650).
• Draft IIM for QA/QC for Tunnels • Contains definitions, training and certification requirements for team leaders, procedures for office and field reviews and QA/QC forms (per CFR 23- Part 650.513(i)). Inspection Updates - Improvements Review of initial inspections resulted in • Requiring all VDOT tunnel inspections and reports use a uniform stationing system for easy referencing • Noting deficiencies in notes and sketches with the stationing • Maintaining cross references between the sketches, notes and element ratings • Ensuring correlation between element quantities, condition state and notes/sketches • Inspection annual updates include comments/observations from current inspections, inventory and element data updates Key Operations Activities Tunnel Owner Operator Key Operation Activities I-77 Big Walker VDOT VDOT Lighting, Fire life safety, Ventilation, Incident management, ERP I-77 East River VDOT VDOT Lighting, Fire life safety, Ventilation, Incident management, ERP US 460 VDOT VDOT Lighting, Fire life safety, ERP Christiansburg I-664 Monitor VDOT VDOT Lighting, Fire life safety, Ventilation, Incident Merrimac management, ERP, Vehicle inspection I-64 Hampton VDOT VDOT Lighting, Fire life safety, Ventilation, Incident Roads management, ERP, Vehicle inspection US 58 Midtown VDOT Contractor Lighting, Fire life safety, Ventilation, Incident management, ERP, Vehicle inspection I-264 VDOT Contractor Lighting, Fire life safety, Ventilation, Incident Downtown management, ERP, Vehicle inspection I-564 VDOT VDOT Lighting, Fire life safety, Incident management, ERP I-66 Rosslyn VDOT VDOT Lighting, Fire life safety, Ventilation, Incident management, ERP Tunnel Operations – Incident History at Major Facilities
Tunnel All Incidents Crashes Fires I-77 Big Walker 61 23 0 I-77 East River 105 19 6 I-664 Monitor Merrimac 1592 613 12 I-64 Hampton Roads 1996 755 10 US 58 Midtown 267 45 0 I-264 Downtown 872 209 1 Tunnel Operations – Exercise Program Overview
FY # Exercises Planning Participants Recommendations Meetings 2014 1 5 49 23 2015 2 10 103 44 2016 6 19 320 86 2017 6 13 229 53 2018 2 10 85 32 Tunnels - Exercise Program Initiated in 2012 by STOC
Emergency Response Plans (ERPs) • For each tunnel and bridge facility • Implemented in 2013 • In accordance with NFPA Tunnels - Exercise Program After Action Reviews (AARs) For each tunnel and bridge facility Implemented in 2013 • In accordance Homeland Security Exercise and Evaluation Program (HSEEP) • Identify areas of response that may be improved upon for future accidents. Tunnels – Communication Drills Yearly communication drills • At each tunnel • Involve local and statewide partners • Local Police and Fire Departments • City and Town Officials • State Police • Virginia Dept. of Emergency Management • Towing Facilities • United States Coast Guard Mountain Tunnels – Emergency Response Team Remote Location of Mountain Tunnel
Response Time
Need of Emergency Response Team • Started in June, 2015 • Very effective in fire response Tunnel Preservation Robust Tunnel Preservation Program • Cyclic • Schedules - Bimonthly, monthly, biweekly, weekly and daily • Tunnel washing • Underground tank inspections • Fire extinguishers • Cleaning Tunnel Preservation Robust Tunnel Preservation Program
• Condition Based • Sidewalk Hand-hole Cover Replacement with stainless steel cover • Egress signage added to the tunnels for Fire, Life, Safety improvements • Drainage Improvements
Design‐Build Procurement of the Hampton Roads Bridge‐Tunnel (HRBT)
Martha E. Gross, PhD, PE Virginia Department of Transportation October 16, 2019 Overview
■ Context Tunneling in Hampton Roads Challenges and solutions ■ Design‐build procurement decisions Procurement of new HRBT Scope of design‐build contract ■ Tools for generating value Cost estimate and risk review Assigning value to innovation
10/16/2019 2 Hampton Roads
■ Virginia’s second‐largest metropolitan area ■ Many river crossings ■ Heavy traffic congestion
10/16/2019 3 Hampton Roads and Its Crossings
Chesapeake Channel Tunnel (1964)
Hampton Roads Bridge-Tunnel (1957 & 1976) Thimble Shoal Tunnel (1964)
Monitor-Merrimac Memorial Bridge- Tunnel (1992)
Midtown Tunnel Downtown (1962 & 2016) Tunnel (1952 & 1987)
10/16/2019 4 10/16/2019 65 ■ 1950 Two Downtown Tunnel #1 Years
Much Today’s 1955
observations: Hampton Roads #1
has 1960 of
tunnel Midtown Tunnel #1
changed
1965 Thimble Shoal #1 Tunneling ‐
builders & Chesapeake #1
1970 in
tunnel
have 1975 Hampton Roads #2 ‐
building less
1980 in firsthand
Hampton
1985 technology Downtown Tunnel #2
experience 1990 Monitor‐Merrimac
over 1995
Roads
six to 2000
decades draw 2005
from 2010
2015 Midtown Tunnel #2
5 2020 HRBT Facts and Figures
■ Existing: 2‐lane immersed‐tube tunnel on artificial islands ■ Superlatives when completed in November 1957: Longest immersed‐tube tunnel in the world First marine tunnel between artificial islands ■ Lowest point of roadway is 105’ below water ■ Tunnel length = approx. 7500’ ■ Total crossing length = approx. 3.5 miles ■ Second immersed‐tube tunnel opened in 1976 ■ Third crossing (twin 2‐lane bored tunnels) planned for 2025
10/16/2019 6 Design‐Build Procurement
■ Industry outreach in early 2017 to explore optimal procurement method for new HRBT crossing Technical aspects Financial aspects ■ Considerations for design‐build procurement of underground projects ■ Balance of prescriptive and performance‐based specifications ■ Value of proposer feedback and alternative technical concepts (ATCs)
10/16/2019 7 Procurement of Third HRBT Crossing
ACTIVITY DATE RFQ Issued December 15, 2017 Shortlist Announced April 26, 2018 Draft RFP Issued May 22, 2018 Selection of Tunnel Construction Method July 31, 2018 Final RFP Issued September 27, 2018 Technical Proposal Submission January 15, 2019 Price Proposal Submission February 8, 2019 Contract Award April 3, 2019 Design‐Builder LNTP 1April 12, 2019 Project Complete November 2025
10/16/2019 8 Project Overview
. I‐64 improvements from Settlers Landing interchange in Hampton to I‐564 in Norfolk (10 miles) . Highway widening and construction of new harbor crossing = four‐lane bridge‐tunnel . 2 existing HRBT tunnels will serve westbound traffic . New HRBT tunnels (twin 2‐lane tubes) will serve eastbound traffic . Design‐build contract: $3.3 billion . Total project cost: $3.8 billion . Scheduled completion date: November 2025
10/16/2019 9 Project Scope
City of Hampton Tunnels Marine Trestles Other Trestles Standard Bridges Roadway Works Tunnels 2 x 7,900 ft North Trestles 2 x 3,400 ft City of Norfolk
South Trestle 1 x 5,900 ft
10/16/2019 10 Project Scope
By the numbers:
Tunnels Structures • Length 7,900 ft • Bridges to Demo 5 • Inner Diameter 41.5 ft • Bridges to Build 4 • Excavation 950,000 CY • Bridges to Widen 23 • Segmental Lining 120,000 CY • Total Length 39,000 ft • Ground Improv. 500,000 CY • Total Surface 2,000,000 SF
Islands Expansion Roadway • Footprint 860,000 SF • Excavation 130,000 CY • Fill 170,000 CY • Embankment 90,000 CY • Dike 190,000 CY • Noise Walls 730,000 SF • Armor Stone 350,000 tons • Retaining Walls 100,000 SF • Splash Wall 6,000 CY
10/16/2019 11 Project Schedule
Anticipated Permit Approval Date = NTP Substantial Completion Target 540 days (18 months) after LNTP1 06/30/25 = October 2020 Substantial Completion Contract Execution +LNTP1 Deadline 09/01/25 April 2019 Final Completion LNTP2 +LNTP3 Deadline 11/01/25 September 2019 2019 2020 2021 2022 2023 2024 2025
LNTP 1 Design and Investigation Works for Environmental Permitting 6 Months of Scope Validation LNTP 2 LNTP2 : Authorization for TBM Procurement LNTP 3 LNTP3 : Launching Pit Construction to Start
Permanent Works over 55 months
Launch & Receiving Pit Ready for TBM TBM Assembly and Mining Interior Works Tunnels Commissioning and Testing North & South Marine Trestles Land Work I‐64 Widening
10/16/2019 12 Assigning Value to Innovation
■ During procurement, owner’s team refined project risk register as project scope developed ■ 37 key risks (34 threats, 3 opportunities) were distilled from risk register and quantified for FHWA risk model ■ FHWA cost estimate review (CER) used Monte Carlo analysis of risk model to identify range of impacts ■ Impact at 70% confidence interval was calculated for both DB contract costs and owner’s oversight costs ■ Innovation generated tangible value by mitigating risks and enhancing opportunities
10/16/2019 13 FHWA’s Cost Estimate Review Methodology
• Major cost elements • Allowances/contingencies Verify • Adjust estimate as necessary
• Base variability • Market conditions and inflation • Risk events (cost, schedule, probability,impact, relationships) Model • Monte Carlo simulation
• Closeout presentation •Finalreport • Approval of financial plan Communicate
14 Design‐Build Contract
10/16/2019 15 Owner’s Oversight
10/16/2019 16 Total Project Cost
10/16/2019 17 Total Project Cost in Year of Expenditure ($YOE)
■ Pre‐review estimate: $3.9 billion
■ Post‐review estimate at 70% confidence interval: $3.8 billion
10/16/2019 18 Sample Risk in CER: Geotechnical Risk at Island
■ Soil variations at north and south islands HRBT has the geotechnical feature of one “good island” and one “bad island” ■ Mitigation of soft material at HRBT south island 1957: material was excavated and replaced with sand fill 1976: up to 25’ surcharge and wick drains were used to consolidate compressible layers Maximum settlement: 13 feet
10/16/2019 19 Expansion of HRBT South Island in 1970’s
10/16/2019 20 Proposed Work at South Island
■ Expansion of island footprint ■ Excavation for tunnel entrance ■ Buildings and related utilities ■ Protection/ monitoring of existing facilities
10/16/2019 21 Ground Improvement at South Island
10/16/2019 22 Value‐Generating Innovation vs. Risk‐Taking
■ Issues: Constructing launch shaft for tunnel boring machine Limiting ground movement for adjacent structures Maintaining tunnel alignment in soft soil
■ Approach: Prescriptive vs. performance‐based geotechnical design requirements Monte Carlo risk review helped evaluate maximum, minimum, and probable impact outcomes
10/16/2019 23 Closing Thoughts Today’s Participants • Bill Bergeson, FHWA, [email protected] • Lou Ruzzi, Pennsylvania DOT, [email protected] • Conrad Felice, CW Felice LLC, [email protected] • Prasad Nallapaneni, Virginia DOT, [email protected] • Martha Gross, Virginia DOT, [email protected] Get Involved with TRB
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