TABLE OF CONTENTS 3

COVER STORY 16 Weighing the Options Is Industry Bias Toward

INSIDE this issue JUNE 2018

22 DEPARTMENTS Groundwater –The Relentless Enemy A look at the realm of groundwater control methods currently in use. 4 By Paul C. Schmall and Gary E. Taylor Publisher’s Message By Jim Rush 28 On the Cutting Edge 6 A conversion about cutting tools with Herrenknecht’s David Krauter. Business Briefs om acr 32 and around the world. World Tunnel Congress 2018 A recap of ITA’s annual event, recently held in Dubai. 49 36 Business Cards A Rosetta Stone How to improve communication between the geotechnical engineer and 49 project manager. Ad Index By Geoffrey Potgieter and Omer Yeni 49 40 Calendar Tunnel Update A recap of projects underwa

TBM: Tunnel Business Magazine (ISSN 1553-2917) is published six times per year. Copyright 2018, Benjamin Media Inc., 10050 Brecksville Road, Brecksville, OH 44141. USA All rights reserved. No part of this publica- tion may be reproduced or transmitted by any means without written permission from the publisher. One year subscription rates: complimentary in the United States and Canada, and $99 in other foreign countries. Single copy rate: $20. Subscriptions and classified advertising should be addressed to the Brecksville office. POSTMASTER: send Changes of Address to TBM: Tunnel Business Magazine, 10050 Brecksville Road, Brecksville, OH 44141 USA.

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TUNNELINGONLINE.COM TBM: TUNNEL BUSINESS MAGAZINE // JUNE 2018 4 PUBLISHER’S MESSAGE

Blasts from the Past

As I noted in this space in February, 2018 October 2013 – “Underground Scene.” This article fea- marks our 20th anniversary here at un- tured the massive amount of tunneling work under- . Since anniversaries are taken by the San Francisco Public Utilities Commis- naturally an occasion for reflection, I thought I sion Water System Improvement Program. The main would take the time to take a look back at some tunneling components of the program included the of my more memorable cover stories from the last 20 years. ington Tunnel, Bay T stal Springs Bypass. The $4.6 billion program was needed to update or replace systems of the drinking water built in the 1920s and 30s March 1999 – “Robbins Changes Direction.” This cover and susceptible to earthquake damage. featured Lok Home, who had just three years earlier purchased The Robbins Company (headquartered in June 2017 – “Breakthrough in Seattle.” In April 2017, Solon, Ohio, conveniently located just a few miles from eached our-then offices in Peninsula, Ohio). Interviewing Lok eople – in the industry and outside and learning about the great legacy of The Robbins of the industry – are familiar with the travails of the Company, including founder James Robbins and industry icon Dick record-setting 57.5-ft diameter machine. The successful Robbins, was a great introduction to the marketplace. completion of the tunnel was an important milestone in proving the viability of tunneling generally and large diameter tun- April 2003 – “Boston’s Big Dig.” Still one of the most neling specifically to an engaged public. amazing infrastructure projects completed to date, the Big Dig was the focal point of the industry for Help Us Help You many years. Beginning with the award of the Ted In order to publish , both in print and on the web, we need Williams Tunnel contract in 1991, major construction to be able to reach our audience. We periodically ask readers to was the norm for more than a decade. 2003 marked update their contact information so that we can ensure we are significant milestones toward the project’s completion, including reaching the right people at the right place. Even if your position the opening of I-93’s northb ch and the south- and address haven’t changed, it is important that we are able to bound tunnel in December. confirm your information on an annual basis. It only takes a few minutes to update your information. As incentive, we will select a April 2012 ” This article highlighted the random winner from anyone who updates their information be- mega projects that were simultaneously being con- fore June 30. The lucky winner will receive a Yeti 45 cooler ($300 structe A. The projects includ- value)! See the ad on page 40 for details. ed the Second Avenue Subway, East Side Acc 7 Line Extension. These projects represented the first major underground works in the city’s transportation system in half a century. While work continues on the East Side Ac- c Extension (opened 2015) and Second Avenue Subway-Phase 1 (2017) are in service. Jim Rush EDITOR/PUBLISHER

PUBLISHER/EDITOR PRODUCTION + FULFILLMENT James W. Rush Production Manager: Chris Slogar [email protected] [email protected]

CONTRIBUTING STAFF EDITORS Graphic Designer: Deborah R. McManus Sharon M. Bueno [email protected] Chief Executive Officer: Bernard P. Krzys Brad Kramer [email protected] Andrew Farr Director of Web and Audience President: Robert Krzys Mike Kezdi Development: Mark Gorman [email protected] [email protected] SALES + MARKETING Controller: Marianne Saykes [email protected] Director of Marketing: Kelly Dadich Audience Development/Sustainability [email protected] Coordinator: Cayla Poteete 10050 Brecksville Rd. [email protected] Brecksville, OH 44141 USA Regional Sales Representative: Todd Miller Ph: 330.467.7588 - Fax: 330.468.2289 [email protected] EDITORIAL COUNCIL www.tunnelingonline.com Gary Brierley, P.E - Dr. Mole Inc. e-mail: [email protected] Event Sales Manager: Brittany Cline Randy Essex, P.E. - Mott MacDonald [email protected] Dr. Levent Ozdemir, P.E. - Ozdemir Engineering Inc. William W. Edgerton - McMillen Jacobs Associates Reprint Information: Joe Gildner - Sound Transit Wright’s Media Paul Roy - AECOM Ph: 877.652.5295 - Fax: 916.983.6762 David Caiden - Arup TBM: TUNNEL BUSINESS MAGAZINE // JUNE 2018 TUNNELINGONLINE.COM

6 BUSINESS BRIEFS

Robbins TBM Uncovers Spectacular Cavern at Galerie des Janots

We have good production and it’s a good machine for hard rock. But sometimes it’s not hard rock that we encounter,” said Dhiersat. The weak rock and clay conditions necessitated ground support including resin-anchored bolts and rings in bad ground, topped with a 10 to 15 cm (4 to 6 in.) thick layer of shotcrete. Despite five months of poor ground conditions, Eiffage is optimistic that conditions will improve and the tunnel will be complete in the next four to five months. Galerie des Janots is one of the 14 oper- ations designed to save water and protect resources, which are being carried out by eille-Provence metropolis, the wa diterranean Corsica, and the State Government. The future Janots gallery will replace existing The Robbins TBM encountered an unexpected cavern measuring 8,000 cubic pipelines currently located in a railway meters (283,000 cubic ft) in size. tunnel—these original pipes have signifi- cant deficiencies with estimated water Contractor Eiffage Civil Engineering is more unknown caverns. We have a geo- losses of 500,000 cubic meters (132 mil- operating the machine, which launched te stem on the machine, lion gallons) per year. in 2017 for the Galerie des Janots project and are conducting probe drilling, shot- The completed tunnel will pass under in La Ciotat, France. The cavern, studded creting, and maintenance in a separate Le Par tional des Calanques, with with stalactites and stalagmites and mea- shift,” said Dhiersa stem, cover between 15 and 180 m (50 to 600 suring 8,000 cubic meters (283,000 cubic standing for Bore-tunneling Electrical ft), in order to replace the pipes that are ft) in size, was grazed on the tunneling ound predic- currently being utilized for the water operation’s left side. The crew named the tion technique using focused electricity- supply networks. “The current pipes have cavern “gr esimple” after their induced polarization to detect anomalies a capacity of transit limited to 330 liters site geologist. (87 gallons) per second, which is largely “We hit the corner of it. To cross it, we The crew encountered difficult ground insufficient in the summer period. The had to erect a 4-m (13-ft) high wall of con- conditions early on in the bore, consist- objective of the operation is to secure the crete s ve something ing of limestone with powdery clays. lines and increase capacity to 440 liters to grip against,” explaine c Dhiersat, “When the machine is boring it does well. (116 gallons) per second,” said Dhiersat. Project Director of Galerie des Janots for Eiffage. A small door allowed access in- side the cavity, which formed naturally The 3.5 m (11.5 ft) Robbins Main Beam TBM is boring a 2.8 km (1.7 mi) long at a point 60 m (200 ft) below the surface. tunnel for the Galerie des Janots project in La Ciotat, France. d up and was able to successfully navigate out of the cavern in eight strokes without significant down- time to the operation. “This is certainly unusual, to come across a cavern of this size and signifi- cance. It is somewhat related to the geol- ogy, with karstic and volcanic formations having the most potential for under- ground cavities,” said Detlef Jordan, Rob- ope. Karst cavities were a known risk during the bore, but the cavern was not shown in vertical borehole reports conducted from the sur- face along the alignment. A further 1.8 km (1.1 mi) will need to be tunneled before the 2.8 km (1.7 mi) tunnel is complete. “It is possible there could be

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Virginia Announces Shortlisted Teams for Hampton Roads Bridge-Tunnel Expansion Project

Three private-sector teams will be invited to submit technical proposals and prices to design and construct the I-64 Hampton Roads Bridge-Tunnel Expansion. The Virginia Department of Transportation (VDOT) has concluded its evaluation of State- ments of Qualifications (SOQs) with the shortlisting of private- sector teams, with three submitting SOQs to the department on ch 2, 2018, in response to a Request for Qualifications (RFQ) dated Dec.15, 2017. “These three candidate teams are strong contenders for the next steps in the competitive process,” said Stephen C. Brich, VDOT commissioner. “We are looking forward to learning more about each team’s specific plans and capabilities to deliver this vital project.” The RFQ gave the teams the option of submitting an SOQ under both or either a bored tunnel construction method or an immersed tube tunnel construction method. Both construction methods are currently under consideration by the department. The shortlisted teams are below in alphabetical order:

Hampton Roads Capacity Constructors Lead contractors: Fluor Enterprises Inc. / The Lane Construction Corp. / Traylor Bros. Inc. / Dragages Civil Works Virginia Inc. Lead designer: A echnical Services Inc. Design support: er International / Royal Haskon- ingDHV and Witteveen+Bos Joint Ventur ueser Rutledge Consulting Engineers Shortlisted for bored tunnel and immersed tube tunnel con- struction methods.

Hampton Roads Connector Partners Lead contractors: Dr Grands Projets SAS / Dodin Campenon Bernard SAS Joint Venture Lead designer: I-64 Design Joint Venture (HDR Engineering Inc.

Design support: Whitman Requardt and Associates LLP / Harris on Inc. / Pre ements Inc. / AI Engineers Inc. / GET Solu ttern & Craig / Athavale Lystad & Associates Inc./ Diversified Property Services Inc. Shortlisted for bored tunnel and immersed tube tunnel construction methods.

Skanska Kiewit Joint Venture Lead contractors: Skanska USA Civil Southeast Inc. / Kiewit Infrastructure Co. Lead designer: WSP USA Inc. Design support: COWI / Vanasse Hangen Brustlin, Inc / CAPITA Shortlisted for immersed tube tunnel construction method

The teams will be invited to submit detailed technical propos- als and binding prices in fall 2018 for one tunnel construction method. A draft RFP was targeted for release in y 2018. The contract award is anticipated in early 2019 with project comple- tion targeted in 2024.

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Dugway Storage Tunnel Marks Breakthrough BART Board of Directors Approves The Single-Bore Option Regional Sewer District reported that contractor in San Jose Salini Impregilo/Healy achieve ough ch 21, completing the The Bay Area Rapid Transit (BART) 3-mile long Dugway Storage Board of Directors on April 26 ap- Tunnel. Salini Impregilo/ proved a plan to proceed with a single- Healy was the low bidder in bore tunnel as part of its expansion September 2014 with a bid project into San Jose. Planners were of $153.3 million. deciding between using a large single The Dugway Storage bore or more traditional twin-bore Tunnel project involves tunnels under San Jose. the installation of a 24-ft According to the San Jos cury diameter storage tunnel oject involv- extending approximately ing BART and the Santa Clara Valley 15,000 ft in length from its Transportation Authority could get connection to the Euclid begin by 2020. The approval was re- Creek Tunnel (ECT) at the quired to secure $1.5 billion in federal - funding. nus near Superior Avenue/ The single-bore proposed for San Lakeview Road. José would use one 45-ft diameter tun- The tunnel was constructed with a Herrenkne t was previously used on nel b onstruct the Euclid Creek Tunnel. The alignment passed predominantly through Chagrin Shale a 5-mile long circular tunnel structure. at depths approaching 200 ft below ground level. The project also includes several con- The boarding platforms will be con- solidation sewers, diversion structures, and drop shafts to capture and store CSO from structed one above the other inside the the Dugway service area. The diversion systems feeding the drop structures will be tunnel bore without construction dis- equipped with the inflow control gates to manage the dynamic flow within the ECT/ ruption at the surface. DST tunnel system.

COWI Purchases U.S. Tunnel Resources of ILF Consultants Inc.

CO - President. He is a well-recognized man- phases of major tunneling projects, both ca (COWI) an- ager and engineer with extensive experi- in soft ground and hard rock. nounce y 8 ence delivering successful tunnel design Steven Kramer, Senior Vice President the addition of tunnel professionals from and construction projects acr comments, “These additions to the COWI the U.S. operating company of ILF Consul- America. He has over 36 years of engi- team are a sign of the continued success tants, Inc. neering expertise and has worked both and development of COWI’s tunnel busi- The addition of the key staff to COWI’s in consulting engineering and as Engi- eration continues to neering Servic or Kiewit. His With their experience working on a va- strengthen COWI’s tunnel expertise. Cur- career has covered a broad spectrum of riety of tunnel projects across the coun- rently, COWI has one of the largest tunnel large and complex projects including tun- try they add engineering strength and engineering groups in the world with over nels, bridges, dams, hydroelectric gener- invaluable knowledge and expertise to 600 tunnel engineers. The new additions ating plants, highways, deep excavations, our group.” to the team bring complementary skills in transportation, water/sewer systems, and COWI & ILF will continue to look for tunnel and bridge, and design with note- environmental management. opportunities to collaborate going for- worthy experience on several projects in Skovajsova will join COWI as Chief ward in the area of fire-life safety in California. Current projects include pre- Tunnel Specialist. She is a leader in the e advantage liminary engineering design for the Cali- design of tunnels and underground struc- of the shared experience provided by this fornia High Speed Rail Authority for the tures, and has extensive knowledge of purchase. CO section between Bakersfield to Palmdale. the application of sequential excavation the engineering consulting firms Buck- Among the new staff members, COWI and ground support systems, as well as land & Taylor, Jenny Engineering Corp., welcomed two highly respected tunnel geotechnical instrumentation and moni- Ben C. Gerwick, and Ocean and Coastal pr on, PE, and Zu- toring. She is actively involved in multiple Consultants. ILF will continue its opera- zana Skovajsova, PE. design project from conceptual/prelimi- tions in America in the areas of oil on will join COWI as a Vice nary engineering to detailed/final design & gas and transportation & structures.

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Schnabel Engineering Opens Seattle Office Dallas City Council Approves $207M ical presence was inevitable. Rutledge and Indri will be supported by Tunnel Contract a national team of skilled technical profes- sionals as they provide dam and levee, geo- Dallas, Texas, City Council on Feb. technical, and geostructural engineering 14 approved a $206.7 million con- design services in the region. tract to build a 5-mile long drainage CEO Walt Rabe, PE, said, “This is the sec- tunnel north of downtown. The Alex Rutledge and Rob Indri recently ond new office we’ve opened recently in a project, to be built by Southland opened Schnabel Engineering’s office in major market. These endeavors underscore ch. Seattle. our strategic plan, which places emphasis on eek Drainage Relief Schnabel Engineering has opened its first ‘being there’ for our clients.” tunnel will be 30-ft ID and approx- office on the West Coast in Seattle. A combi- Rutledge, a West Virginia native, holds imately 70 to 150 ft deep. It will nation of active projects in the vicinity and dual master’s degrees in civil engineering be built primarily within Austin two talented engineers willing to relocate and geology. He made Greensboro his home chalk. The project includes seven and make it happen clinched the deal. after joining Schnabel in 2006. shafts ranging from 12.5 to 40 ft ID. When given the opportunity to open the Indri hails fr ey. Prior to Project completion is estimated for company’s 20th location, Alex Rutledge, joining Schnabel in 2005, he was in the December 2022. PE, PG, and Robert Indri, PE, embraced heavy construction industry for 10 years The project is designed to reduce the challenge despite daunting logistics. and is an Army veteran. floo eek and Peaks The engineers, who have each been with “We each have something a little differ- Br eek and Peaks Branch Schnabel’s Greensbor C., office for ent to offer. I’m more on the structural and were natural streams that were en- more than 10 years, were already used to general civil side, whereas Alex is more geo- closed in the early 1900s. During long-distance travel to job sites. Thanks to technical and geology. We also share a simi- heavy rains as the channels reach ongoing projects with clients in the Pacific lar, ‘get it done’ work ethic and place a high capacity, street flooding — as much west and Alaska, establishing a phys- value on teamwork,” Indri commented. as 10 ft in some areas — can occur.

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Keller Group Acquires Moretrench MAT Rebrands to BAUER MAT

Further to its announcement on Jan. chanlagentechnik has 5, 2018, K ch 29 an- been delivering state-of-the-art nounced that it has acquired the en- mixing and separation technology tire issued shar etrench Inc., a geotechnical con- for over 25 years. Since April 1, tracting company operating predominantly along the East 2018, the branch office of BAUER Coast of the United States, from its employee shareholders for chinen GmbH has been oper- $90 million. At the end of February, the business had net cash a of $4.3 million. Systems, underscoring its affiliation with the international etrench has a strong heritage of complex geotechni- BAUER Group. cal projects and in the year ended Dec. 31, 2017, had revenue “We are now merging even more closely with the group, of $168.3 million, operating profit of $11.3 million and EBITDA and this will also be reflected in our name. We are reposition- of $15.8 million (both excluding $2.8 million of charges relating ing ourselves, and we’re doing it together with Bauer,” says directly to the Employee Share Ownership Plan and the trans- Alexander Konz, branch manager a . etrench’s net assets as of Dec. 31, 2017, were $66.4 With the new name, the company will take the next step million. The acquisition was funded wholly in cash from Keller’s in its future strategy. This will include strong growth in the existing borrowing facilities. international markets as well as significant expansion of the Following the acquisition, Keller will be by far the most ca- company’s tunneling business. pable geotechnical solutions provider on the East Coast and will stems plans be well positioned for the expected long-term renewal of infra- to further expand its core business of developing and manu- structure in the region. In addition, the acquisition gives Keller facturing state-of-the-art mixing and separation equipment access to new niche geotechnical products as well as new indus- for challenging specialist foundation engineering and tun- trial customers and should result in good revenue and cost syn- neling projects. By doing this and expanding the sales and ergies. K etrench have partnered on a number of service network, the company will be in an even better po- successful JVs in the past, which gives confidence in the mutual sition to tap the full potential of local markets in the future, compatibility of culture and management approaches. according to Konz. ecutive of Keller, said: “The acquisi- “As a global player, Bauer has production and sales loca- etrench is in line with our strategy of growing our tions in numerous countries around the world. I’m confident product range and building strong customer-focused businesses. that both our customers and employees will benefit further I am confident this will be an excellent addition to Keller. We from our increased cooperation,” says Konz. know the business well, its people, technologies and geographic Outwardly, the most visible change will come in the form focus complement Keller’s existing businesses in the United of a new logo. Also, the company’s web address changed to States and there should be good synergies.” www.bauer-mat.de.

In Memoriam: George Yoggy

George Yo- Division manager for the contractor’s proje ter ggy, a 50-year equipment manufacturing division, but T ebanon and the Lehigh and veteran of the in 1968, the desire to own his business Cumberland Gap Tunnels. In addition to concrete and took hold. UCA and ASA, Yoggy was involved in shotcrete indus- He owned and operated Concrete the International Tunnelling Association, try, passed away Equipment Corp. and Shotcrete Plus American Concrete Institu ch 27. Inc., a business engaged in the design, He also served on the editorial advisory Yoggy was a rec- manufacture and supply of equipment b ognized leader in for ground support, shotcreting and from 2001 to 2013. the field, includ- concrete placing sy “I am so thankful to have crossed ing serving as president of the American American tunneling, repair and mining paths with George. He was a mentor Underground-Construction Association industry. In 1986, the company was ac- and dear friend to all of us,” said Patrick (now UCA) and founder of the American quire - Bridger, general manager for King Shot- Shotcrete Association (ASA), and was a tablished the Underground Construction crete Equipment. frequent speaker and author. group f ollowing his “George was a true colleague, friend Originally from Johnson City Y., retirement fr and mentor, always with a smile and a college construction job in 1956 set continued working in the industry as a fantastic personality,” said Lonnie Ja- Yoggy’s career path. The contractor he consultant and remained active in asso- cobs, project manager for Frontier-Kem- worked for had a shotcrete division and ciations and conferences. per Constructors. “The industry lost a he learned about the process on the fly. Yoggy’s work took him across the Unit- legend and institutional knowledge that Eventually, Yoggy became the Eastern ed States and internationally. Some of his cannot be replaced.”

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12 BUSINESS BRIEFS

Herrenknecht TBM Helps Modernize Czech Infrastructure

project manager at Herrenknecht. The cutting tools were also changed for the second section of each drive. 19-in. disc cutters were thus installed for the single- shield mode section instead of the previously used 18-in. disc cut- ters. The larger disc diameter allowed higher contact pressure in the solid hard rock and longer running times. With small over- burdens in parts, the flexible all-arounder among the tunnel bor- ing machines achieved weekly top advance rates of up to 182 m. After 12 months, in October 2017 the site crew was able to cel- With the expansion of the railway line between Rokycany ebrate the final breakthrough for the second tunnel tube. In ad- and Pilsen as a high-speed rail link, the Czech railway network enknecht provided additional equipment, is being modernized. The line in the western part of the Czech such as multi-service vehicles from su ooling Republic is part of the railway corridor linking Pilsen to Prague tower and belt conveyor systems. and thus to the European railway network. Over a distance of The new high-speed rail link reduces the average travel time 4,150 m it consists of two single-track tunnel tubes. The tubes between Rokycany and Pilsen by around 10 minutes, and the were built by the Czech contractor ostav. For the first time capital city of Prague can be reached from Pilsen in less than one in Eastern Europe, a convertible multi-mo om EPB hour. As a result the region around Pilsen – with about 170,000 mode to single-shield mode) was used for the proje inhabitants the fourth largest city in the Czech Republic – will be was specifically designed and manufactured by Herrenknecht better connected to the trans-European transport network. The at its Schwanau, Germany, plant. modernization project not only makes the railway line faster, but The multi-mo also brings it up to the state of the art. This includes, for example, of the two tunnels through quartzite shale stone and clay soils in special safety features such as fire protection solutions and escape closed EPB mode with screw conveyor muck removal. On the last routes in the new tunnels. 1.1 km of each route the machine, model S-799, had to penetrate Herrenknecht is also involved in other infrastructure develop- hard spilite rock, for which it was converted to open single-shield ment projects in Eastern Europe. They include Poland’s largest mode with belt conveyor removal. Each of the conversions was tunnel structure – the 10-km long “Slowacki Route” in Gdansk. realized inside the tunnel in only two weeks. The road tunnel crosses under the Vistula River and connects the “For variable ground conditions along the tunnel alignment, a airport to the motorway and the deep sea port. Tunnel boring ma- convertible multi-mo est and most flexible solu- chines from Herrenknecht have also been used in the expansion tion. It can be run in different tunneling modes and thus operate of the metro in numerous Eastern Europ - in changing geologies,” explains Korbinian Kröger, responsible cow, Sofia and Warsaw.

GraphicSchedule Software Available for Large, Complex Projects

to know what’s in that 70-page schedule executives and other stakeholders how with 3,000-plus activities,” says Wonne- active projects are progressing.” berg, “but our industry lacks the tools to Wonneberg and Drake also continue communicate that information in a way their work in underground construction that the entire team can understand.” management, supporting WSDOT’s Alas- GraphicSchedule runs in Excel and kan Way Viaduct Replacement Program, GraphicSchedule is a software startup plots shapes with respect to time and lo- o’s Regional Connector proj- providing an Excel application that makes cation, to graphically depict how a project ect, respectively. And they frequently it easy to create linear schedules and one- will be constructed. These graphics can give presentations to help educate the page bar charts that communicate the big be linked to the master schedule for rapid industry about how this method can help picture for large and complex projects. updates whenever things change. The major projects. After years of tediously creating app is used by contractors, engineering “It’s exciting to be able to provide a tool one-page schedules by hand for major firms, and project owners seeking a better that helps the industry we serve,” says underground construction projects, co- way to communicate their projects. Wonneberg. “This is our way of leav- founders James Wonneberg and Ron “We are seeing more and more heavy ing the wood pile a little higher than we Drake launched GraphicSchedule to de- civil contractors using GraphicSchedule found it,” adds Drake. velop an app that the entire industry can to develop and optimize their bid sched- To download their eBook, or request a use and benefit from. “We believe that ules,” explains Drake, “meanwhile, project free trial of the app, visit www.Graphic- people who work on these projects want owner teams are using it to show their Schedule.com.

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MWD of Southern California Votes to Approve WaterFix Funding

The board of dire opolitan Water District of Southern California voted April 10 to provide the additional fi- nancing necessary to allow for the construction of the full Cali- fornia WaterFix project. The board authorized $10.8 billion for the project to modernize the state’s aging water delivery system, opolitan the primary investor in the project and more than doubling the agency’s initially planned investment to ensure the project is completed as originally proposed. WaterFix will be paid for by the people and businesses that use the water it helps deliver via the retail water agencies and cities that serve thos opolitan’s financing of the full project is expected to cost households on average up to $4.80 a month, though that average cost would be reduce o- politan recoups some of its investments from the agricultural sector opolitan will be selling or leasing capacity in the tun- nels to allow water deliveries or exchanges for other parties. About 30 percent of the water that flows out of taps in South- ern California comes fr alifornia via the Sacra- mento-San Joaquin Delta. But the Delta’s delivery system is bad- ly outdated, its ecosystem is in decline and its 1,100-mile levee system is increasingly vulnerable to earthquakes, flooding, salt- water intrusion, sea level rise and environmental degradation. Attempts to help the Delta have led to regulatory restrictions that have reduced water exports from the region. California WaterFix would modernize the state’s water delivery system by building three new water intakes in the northern Delta and two tunnels to carry the water under the Delta to the existing aqueduct systems in the southern Delta that deliver water to cities and farms. In Octob opolitan’s board initially voted to par- ticipate in WaterFix and contribute up to 26 percent of its $17 billion cost, or about $4.3 billion. But the majority of federal agri- cultural contractors who also import supplies via the Delta have yet to commit to investing in the project, leaving part of the proj- ect’s costs unfunded. In February, the state proposed building the project in stages instead – starting with two intakes and one tunnel, with a capac- ity of 6,000 cubic feet per second. An additional intake and tun- nel would be added when funding allowed. In its rec opolitan’s board chose between supporting this staged construction of the project or helping finance the full 9,000 cfs project all at once, with the hope of recouping the investment from agricultural interests once the project is completed.

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Aldea Services Hires Mahdavi ing d in soft ground; earthwork; building and dam foun- dations; retaining systems; earth/rock slope stability; remedial Aldea Services LLC announced that Hiv - treatment and instrumentation. davi, PhD, PEng, has been ap-pointed as a Senior In addition to his technical capa on has served as Tunnel Engineer/Project or the Aldea project manager on several tunnel projects, most recently pro- office in Tor vi brings more than a de- viding construction management and preliminary design ser- cade of international engineering and tunnel de- vices as a resident engineer and task leader, respectively, on ma- sign experience to her new position, with a spe- jor soft ground tunneling proje . Mahdavi cial interest in geotechnical design. on has authored or co-authored several publications, viw’s proven ability to manage, design most rec unneling Application in and deliver transit and utility tunnel projects utilizing best prac- ough Super-storm San- tice methodology for the conditions makes her an invaluable dy” for the World Tunneling Conference in 2016. He also has asset to the Aldea team. In fact, one of her most recent projects research experience a chanics Institute at Colo- for the city of Calgary was name AST rado Scho Project of the year competition in 2015 and winner of the award on earned a master of science in mining and earth systems of excellence in Consulting Engineers of Alberta in the Category engineering from Colorado Scho of Sustainable Design in 2016. science in geology from Korea University, South Korea. He is an vi’s path into the tunneling industry has been unique, associate member of the American Society of Civil Engineers. and includes analysis of pipe-soil interaction, geotechnical in- Kasperski is a senior project engineer who has vestigation, and design of tunnel and underground excavation. 18 years of diversified experience in planning, and structural design and analyses. He served as Brierley Associates Welcomes Painter a technical lead and project manager on numer- ous multidisciplinary projects where he was re- After successfully serving as the Proje - sponsible for coordinating and overseeing the er for Sou onstruction of Kasperski design and development of contract documents. the Kaneohe Kailua Sewer Tunnel (KKST), an ap- His underground design and construction expe- proximately 3-mile long gravity sewer tunnel rience includes tunnels, shafts, station caverns, and cut-and- from the Kaneohe WWPTF to the Kailua Re- cover structures, excavated using conventional drill & blast gional WWTP, Painter has rejoined Brierley As- method, sequential excavation metho Painter sociates. He will be based in Honolulu to serve both soft ground and hard rock. the firm’s island clients and grow the existing TB, Kasperski served another consulting infrastructure practice in the Aloha State. firm. He has been publishe unicipal En- Painter has over 43 years of experience, including almost 20 gine esented a - years working with Brierley Associates on various projects, in- tional Seismic Conference for Bridges and Highways. cluding as Senior Tunnel Consultant from 2005-2008. In addi- Kasperski earned a master’s degree in civil engineering from tion to his recent assignment at KKST for the City and County of Polytechnic University ee in Honolulu, Painter previously served as General Tunnel Superin- civil engineering fr ofes- tendent for the H3/Haiku Tunnels on Oahu. sional engineer, registere Painter’s extensive experience with conventional and tunnel b onstruction for wastewater, wa- La. Tech’s Behbahani Earns UCA Scholarship ter and transportation projects utilizing open (main beam) and shielde Louisiana Tech University doctoral engineering systems, brings to Brierley Associates a unique constructability student Seyedsaleh “Saleh” Behbahani has re- knowledgebase. ceived a scholarship from the Underground The new office is located at: 1003 Bishop Street, Suite 2700, Construction Associa Honolulu, HI 96813. Phone: (808) 237-2459. Email: dpainter@bri- The scholarship provides a $5,000 monetary erleyassociates.com. award in addition to covering Behbahani’s trav- Behbahani el to Washington, D.C., for the American HNTB Adds Moon, Kasperski Tunneling Conference in June. While there, he will represent Louisiana Tech at networking events and techni- Changsoo (Kev on and Artur Kasperski, PE, have joined cal sessions. TB Corp.’s tunnel and underground practice in technical and The scholarship was established to promote the study of tun- project leadership positions. Both are based in the firm neling and underground construction and careers in the field. York City office and work with clients nationwide. It is awarded to students who demonstrate a desire for and a on, principal geotechnical and tunnel engi- probability of success in a career in underground construction neer, has 27 years of experience in geotechnical and tunneling. s Louisiana Tech’s Trenchless Technology Center and tunnel engineering services. He has worked (TTC) manager of the Certification of Training in Ass - on a variety of projects both in the United States ment and the Underground Infrastructure Training Compe- and abroad, including mined and cut-and-cover tence Center online training, the coordinator of the TTC Spe- tunnels; caverns; shafts; tunnel boring machine cialty School programs including the Auger Boring School and Moon and drill-and-blast hard rock tunnels; sequen- the Utility Investigation School, Behbahani’s experience in the tial excavation metho unnel- field is well documented.

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AECOM, SNC-Lavalin Preferred NEORSD Awards Westerly Storage Consortium for Réseau express Tunnel to Jay Dee-Obayashi métropolitain (REM)

egional WST-3: 40-ft diameter baffle drop ed tha en- Sewer District Board of Trustees at structure a eral P - ch 15 meeting awarded the Ancillary work includes Gate ner of the design team, has been selected by Westerly Storage Tunnel contract to Structure and Gate Control Structure, CDPQ Infra Inc. as the preferred proponent a joint venture of Jay Dee–Obayas- at both the WST-2 and WST-3 sites, to for the infrastructure engineering, procure- hi. Jay Dee-Obayashi’s bid was regulate flow entering the tunnel, ap- ment and construction of the Réseau express $135,000,000. proximately 90 lf of 46-in. diameter métrop The project includes approximate- sewer, and miscellaneous modifica- General Partnership – a consortium ly 9,600 lf of 25-ft ID CSO storage tions to existing sewers. compose -Lav ojects Inc., tunnel excavated in rock and sup- The design contract was awarded Dragados Canada, Inc., Groupe Aecon Québec ported with a bolted, gasketed, one- to a joint ventur Ltée, Pomerleau Inc. and EBC Inc., in collabo- pass steel fiber reinforced concrete c in 2015. ra segmental lining. The contr ’s of a consortium compose -Lavalin Inc. In addition to the tunnel, there are Project Clean Lake, a 25-year program b-consultants. three deep shafts: that will reduce pollution in Lake Erie As part of the proje WST-1: 46-ft diameter online ac- by 4 billion gallons per year. A com- tunnels, bridges, stations, railway infrastruc- cess shaft a etrieval site. bination of large tunnels, treatment ture (tracks, power and traction systems, etc.), WST-2: 12-ft diameter baffle drop plant improvements and expansion, road improvements, intermodal equipment structure, connected to the main and green infrastructure is reducing and other structures as well as work on obtain- tunnel via a 5-ft diameter, 50-ft long the volume of combined sewer over- ing environmental permits, environmental adit in rock. flow discharging to the lake. monitoring and urban integration.

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Weighing the Options

Is Industry Bias Toward New Machines Limiting?

uch has been made worldwide of the dif- ference in performance between new and r - ists that seems to favor new machines, Rebuilt TBMs Mbut is the bias warranted? The reuse of machines can, offer a number if done to exacting standards, reduce costs and time of advantages, to deliver. including faster Guaranteeing the q ebuilds, howev- delivery times, lower er, is another issue. International guidelines have been costs, and proven developed to standardize the process of r equipment success. for another project. But is standardization possible? And can a use erform to the same standards Many TBMs, like as a new one? the one pictured in St. Louis, Missouri, The Worldwide Marketplace have excavated “There is no reason why a used machine shouldn’t dozens of km of perform as well as a new machine if you know the tunnels and have operational history of the machine and if it’s used been in use for decades.

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in geology for which it’s suitable,” said A Record of Success independent consultant Joe Roby, who So is newer really better? In many cases has decades of industry experience. “I’d the record shows that they are equivalent. argue that history shows the reverse— Changing opinions about rebuilt machines ra erforming can be done, says Roby: “We have to show better than used — a used machine is a evidence where refurbished machines proven design and more likely to have a have been used, and show their track re- successful future.” cord. If you can show that performance Large metro projects worldwide often and price were good on a given project ulta- that is important. Time should also be neously, resulting in a glut of secondhand considered: A refurbished machine can be machines on the marketplace at any given important if you’re looking to get started time. But contractual constraints often quickly. It can save a lot of lead time.” form barriers toward using these ma- If the age and number of projects bored chines on subsequent projects. “Consul- een by some as an issue, tants employed by project owners often a history of record-breaking projects over-specify technical specs — I’ve also achieved using rebuilt machines does ex- seen a lot of cases where they are doing e than one third (36%) of currently a cut-and-paste job on the specifications standing world records have been broken without checking on the requirements. using a refurbishe ome of them Sometimes the consultants don’t have the in service for decades. Rec erience, and it shows in the speci- manufactured in 1980 achieved three fications,” said Roby. world records in the 6 to 7 m diameter example, a contractor may wish to save He added, “I think it’s important to range at the Deep Rock Tunnel Connec- money by purchasing a use continue education — the risks of over- tor (DRTC) in Indianapolis, Indiana. The rebuilding it to its original specifications. specification may cost contractors and 6.2-m diameter Beam had pre- ebuilt owners in the end. I think what owners viously bored at least five other hard rock to the same diameter and specifications, ought to be doing, rather than over-speci- c- will cost less than rebuilding the same fying or specifying new machines only, is ond Avenue Subway. Design updates for machine but increasing the size to 4 m to specify the quality of the rebuild that the DRTC included a new back-loading and adding custom elements. But are the is necessary. But that requires a certain cutterhead with 19-in. disc cutters, vari- savings truly obtaine lev dge from the consul- able frequency drive (VFD) motors, and specifications do not fit the geology? Cut- tants. Certain things could be specified, a rescue chamber. The records included terhead configurations are a particularly like that the main bearing is new or has to e d in One Day” (409.8 important example, with cutter spacing, be certified for a certain number of hours. e d in One cutting tools, cutterhead geometry, and A cutter load could be specified for hard We eet muck openings all coming into play and rock tunneling, but details like thrust and ” (5,754.6 ft/1,754 greatly affecting the rate of penetration. torque should not be specified.” m). The machine is currently boring the A good example of this concept can be F unnel- next phases of the DigIndy network—a seen at o City’s Túnel Emisor Ori- ing and Civil at iPS who has rebuilt ma- further 28 km in addition to the 12.5 km ente (TEO). The geology is highly variable, chines worldwide, the bias toward new DRTC already completed. with the tunnel 62 km in length and up to machines is readily apparent. “For ex- In cases where it is believed that new 150 m deep. One 8.93-m EPB was used to ample, over-specification was initially erform better, there is likely bore two separate lots with very different quite prevalent in Singapore. There was an experience bias at work, says Roby: “I geology: Lot 1 and Lot 5. no reuse of machines allowed on the would expect people might have experi- At Lot 1, the machine was used with its early round of metro projects. At one ence of one such job where that was true, original cutterhead and soft ground cut- time, there were eight used machines and it’s dominating their thoughts. y ting tools, along with a two-stage screw sitting in a storage yard of identical size experience over the years has been that conveyor, to excavate watery lake clays to what was specified but we couldn’t there are a lot of successful secondhand with great success. The machine bored use them.” es are rare and gener- 4.6 km to complete its section of tunnel However, over time a more enlight- ally only happen in extreme conditions. on the critical path. The cutterhead was ened view did develop to allow reuse of A failed project can oftentimes be the re- designed as adaptable for both hard rock y machine proposed for ed where it wasn’t and soft ground configurations, but before reuse had to leave Singapore for refur- suitable or wasn’t rebuilt properly.” He it began excavation of the 8.6 km long Lot bishment in the original manufacturer’s added that, if an older machine was “ini- 5, it needed some modifications. Person- facilities. Willis continued that on some tially built for sandstone, it will not have nel added grizzly bars across the muck projects, such as India um o, enough power to work well in granite 25 openings as well as heavy duty abrasion- initially there was a similar philosophy years later without modifications.” resistant wear plating. Wear plating was but a stipulation was later added to allow A custom design, for a project’s specific also added to the screw conveyors so they refurbished machines to help meet the requirements and geology, is just as impor- could be used in open mode during ex- aggressive delivery schedule. tant on a rebuilt machine as a new one. For cavation in rock. Lot 5 is one of the most

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At Bangalore, India’s recently completed o, iPS rescued and refurbishe om a European manufac- turer, and then operated it for owner Bangalor o Rail Cor- pora C) alongside the project’s original contractor. “We found severe wear — the cutterhead was essentially bare; the cut- ters and grill bars had been worn away. We also found a serious crack in the screw conveyor and the flights had been severely worn. een operating for 12 months and had bored 300 m of abrasive ground with insufficiently thorough mainte- nance. It came to a standstill below the main railway lines at a ma- jor Bangalore metro station. iPS were able to build an intermediate shaft and r oint that it could advance into that shaft for further rebuild work including a replacement cut- terhead. Once the rebuild was complete, iPS then trained the crew on the importance of maintenance and inspections. “We showed them how to do regular inspections and interventions, what to look for, and how to prevent significant damage. For example, if you do regular inspections of the cutterhead you can detect cut- ter ring damage early on. With timely replacement one can avoid damage to the hub, put a new disc on, check the seals, and a cutting disc can be reused for a third of the price.” The new Robbins cutterhead with back-loading etween projects also af- disc cutters provided for the record-setting TBM at fects equipment life and can minimize the costs of a subsequent Indianapolis, Indiana, USA’s DigIndy Tunnels. rebuild—such as storing components indoors, coating the equip- ment with anticorrosive spray, and making sure the main bearing challenging on the project, at maximum depth and with geology ranging from lake clays to abrasive full-face basalt. Despite the challenges the machine has been able to achieve a project record of 30 m in 12 hours, showing that an EPB can indeed be used in very different conditions.

The Importance of TBM Maintenance It is essential to consider the total life cycle of a machine, and in maximizing the efficiency and life of the equipment through good design and maintenance. “I’m a mechanical engineer — if you maintain a car, it will last a very long time. If you don’t maintain it, it breaks down. The same can be said f e a proper preventative maintenance schedule will pay dividends,” said Wil- lis. “The structure of a is metal — as long as the structure is intact, you can then check on the bearings, conveyor, hydraulics, and other components. You must pay particular attention to com- ponents that are hard to reach. The main bearing is one of those parts that is very challenging to replace during tunneling.”

More than one third (36%) of currently standing TBM world records have been achieved using rebuilt machines.

TUNNELINGONLINE.COM TBM: TUNNEL BUSINESS MAGAZINE // JUNE 2018 20 COVER STORY is fille d hidden benefits including familiarity of machine operation and proven performance for that particular piece of equipment.

Rebuilt, Remanufactured or Refurbished The r oth the process and the standardiza- tion of rebuilds — has become a focus for the industry as more proj- ects with multiple machine requirements and short time frames are being proposed. The focus has been further highlighted by the ITAtech, a technology-focused committee for the International Tunneling Association (ITA-AITES) that produced guidelines on rebuilds of machinery for mechanized tunnel excavation in 2015. For Robbins, the preferred term is “rebuilt,” which describes any manner of crea om already existing compo- nents. The ITAtech guidelines introduce different terminologies dep ebuilt. They are, very shortly, described here: • Remanufacturing – Remanufacturing is a process with the aim to start a new life cycle of the product using its current or modified configuration. • Refurbishment – Refurbishment can be considered a full iPS rescued and rebuilt a European- maintenance, where defect parts are replaced to extend manufactured TBM at Bangalore, India’s Namma the life of the product in its original configuration or with Metro. The cutterhead features including cutters small modifications. and grill bars had been worn away. The guidelines describe the requirements of each process in or- der to designa efurbished” or a “remanufactured,” but in reality the majority of “rebuilt” may be somewhere in- portant but can be unreliable. So do interventions until you have between these qualifications. a baseline knowledge for how the machine is reacting in specific In terms of the international guidelines, they are certainly nec- types of geology. Don’t be complacent — just becaus essary and welcomed. However, the strictness of the guidelines big machine with a hard metal cutterhead and tungsten carbide can make them hard to adopt f ebuilds, cutters, it’s not true that nothing can damage it.” which are customized based on project needs. That is not to say that the guidelines are not useful. “I think the Used vs. New guideline, as written, would make a very good standard for own- Is a use od as a new one? In short, the answer is yes, ers to reference when allowing the use of a sec ” with qualifications. The machine’s rebuilt specifications should fit says Roby, but he cautions that certification as to the quality of that project’s geology and unique requirements. With a proper de- the rebuild is necessary: “The owners should specify that any sec- sign and rebuild, a used machine has advantages: “The design is ondhand machine be certified by an independent third party en- proven, the cost is usually lower and there is an advantage in fast- gineer. I would suggest that the owner also require the tendering er delivery times. The risks ar operly contractors to list in their bid the history and technical specifica- built or when a machine is put into geology where it’s not suitable,” tions any sec e and to include in said Roby. their bid the name of the company they intend to use to remanu- Overall, there are many benefits, both obvious and hidden, to facture the as well as the third party engineer they intend to using a rebuilt machine, but the rebuild should be done within employ to certify the remanufacturing. All of these should be in certain design restraints to remain economical. “There’s always accordance with the ITA guidelines.” the possibility to upgrade power and thrust on a machine but For Willis, rebuild guidelines may be less pressing than chang- there are strict engineering limits. If you increase the cutterhead ing the culture of operation and maintenance for many con- drive motor power, the gear reducers and final drive ring gear and tractors worldwide. “I know it can be done — it’s just a matter of pinions must have the capacity to take that increase in power. If convincing contractors to operate the machine properly. This will you’re increasing thrust, you need to check the bearing life and mean the machine at the end of a project will need less mainte- make sure that the bearing can take the increased forces. If you’re nance before it can potentially be reused. However, it’s also impor- exceeding gripper capacity on a hard ro ou have the tant, where possible, to encourage project owners to standardize wrong used machine for the job.” Roby added that the typ the sizes of tunnels, thus increasing the p euse.” and whether it is shielded or not also matters. “If you’re chang- Training should be specific to the machine and the geology, ing the diameter of an EPB such that it requires new shields that though there are some commonalities in what is required for may not be the best choice economically. Purchasing a larger EPB maintenance. “What I say is that when you first start a machine, would make sense in that situation.” inspect it often, until you know what to expect. The cutterhead Over or the long haul is simply a cost and screw conveyor may need an intervention once a week, or effective, energy efficient, and sustainable way of thinking about once a month. Someone has to perform inspections often enough tunnel boring. Used machines can and have shown their ability to know that a particular component has damage or is becom- to excavate projects at world-class rates of advance and complete ing worn out,” said Willis. He added that even when the geology many kilometers of tunnel with success. seems predictable, that should not be taken as failsafe, and has some advice for contractors: “Geological surveys are extremely im- This article was contributed by The Robbins Company.

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Groundwater –The Relentless Enemy

BY PAUL C. SCHMALL & GARY E. TAYLOR Ground freezing for cross passage mining.

Specialty geotechnical contractors such as Hayward nybody who has been fortunate enough to work with renowned Baker, Moretrench – now a Hayward Baker Company geotechnical consultant Ron – and others have long been key players in advanc- Heuer has been blessed with his Acolorful word pictures that bring geotech- ing the state of the groundwater control practice in the nical concepts to life for us common folk. United States. The authors, both industry specialists, “Grout is dumb and slow, but groundwater is smart and tenacious” is a good example. discuss the realm of groundwater control methods We may not have stated it quite like that, currently in use. but his point is crystal clear– groundwater is a fierce and unrelenting enemy. When-

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ever you let your guard down, it will act, and often with swiftness and power. As long as the properties of soil and wa- ter remain constant (which we can proba- bly count on for a long time) groundwater will remain the 1 source of problems in underground construction. Could this be due to the Ron Heuer groundwater tenacity or the fact that there is a very wide range of factors and conditions that aggregate successful or unsuccess- ful groundwater control? It’s probably a combination of the two. With tunneling work particularly, we put our methods to the test. We go deep. Sometimes really deep. We tra- verse variable ground conditions many times along uncompromising alignments which cannot be varied to avoid unfavor- able conditions. In tunnels, shafts, adits, breakouts, cross passages, etc., we never have to space to accommodate “additional measures.” It is an unforgiving environ- ment and tunneling rarely allows a “work around” when there is a problem. We typi- cally cannot afford a “hiccup” in the work. That’s why the groundwater control ap- proach on a project is so critical. Before the common use of the pressur- ized fac tering was a huge component of most soft-ground tunneling projects. The open face digger shield, for example, would struggle when perched or residual water was encountered in poten- tially running ground conditions, and cat- astrophic soil run-ins would occur when an isolated pocket of undrained sandy soil would be encountered by surprise. In easily dewaterable ground like thick deposits of sand and gravel, it was like a Jet grouting for sewer encapsulation. tunneler’s dream. If there was little risk of off-site adverse effects (consolidation of compressible soils or moving plumes) or the ground could be dewatered with- out concern about difficult changes in geology, perching layers, or recharge from open water or even utilities, a dewatering approach was the lowest risk option. The greatest risk hinged on the effectiveness of the dewatering program. That risk re- mains today with sequentially excavated tunnels; however, the third-party impacts are less likely because the ground is in- variably of lower permeability or “tighter” as that condition is a prerequisite for the stand-up time that goes hand-in-hand with the sequential excavation. It seems as if today there are more concerns about groundwater lowering perhaps because we are driving tunnels through some of the most congested urban areas, there is contaminated groundwater everywhere, Two levels of wellpoints for dewatering of TBM launch box. and there is always the perception that

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Permeation grouting for soil stabilization behind the microtunnel break-in eye.

dewatering is just going to cause problems. off, plus a non-cohesive soil. Looking back option doesn’t apply to vertical cut-off The typical tunneling project today is on some of the more horrific ground loss walls. When there are defects in cut-offs, a sequence of “bathtub excavations” con- events that we have been called in to, unfortunately we aren’t usually aware of nected by tunnels. The bathtubs are relied there is a common theme – excavation them until they reveal themselves with a upon even when the ground conditions well below the water table, some kind vengeance. The desired response is usu- are highly favorable for dewatering. The of an unanticipated gap in a cut-off, and ally chemical grouting and/or jet grouting, vertical walls of the bathtub are construct- surprisingly, a low permeability, but non- and compaction grouting to replace lost ed with slurry walls, secant piles, soil mix- cohesive silt. y people disregard the ground. But a high degree of ground dis- ing, and steel sheeting. Ideally, a natural, unstable potential of a non-cohesive silt turbance is a potential game changer. This low permeability cut-off stratum exists to (like Bull’s Liver) because they recognize is when we call on ground freezing. act as a bottom of the bathtub, but when it as a low permeability material. Low We usually rely on ground freezing that doesn’t exist, we must make the bot- permeability material is just assumed to when there is absolutely no room for er- tom with jet or permeation grouting. The be less susceptible to ground loss. Experi- ror, when we are deep and in ground con- bathtub approach is not risk-free by any ence has shown just the opposite. We let ditions that are not amenable to displace- means. A slight imperfection in a deep our guard down and the tenacity of the ment or erosion, when we have disturbed cut-off in the right (wrong) soil conditions groundwater wins. conditions or we are attempting to work can be catastrophic. Good craftsmanship is Typically in tunneling, there is little in and amongst the grout of previous at- more important the deeper one goes. Soil/ we can do to accommodate leakage and tempts. This is where ground freezing structure interaction and compatibility of groundwater intrusion without ground excels. It fulfills a need that is difficult dissimilar cut-off methods cannot be over- loss. A bottom seal can be configured as or sometimes impossible to fill through looked. There are a lot of elements of the a deep blanket with soil between sub- other geotechnical methods. But in un- work that must be executed flawlessly. grade and the deep blanket to accom- derground construction below the water The recipe for a bathtub disaster is a modate some leakage through properly table nothing is ever 100% guaranteed deep excavation, a slight defect in a cut- constructed wells or wellpoints. But this and even ground freezing has its Achilles’

TBM: TUNNEL BUSINESS MAGAZINE // JUNE 2018 TUNNELINGONLINE.COM FEATURE STORY 27 heel – moving groundwater. Excessive groundwater velocity can hinder the formation of a freeze, lead- ing to windows in the frozen wall. We have learned how to diagnose the potential for this and address it early on with localized grouting to reduce the per- meability of the soil and achieve closure. It’s all in reading the groundwater behavior and responding quickly and precisely. As history has shown in the many, many instances of projects significantly impacted or even abandoned because of groundwater inundation, this is often the riskiest and most challenging element of a project. It is hard enough to do it flawlessly when you have the right approach. An inappropriate or ineffective groundwater control approach is a recipe for disas- ter. It’s critical, therefore, that groundwater should always be addressed early in the project cycle and the most appropriate groundwater control method or methods determined. Striking the right balance be- tween cut-off and dewatering is a key factor, and for this, experienced practitioners are essential.

Paul C. Schmall, Ph.D, P.E., is a Senior Vice President and Chief Engineer for Moretrench, a Hayward Baker Company. Gary E. Taylor, P.E., LEG, is a Vice President with Hayward Baker’s Western Division. Jet grout bottom seal for microtunnel retrieval box.

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on the cutting edge A Conversation with Herrenknecht’s David Krauter

avid Krauter, a mechanical engineer for Herrenknecht, has spent three decades in the tunneling industry, most of them directly dinvolved in cutters and excavation tools. Throughout that time, mechanized tunneling has improved in its efficiency and reliability across the board, including the cutters themselves. We sat down with Krauter to discuss his background as well as the past, present and future of cutter technology.

How did you get involved with the tunneling industry? I grew up on a farm south of Bakersfield, California, and I actually had planned to be a farmer. It was on the farm that I got practical experience with machinery, which led me to pursue a degree in mechanical engineering at UC-Berkeley. From there I went to work for a shipyard in Seattle, and in 1988, I went to work for The Robbins Company.

What was your first experience in tunneling? I first started working in the conveyor department, but quickly began working with roller cutters. Almost immediately after that I was sent to a proje y to learn more about the business and what crews were experiencing. At the time, V-Block cutters were predominant, but that design led to lots of broken fixation bolts which caused excessive downtime and delays. Cutterhead maintenance costs were very high, and it could take up to 4 man-hours just to fish a broken bolt out of the cutterhead. It was a bad situation. So when I got back to Seattle, I was assigned as part of a team of young engineers to come up with a better way f planned for the Svartisen Hydroelectric Proje y . Together we developed the first front-loading Wedge-Lock cutter mounting system for 19” cutters. That has evolved into the back- loading design that is the predominant cutter housing today. It is still amazing to me that my boss at the time, John Gibson,

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the cutter size, then you have to determine what kind of cutting structure to use - steel, hard face or tungsten carbide insert with hard facing. That comes down to the ground conditions. Beyond that you have to determine whether entrusted a group of young engineers ground types like glacial till. The you want monoblock or replaceable with the task of devising a new way. inserts “grip” soft ground and cause ring cutters. Replaceable ring is the cutter to roll instead of slide. economical choice and start at 12 How was the new cutter Another development has been in in. and go up to 20 in. Below 12 in. it mounting system better? the area of pressure compensators. has to be a monoblock as the rings The wedge was a beautiful thing. I was skeptical that pressure get too weak, which is made of the The key was getting the bolt or compensators would be effective same material that the replaceable fastener out of the load path between in the underground environment disc rings are. Finally, you have the rock and the cutter. With the when they are exposed to pressurized to determine if other features are V-Block the bolts were in the load mud, dirt and water. But we supplied needed – whether to use pressure path, whereas on the Wedge-Lock roller cutters that worked under 27 compensators or excluder seals, the bolt was off to the side in the bar pressure for a shaft drilling job for example. There are all kinds of wedge and that greatly improved ada in which we used two designs in order to keep the cutter the situation for the bolt not to see types of pressure compensators – one rolling. That is the process we go fluctuating loads and break. This piston-type compensator and one through with customers. concept eventually would become the bladder-type compensator. At the industry standard for all diameters of end of the project we took apart the What’s next in cutter technology? roller cutters. roller cutters and the cutters that had One new thing we are working bladder compensators were still full of on is a radio frequency ID tag (RFID) Where else did you work? oil – not dirt and water like the cutters for cutters. The hardest thing about I worked all over the world – in with the piston compensators so that getting the RFID tag to work was the United States, Africa, Asia, India proved to me that they work. Initially finding one that would stand up and Europe; I even got to visit the they were developed for deep mining to the underground environment. Channel Tunnel while it was being shafts, but we have adapted them for With the RFID tag and software we constructed. Eventually I joined CTS are developing, you can just point in 1997, and then in 2006, I joined that will mine the Rondout tunnel a reader at the cutter and it will tell Herrenknecht after it purchased enknecht you its history, like how many times CTS. Joining Herrenknecht was Lak ada. it has been through the cutter shop a real eye-opener for me because and what parts have been used up until that time I had only been How does one select the right on it. It also helps with inventory involved with hard-rock cutting size cutter to use? management in the cutter shop. The tools. At Herrenknecht, we work On hard rock, typically you go as first iteration will just be used for on all different types of cutting tools large as you can – 19-in. cutters if you the shop but eventually we want to from static soft ground tools to roller can fit them. But as the diameter of integrate that into the cutter changing cutters for shaft machines and small the cutterhead gets smaller, below 5 process in the tunnel as well. The diameter machines. At our shop in m or so, it becomes difficult to fit 19-in. RFID technology will make it easier Sumner we manufacture more than back-loading cutters so you have to go for the cutter shop personnel to make 60 different types of roller cutters to a smaller cutter – 17 in. or smaller. informed decisions about how the from 6.5 to 20 in. in diameter. For soft ground machines it is more roller cutters get rebuilt. an art of compromise. If you want a What are some of the more maximum amount of openings for What steps can a contractor recent changes to cutters? driving in sand or clay, the available take to get the most life out of its The biggest right now is the space for cutters is reduced. So, you cutters? availability of different cutting tips. need to weigh what you will expect The key is to be proactive and not There is the standard tool steel ring, as the predominant ground along reactive with maintenance, and it is but now we have a hard-faced tool with the likelihood of encountering important to change cutters before steel and tungsten carbide insert boulders or lenses of hard rock or silt they block. On soft-ground machines with hard facing (TCI-HF). Tool steel – it is a compromise. Ultimately the sometimes that is difficult as is the most commonly used cutting contractor will choose the set up he contractors may want to push longer tip and the best choice for most hard is most comfortable with, and that distances to avoid the time and rock boring applications where high varies from contractor to contractor. expense of performing a hyperbaric impact loads are expected. Hard faced intervention. Careful steering in tool steel is effective in soft, extremely Now that you know what size hard rock conditions can also help abrasive rock like sandstone and cutter, what other factors need to ensure that individual cutters are not completely decomposed granite. TCI- be considered? being point loaded, which could lead HF is often effective in boulder laden Once you have determined to failure.

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32 FEATURE STORY

World Tunnel Congress 2018 Convenes in Dubai

eld in Dubai, from April 21-26 region, especially in the field of tunnels by the Society of Engineers and the use of underground space, with (SOE) and the International a number of ongoing mega-projects. We Tunnelling and Underground are honored to be the first country in the HSpace Association (ITA), the World Tunnel East to host the World Tunnel Congress and 44th ITA General Assembly Congress. We welcome all the academics were a momentous occasion and an un- and the specialists in the field, who will be doubted success for the global industry. sharing their knowledge to upgrade the Focused on “The Role of Underground engineering sector in the UAE, and the Space for Future Cities,” the World Tun- tunnel sector in particular,” Alhajri said. nel Congress shed light on the sustain- From this point flowed with presenta- able aspects of developing underground tions, working groups and seminars, in- construction. The challenge faced today cluding 125 technical papers presented by many key players of the industry (en- orally and 60 posters. During the 44th ITA gineers, urban planners, architects) when General Assembly, Copenhagen was cho- Traditional dancers were part of building new underground facilities is to sen to host the World Tunnel Congress in the gala banquet dinner. fully respect the surrounding nature. ear it will b , The opening ceremony was well at- and in 2020 in Kuala Lumpur ysia. tended by VIP guests, delegates from gov- ernment and private sectors, presidents New Approaches of Underground of international engineering associations, Spaces and Sustainable Development representatives from major engineering There is a common trend in saying un- and tunneling companies, as well as key derground space must be developed in ur- stakeholders in tunneling industry from ban areas facing space scarcity. Although all over the world. new global demand, urban agendas and Inaugurated by Eng. Dawoud Al Hajri, sustainable goals require different ap- Director-General of Du unicipality proaches to underground spaces utiliza- and President of the Society of Engineers, tion. For this edition of the WTC, the link and Prof. Tarcisio Celestino, ITA President, between sustainable goals and under- the ceremony was highlighted by lectures ground space is more than ever at the core and speeches from leading experts. The of many discussions. Prof. Tarcisio Celestino, ITA uir Wood Lecture was given by Ed- The International Tunnelling and Un- President, addresses the crowd. ward Cording and the Landmark Lecture derground Space Association’s Committee on Roman underground road network in on Underground Space (ITACUS) techni- en by Stefano de Caro. Eng. cal session highlighted various innovative Suleiman Abdelrahman Alhajri also gave concepts including those presented by presented by Karin Dehaas showcased a lecture on major works ongoing in the the Young Professionals’ Think Deep Pro- the potential benefits of a fully digital United Arab Emirates (UAE). gramme, such as a virtual reality model tunnel, allowing to identify with preci- “The United Arab Emirates has always of hard rock wastewater tunnel used in sion the surrounding environment and to been a pioneer of development in the Stockholm. Also, the digital twin tunnel share data to predict aging behavior, mal-

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34 FEATURE STORY

Global Tunneling Group (TG 10) to propose a new form of Activity contract for underground works: The Em- erald Book. • Global output (2016): €86 Approached during roundtables of the billion ($103 billion US) Open Session, the major points included in • The yearly average of the Emerald Book are: constructed tunnels: 5,200 • Balanced sharing of the ground re- km (3,200 miles) lated risks between owners (ground • The average growth of conditions risks) and contractors around 7% per year is twice (time and cost risks in the expected the global construction ground conditions) The Robbins Company was growth • Provisions for dealing with unfore- among the U.S. companies present seeable ground conditions will be in the exhibit hall. included in the general conditions function or failure, in order to preserve of the contract the existing nature around underground • A provision for a standing Dispute constructions. Avoidance and Adjudication Board For this edition, Han Admiraal and An- (DAAB) tonia Cornaro, co-chairs of ITACUS, pre- • Guidance for the preparation of ten- sented their new book “Underground Un- der documents veiled: Planning and Creating the Cities of the Future.” The book explores a new way Innovative Initiative to Face of thinking about underground spaces, in- Wastewater Treatment Issues in the tegrating visions of all stakeholders: urban Middle East planners, urban designers, architects, ge- Abu Dhabi Sewerage Services Com- ologists and engineers. pany (ADSSC) has developed the Strategic Technical discussions and The authors give a global overview Tunnel Enhancement Program (STEP), a panels are a hallmark of the World of innovative concepts ongoing around huge gravity-driven hydraulic wastewa- Tunnel Congress. the world, supporting the idea of under- ter tunnel network solution to relieve the ground space as a lever of sustainable hydraulic burden on the existing sewer- development, including underground age network and to accommodate the de- farms, multi-functional tunnels and un- mand created by the projected population derground pedestrian lines. growth in the Emirate of Abu Dhabi. The deep gravity sewerage system’s Contractual Practices in the 21st aim is to collect wastewater in Abu Dhabi Century Island and the mainland. The program in- Underground construction is a fast- cludes one of the deepest gravity sewer growing market sector and a special one tunnels in the world, and the first and in many regards. The underground works largest in the Gulf Region. differ from high-rise construction because The 41-km long deep sewer tunnel the creation of the necessary space within was completed using a total of eight earth Focused Working Groups meet the ground and the nature of the ground pressure balance (EPB) tunnel boring ma- at WTC to discuss and share is often unpredictable. Underground con- tilizing a pre-cast concrete information on best practices. struction therefore involves greater un- bolted segmental structural lining along certainty and greater risk. its entire length. The risk of differing ground conditions The tunnel varied in depth from 30 to ing station which will accommodate an is at the roots of many issues in contract- 85 m deep and the 17 shafts along the tun- average wastewater flow of 1.7 million ing processes. When the ground within nel route (at approximately 2.5 km centers) m3/day by 2030. which a tunnel is to be built is worse than were all constructed using diaphragm expected, the tunnel is more expensive walls for temporary ground support. The Looking Ahead and takes longer to build than anticipated. finished internal diameter of the tunnel The whole congress showcased the best ys, fixed-price, fixed-time con- varied from 4 to 5.5 m, which included a of the tunneling industry, and the upcom- tracts, as they are often successfully used corrosion protection lining comprising an ing evolutions of underground construc- in high-rise, have not proven to be effec- HDPE primary lining and unreinforced tion seem to lie in digital applications tive in underground works, causing high- concrete secondary lining to protect the and innovative concepts of underground er costs and time overrun. tunnel from acid attack and corrosive spac e completely FIDIC (The International Federation compounds typically found in sanitary autonomous? How can innovative sys- of Consulting Engineers) and ITA, both waste water environments. tems already working for aeronautics, rail organizations recognized by the United In addition to the 41 km long tunnel, and automotive industries be applied to tions, the World Bank, Development STEP includes 45 km of “link sewers” to the tunneling? All these questions under- Banks and the International Tunnel Insur- connect the existing sewerage system to lined the congress and shall be addressed ers Group (ITIG), have formed a joint Task the new deep tunnel, and one large pump- in a short-term future.

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36 FEATURE STORY

A ROSETTA STONE BETWEEN GEOTECHNICAL ENGINEER & PROJECT MANAGER FOR TBM TUNNELING

BY GEOFFREY POTGIETER AND OMER YENI

he geology intersected along a safety and project performance should parent until the project starts to run into tunnel is an overriding factor in easily offset the additional cost. significant cost and/or time overruns. many of the decisions that must A number of clients and contractors ers construct equipment be made in planning, designing, underestimate the importance of the geo- according to the provided specifications Tand construction. During planning and technical input. This does not become ap- and take no responsibility for errors in design, the geotechnical engineer must an- ticipate the behavior of the tunnel under several excavation and support scenarios. His or her ability to predict this behavior Tunnel Boring Machine is critical for an accurate cost estimate as (rotational cutter head) well as on-time delivery of the project. Geotechnical interpretation should be performed carefully to take into account the significant geology while accounting Segment Gripper for the uncertainty associated with un- derground design and construction. Due to the unique nature of each project, there are no fixed standards or check-off list that Slurry Earth Pressure Mechanical Shield Beam can be used to fully determine the scope Type Balance Type Excavation Type Type or provide a comprehensive how-to guide. (Closed) (Closed) Type (Open) (Closed) (Open) A knowledge gap is almost always pres- ent between what is obtained by the cli- ent during the design phase and what is required by the contractor for equipment purchase and construction. This knowl- Soft Ground Rock edge is often the underlying cause for contract disputes. Therefore if additional effort is spent early in the project to mini- mize this knowledge gap, the payoff in Figure 1 - TBM quick selection chart (General).

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geotechnical interpretation. Input from the geotechnical engineer TYPE CONS BEST FOR should be considered both early in the Slurry Type • Require significant backup • Allows soft, wet, or unstable project scoping and continuously sought systems and power ground to be tunnelled during construction. • Drive can be hindered by • Suitable for ground with high This paper sets out to provide both large stones and boulders water pressures a ready reference to project managers • Limits ground settlement and as to when and what input they should produces a smooth tunnel wall seek from geotechnical engineers and give guidance to geotechnical engineers Earth Pressure • Not suitable for ground with • Allows soft, wet, or unstable on how to present information to project Balance (EPB) high water pressures ground to be tunnelled managers in such a way that they can • Not suitable for hard rock • Limits ground settlement and make informed decisions around project conditions produces a smooth tunnel wall management, reducing disputes and ulti- mately providing better outcomes for the Shield type • High capital cost • They offer a continuous and industry. • Difficult to transport controlled means of tunnel- • Very sensitive for weak ling capable of high rates of TBM SELECTION STAGE ground conditions advance under favourable election is critical to the success • Limited options to deal with conditions of the project. Once made, this decision ground water cannot easily be changed. Tunnel purpose, type and design are not the only criteria to sele election chart Table 1 - Basic comparison of TBM types Figure 1, which is used by a lot of contrac- tors, is not the recommended method to sele

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TBM DESIGN STAGE ute or week to week in conditions ranging After sele e then from very wet to very dry, and from soft the geotechnical engineer should still be ground to hard rock. actively engaged during the design and To prevent surprises, the geotechnical manufacture as there are many variables engineer needs to be present at the job that will affect the performance of the site. Working remotely is not an option. tter- The advantages of having a geotechnical head, maximum trust and torque, over- engineer on site at all times are: boring, probing and ground improve- • Prediction of ground conditions ment capabilities. ahead of the cutterhead both good Of secondary importance is the fact and bad along with expected im- that during this stage any further geo- pacts on advance. Figure 2 - Knowledge vs Ability to technical assessment will allow for opti- • Providing solutions to allow ad- change over time. mization of the TB ease vance rate to be maintained. performance. • Advise as to when mining can or There will always be pressure to re- cannot be stopped and advise if this There are a few variants to these main duce costs however understanding con- will require a contract variation typ chanical Excavation Type,” sequences of each compromise must from the client. “Beam Type, ed Shield Slurry Type.” be appreciated in each instance. Saving • Analyze performanc Table 1, however, is sufficient to demon- money on a probe drill may make it im- and provide understanding to the strate the idea. possible to conduct adequate probe drill- project manager as to why variation As you can see from the Table 1, prior ing ahead of the cutterhead during main- is occurring. knowledge of expected ground conditions tenance periods, creating the situation • ound conditions and re- is critical. Hard rock may be indicated dur- where you need to either mine without sponding to mining and updating ing feasibility studies based on limited core sufficient cover, delay mining to achieve the geotechnical model to enable drilling. This would result in the choice of the required cover or purchase and fit better predictions. a Shield typ ber of better drills during excavation. The third Project managers are specialists in faults are present in the rock this would choice may not always be possible. their field they are not geotechnical en- mean much of the ground will be weak The question should not be, “Are all re- gineers. The jargon used by geotechnical or variable, in which case it would have quested designs in place?” but, “Are all re- engineers is often confusing and does not been better to choos quested designs in place and optimized to provide the knowledge required to make type of mistake is costly. The choice of the predicted ground conditions?” decisions. Project managers constantly e a collaborative exercise be- have to weigh up conflicting priorities and tween the geotechnical engineer and the TBM OPERATIONAL STAGE advice as per Figure 3. Geotechnical engi- procurement/tender team. As the project ody likes surpris neers need to understand this and provide matures, the amount of information will like surprises. Project managers do not information in a way that makes sense. increase, however as decisions are made like surprises. Any geotechnical engineer Recommendations must be free of jar- and capital is spent the ability to change who wants a long career in tunnel boring gon and must be given in context. For ex- will decrease. Both geotechnical engineers would do well to remember this. ample, the engineer may detect increased and project managers need to understand Conditions in the tunnel can change cutterhead torque due to mining through this dynamic and the pressures it creates. quickly transitioning from minute to min- a fault and is aware tha e- quired to stop for maintenance within the next few hours. Figure 3 - Considerations Do not tell the project manager the torque is high so he cannot stop. This does not provide context and will create a direct conflict with the mechanical en- gineer and contract requirements so the advice will probably be ignored. If the geotechnical engineer explains that stopping now would result in the cutterhead being stuck and that if the stop was delayed for 50 m or so when better ground conditions are expected, ould safely be stopped for maintenance. A variation would need to be obtained from the client and the maintenance schedule would need to be adjusted. The geotechnical recommen- dation would be far more likely to be fol- lowed and this would produce a better result for the project.

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In addition to making the recommenda- tions clearer, i.e. in terms the project man- ager is familiar with, the geotechnical en- gineer should collect supporting data from additional sources such as sampling and analyzing rocks from the stockpile and/or reviewing probe drill data and use these to then continuing to work with the geo- REFERENCES build a convincing argument. technical engine election 1. HOEK, Evert, “Geotechnical In the modern highly mechanized world and design, the project manager will more considerations in tunnel design and otechnical engi- likely to be able to succeed. contract preparation”, Transactions neer has access to many methods of collect- An experienced project manager un- Inst. Min. Metall. (Sec. A: Min. ing raw data from dozens sources both on derstands that the competence and expe- Industry) 91:A101-9, 1982 ound the site. The geotech- rience of the geotechnical engineer can 2. PARKER, Harvey W., “Planning and nical engineer needs to translate the data make the difference between meeting site investigation in tunnelling”, into knowledge and wisdom and share that the project goals or incurring delays and Seminário Internacional South with the project manager. Data and infor- additional costs. The ability of these two American Tunnelling, Sao Paulo, mation, while critical to the geotechnical people to understand each other and work 2008 engineer, is useless to the project manager together during the construction of the 3. YENI, Omer, KARGI HEP Project and will only confuse the issue if not pre- tunnel is critical. Personal Notes, 2011-2013 sented in a clear and concise manner. The geotechnical engineer must try to understand the pressures that the project CONCLUSION manager is under the conflicting priorities Geoffrey Potgieter is Operational Services oject no matter how much time that he must resolve daily. Deliver knowl- Superintendent with Glencore Copper and money is spent up front will ever have edge and share wisdom and becoming an Australia. Omer Yeni is a Senior Rock all of the information. By getting good geo- ally rather than just another source of Mechanic Engineer with Glencore Copper technical advice early in the project and conflict that has to be resolved. Australia.

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CALIFORNIA Los Angeles Crenshaw/LAX Walsh/Shea Corridor Constructors This $1.278 billion project for the Los An- opolitan Transportation Authority o), being built by a joint venture of Walsh and Shea, is an 8.5-mile light-rail line that will run between the Expo Line on Exposition Bou- levard and the o Green Line. TP was is- sued in September 2013 with revenue service expected by October 2019. The project consists of twin bore tunnels, about 1-mile long each, connecting three un- derground stations. The tunnel is 21-ft OD (19- ft ID) and is approximately 70 ft below ground. Ground conditions are soft ground/alluvial, leading to the choic Construction of the concrete inverts and emergency walkways in both tunnels are com- plete, as is final concrete lining of all five cross passages. The primary activities remaining to be completed in the tunnels are the construc- tion of the trackwork and concrete plinths Los Angeles Regional Connector throughout, and final outfitting/installation of mechanical and electrical systems. tions; Community Outreach: Los Angeles Ur- Beauvoir; Interim DEO, Deputy Project Direc- Parties affiliated with the proje - ban League; Civil Engineering: Jenkins/Gales o): Kimb o): Dana ufacturer – Herrenknecht (Germany); Consul- ctric; Quality Rogers; Proje ard- TB; Construction Support Services: Control: QEI; Survey: Psomas. ner; Deputy Proje ve Stantec; Tunnel Engineering: Arup; Systems: Key Project Personnel – Deputy Executive Pr arl L.K. Comstock; Structural Engineering: SC Solu- Officer, Project Dire o): Charles H. Christensen.

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Los Angeles ment. Pressure balance tunneling u equired, Purple Line Extension – Phase 1 along with precast concrete segments with double gaskets as the tunnel Skanska/Traylor Bros./J.F. Shea JV (STS) lining system. The tunnel depth (cover) ranges from 25 ft to approximately The Westside Purple Line Extension Project is a 9-mile long project that 120 ft and crosses b o Red Line heavy rail tunnels consists of three sections that are being planned to be built and opened with less than 7 ft of clearance. The Regional Connector includes ap- for revenue service before the end of the next decade. Section 1 is a 3.92- proximately 2,100 ft of cut-and-cover and retained cut guideway, a 300 ft mile long subway alignment with three stations that is being constructed crossover cavern excavate chniques, and three cut-and-cover under Wilshire Boulevard in gassy ground and tar sands with prehistoric subway stations. The bored tunnels will be excavated concurrently with fossil deposits utilizing the design-build delivery method. the three station construction, requiring coordination of cut-and-cover TP for the $1.636 million design-build contract was issued on Jan. 12, and tunnel excavation. 2015. Tunneling operations are planned to begin in mid-2018. The tunnel- The Little Tokyo/Arts District Station, located at 1st St. & Alameda St., ing operations will be staged through the shoring box of the Wilshire/La excavation and invert concrete was completed in December 2016 and Brea Station excavation. The Revenue Service Date per the Full Funding tunneling commenced from that location in February 2017. The Grant Agreement is Oct. 31, 2024. first tunnel was completed on July 19, 2017. The was moved and The scope of work includes 17,900 ft of twin-bore tunnel: Reach 1 relaunched for the second drive on Septemb ember 7, is 9,600 lf between Wilshire/La Brea Station and Wilshire/Western 2017, the tunneling crews set a project tunnel production record of 190 etrieval shaft; Reach 2 is 4,400 lf between Wilshire/La Brea and ft in one 24-hour day. The second drive was completed on Jan. 17, 2018, Wilshire/Fairfax Stations; and Reach 3 is 3,300 lf between Wilshire/ Fair- to the Flower Street cut-and-cover section wher - fax and Wilshire/La Cienega Stations. There is also 600 lf of tail track to bilized. Excavation of the three cross passages between the two tunnels the west of Wilshire/ La Cienega Station wher e buried. was complete ch 2018 and cross passage lining and tunnel invert The tunnel is 18-ft, 10-in. inside diameter with 12-in. thick precast con- placement is underway. The excavation of the 90 ft deep Historic Broad- crete lining. Depth varies from 40 ft and 100 ft. The alignment includes way Station, located at 2nd St. and Broadway, is approximately 90% com- three stations and the western retrieval shaft and 23 cross passages. plete as preparations are being made for excavation and support of a 300- Tunnels are planned to be mined by two Herrenkne oss- ft long cross over cavern at the east of the station using excavation passages are planned to be mined by the sequential excavation method techniques in the Fernando forma vern is expected to be using variety of localized ground support systems. Anticipated ground complete by December 2019. Structural concrete placement is on-going at conditions include: Soft ground consisting of Pleistocene-age (San-Pedro) the Grand Ave. Arts/Bunker Hill Station, located at 2nd Pl & Hope St. Pile and Pliocene-age (Fernando) formations; Some alluvium deposits and arti- installation, utility relocation and decking are 85% complete on the 1,350 ficial fill areas above the tunnel; Tar sands comprise almost 25% of tunnel ft cut-and-cover section along Flower Street where hanging of utilities alignment; Expected water table up to 90 lf above tunnel crown; Presence and excavation below the deck is approximately 40% complete. of methane (CH4) and hydrogen sulfide (H2S) gases (tunnels are deemed “gassy” by OSHA). The project is 34% complete. Production of tunnel precast concrete Liners b ember 2016. er Herrenknecht has completed manufacture of e successfully conducted at the Herrenknecht factory in July. Delivery to STS yard was completed in December cheduled for August. Jet grout- ing of cross-passages b ember 2016. Wilshire/ La Brea Station excavation (tunnel launch point) began in July 2016 and invert concrete is nearly complete. Tunnel Designer: PTG/ WEST JV (Stantec/Jacobs). Engineering/ bcontr er: Herrenknecht; Precast: Traylor precast; Support of Excavation/piles: Con- don Johnson; Jet Grou olm Drilling; Geotechnical instrumenta- tion: Group Delta; Dewa etrench; Standpip en. Key Project Personnel: James Cohen, Executive Officer, Program A; Ashok Kothari, Project Director, WSP/Par- sons Brinckerhof e Smithson; (Traylor) uart, Jim Honeycutt.

Los Angeles Regional Connector Transit Project Regional Connector Constructors (Skanska-Traylor JV) The downtown Los Angeles urban location of the Regional Connector provides challenges in the coordination with multiple third parties. The Regional Connector project will be the first tunnel subway project to con- nect three operating rails sy o Blue and Expo Lines on the West and the Gold Line on the East. When complete, transit riders will no longer need multiple transfers and can travel north-south and east-west on the same system. The tunneling portion of the $1.75 billion Regional Connector Transit Project for the L opolitan Transportation Author- ity involves 5,795 ft of twin tunnels with an excavated diameter of 21 ft. TP was issued July 7, 2014, with a forecast completion date of December 2021. The ground conditions range from alluvium soils to siltstone of the Fernando formation, with the potential for methane, hydrogen sulfide gas and boulders. The groundwater table is generally above the tunnel align-

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Other parties affiliated with the project it was designed for. Over the past four years, the San Francisco Bay. – Tunnel Designer for the Contr failures in the system have led to the leaking Once design for this stage is complete, BBJV of raw sewage. will prepare to negotiate pricing for Stage 2, Consultant: Ar er: Her- Barnard, joint venture partner, Bessac, which will consist of the remaining design ser- renkecht. Preliminary design was completed and design engineer, Arup, are working vices to bring the design from 60 percent to 100 by CP o per- with SVCW on a nearly $8 million progres- percent, along with all required gravity pipe- forming design services during construction. sive design-build preconstruction contract line shaft and tunnel construction. Key Project Personnel – o Project Ex- to advance the design of the Gravity Pipeline The BBJV Team and designer Arup continue ecutives: Gary Baker, Proje Project. This new pipeline will provide tempo- to make design progress on the SVCW Gravity Harrington, Engine t An- rary stormwater storage, and stormwater and Pipeline Project. Daily collaboration and coor- o Design sewer conveyance to SVCW’s existing Waste- dination with SVCW, owner advisors, front of ill Hansmire, water Treatment Plant. plant contractor, and community stakeholders Tunnel D o Construction SVCW has split the contract into two stages. have paved the way to the start of good rela- cadis), Ron Drake, Stage 1 requires investigation, surveying, cost tionships between all involved. Technical Advisor/Tunnel Resident Engineer; and schedule estimating for multiple options, With the recent completion of ground in- Contractor Project Executives (Regional Con- and coordination with a separate design-build vestigation work and lab testing, Arup has nector Contractors RCC): (Skanska) e Apari- contractor who is working concurrently on the completed the geotechnical data report (GDR). e Smithson; (Tray site. Beginning with a partnering workshop, Preparation of the geotechnical baseline report agard. BBJV quickly co-located with SVCW last fall to (GBR) will be the next focus. Arup also com- advance the project design from the 10 percent pleted the basis of design report for the airport Redwood City stage to 60 percent. The design scope includes access shaft, which will b Gravity Pipeline Project support of excavation (SOE) for the tunnel bor- location for both tunnel drives. Barnard Bessac JV (BBJV) ing machine launch shaft; SOE for two BBJV identified early the need to increase Silicon Valley Clean Water’s (SVCW’s) ex- retrieval shafts; 3 miles of gravity sewer the shaft diameter from 35 ft (SVCW’s plan) to isting force main sewer system was construct- pipeline tunnel; and all inlets, drop structures, a larger 58-ft. diameter shaft to eliminate site ed more than 45 years ago and was designed and connections to the tunnel, including full congestion and support improve cava- to last between 25-50 years. Additionally, due hydraulics design. The pipeline, to be con- tion production rates. Additionally, Arup com- to significant population growth in the San structed by earth pressure balanc pleted the retrieval shaft 60 percent design, Francisco Bay service area, the system experi- methods, will improve the wastewater convey- which is now configured with a “dog-bone” ences roughly three times more pressure than ance system that eventually discharges into geometry that consists of a 36-ft diametershaft,

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ft – secant piles installed, shaft excavation start- ing summer 2018. Also included are 15 drop/ vent shafts with finished diameter of 30 to 72 in. with OB excavated with a Bauer drill rig and rock excavated with a Wirth drill rig. Al drilling is expected to be complete by end of June 2018 and nine shafts completed with spiral weld pipe installed, 8 adit/deaeration chambers that will be excavated drill and shoot as the main line passes with deearation chambers cast-in- place concrete and adits lined with spiral weld pipe. Ground conditions are red siltstone with basalt encountered a excavation. The project is currently 38% com- plete. Final completion is scheduled f ch 22, 2022. esign Engineer(s): AE- - ager: Jacobs Project Company, bcontractors – Case Foundation Com- pany, R.E.D. Technologies and Gelly Trucking, Freeman Companies, Zuvic, Carr & Associates, and CSI – Precast Concrete Tunnel Segments, er – Herrenknecht. Oregon Avenue NW Sewer Rehabilitation Key Project Pers e Surman, PE Vinny Prestia, General Superintendent Jeff slurry wall support of excavation (SOE), with a neer of Record, Kevin Clinch – Lead Structural on, Superintendents Ronnie Beesley, Jay connecting adit to the front of plant contrac- Designer, Luis Piek – Lead Tunnel Designer, Eric Jankowski, Samora Grant, and Hector (Skinny) tor’s receiving lift station shaft. Sekulski – Lead Geotechnical Engineer - Jimenez, Engineers: Br toshi Akai, Arup and BBJV continue to work toward kol – D , David Halsing – Envi- Dan Guerette, Yuichi Kammoto, Allison Do- preferred inlet options at both of the grav- ronmental Consultant, Teresa Herrera– SVCW nahue, Adam Elkins, and Sanaz Dezfolin, QC ity pipeline tie-in points, Bair Island, and San er, Bruce Laura Wagner - Carlos, which will capture flows from four Burnworth– SVCW Proje . tamaria, Tyler Sheehan, and Javiel Robles. adjacent pumping stations to a design capacity equal to 103 million gallons per day (mgd) dur- CONNECTICUT Wethersfield ing the winter months. Hartford Goff Brook Overflow Closure Parties Affiliated with the Project:ARUP South Hartford Conveyance and Storage Bradshaw Construction Corporation - BBJV Design Engineer, ESA – BBJV Environ- Tunnel Bradshaw is currently constructing a 60-in. mental Consultant, Kennedy Jenks – Owner’s Kenny/Obayashi IV, JV microtunneling/conv oject for Engineer, Tanner Pacific - Construction - Job Specifications include 21,258 lf of 21-ft, 30- and 48-in. FRP sanitary sewer installations. ager for SVCW, JCK Underground – SVCW ored tunnel precast lined The second tunnel, a 420-ft drive through Consultant. to 18-ft ID. The depth of tunnel is approximate- siltstone, was recently completed behind an Key Project Personnel: Jack Sucilsky – ly 200 ft. There are three large shafts all with a Herrenknecht A emaining Proje e Hanley – Project Super- SOE secant piles and rock excavated via drill 1,430 lf of 60-in. steel casing will be installed intendent, Bernard Catalano – Construction and shoot. Finished shaft diameters: Launch over three drives, with the longest drive total- tt Paulisich – Tunnel Superinten- Shaft 39 ft/35 ft – completed except closure ing 850 lf. Ground conditions for microtunnel- ail – Project Engineer, Glen pour; Pump Station Shaft 74 ft/70 ft – OB ex- ing operations will vary between dense sand, Strid – Project Engineer, Jon Hurt – Engineer cavated, OB concrete complete and drill and silty gravel and siltstone, with groundwater of Rec er – Geotechnical Engi- shoot – 50% complete; Retrieval Shaft 32 ft/28 anticipated. The project members include the

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opolitan District Commission (owner), engineer) and Baltazar tion and sewer activation has begun and will continue Contractors Inc. (GC), with Bradshaw Construction performing as tunnel- through the project completion this fall. Information: Todd Brown, Project ing subcontractor. Project Information: Jordan Bradshaw – Proje - [email protected]. ager; [email protected]. FLORIDA DISTRICT OF COLUMBIA Ruskin Washington South County Repump Station Oregon Avenue NW Sewer Rehabilitation Project – DC Water Con- Bradshaw Construction Corp. tract 150130 Bradshaw has begun work on a project that consists of a 1,055-lf two- Bradshaw Construction Corp. pass microtunnel of steel casing and ductile iron water main. The casing is Bradshaw is constructing a $16.8 million sewer project for DC Water 48 in. and the carrier pipe is 16 in. Subsurface conditions are expected to that consists of approximately 4,300 fe of 24-in. sewer interceptor, includ- be sand. Informa e Wanhatalo, Proje wanhatalo@ ing 2,600 ft to be installed by microtunneling in four drives, with the lon- bradshawcc.com. gest being 1,860 lf along Oregon Avenue at depths of up to 90 ft. Both 60- in. steel casing and 48-in. RCP casing were tunneled using a Herrenknecht ILLINOIS A e will be installed. Chicago Subsurface conditions consisted of Tonalite rock ranging from slightly Albany Park Stormwater Diversion Tunnel weathered to highly decomposed. Kenny Construction Company The project also includes the installation of nine access shafts, 1,500 lf of This $62 million project for the City of Chicago’s Department of Trans- open-cut sewer installation, three live connections to the existing sewer portation is for surface flooding remediation. The tunnel is 5,800 lf of 18-ft system and the abandonment of the existing 15-in. sewer that the new 24- finished diameter concrete lined rock tunnel approximately 150 ft below in. one will be replacing. All work will be installed within Oregon Avenue, grade. The inlet shaft is 18 ft finished diameter approximately 150 ft deep. bordering a congested, residential area, and Rock Creek Park, owned by The outlet shaft is 30 ft finished diameter approximately 150 ft deep. tional Park Service. Tunnel excavation was completed using a refurbished main b To date, Bradshaw has completed all tunneling, including a 432-lf in dolomite bedro d through Aug. 30, 2017. Tunnel con- S-curved tunnel.This tunnel consisted of two 625-ft radius curves in op- crete operation is complete. Inlet and outlet surface structures are nearing posite directions to maintain the tunnel alignment within the Bingham completion. Site restoration has begun. The tunnel D Drive fo tional Park Service right-of-way. It also al- construction manager is WSP. Completion is expected by June 15, 2018. lowed the elimination of two shafts that would have severely hampered Key Project Personnel: Bob Rautenberg – Project Executive, Clay Spell- access to the project site, in addition to providing a credit to the owner. man – Proje , Darrell Vliegenthart – General Superintendent, c Potter – Project Engineer, Zach Heinrich – Field Engineer, Paul Lau- ric tt Tumpane – Safety Coordinator, Sarah Baker – Offic .

McCook McCook Reservoir Des Plaines Inflow Tunnel Walsh Construction This $107.7 million project f opolitan Water Resources Dis- ) includes approximately 5,800 ft of 20-ft ID tunnel with two shafts (one permanent and one for construction to be abandoned at completion of work). Entire tunnel is in dolomite limestone and is being constructed via drill-and-blast methods. Tunneling is nearing completion and lining has begun. The tunnel has two live connections, one on each end. On one end it will conne ’s existing Des Plaines Tunnel sys- tem and on the other it will connect to the liv ok Reservoir, which was scheduled to go online in December t down ei- ther the tunnel or the reservoir to accommodate the connections so all work will be heavily weather dependent. TP was issued on July 9, 2016. Completion is scheduled by Jan. 23, 2020. The designer is Black & Veatch. Key Project Personnel evin Fitzpatrick, Carmen Scal- ise, Patrick Jens White, Cary Hirner.

INDIANA Indianapolis White River Tunnel, Lower Pogues Run Tunnel Shea-Kiewit JV The White River Tunnel is a 30,600-lf, 20-ft, 2-in. diameter bored tunnel with an 18-ft finished concrete lining (approximately 250 ft deep). There are two bifurcations in the final alignment and seven CSO connecting structures/deaeration chambers and adits. The Lower Pogues Run Tunnel is a 10,200-lf, 20-ft, 2-in. bored tunnel with an 18-ft finished concrete lining, which bifurcates from the White River Tun- nel alignment, and includes two CSO connecting structures/deaera- tion chambers and adits. The work is for Citizens Energy Group’s Dig- Indy project, which is a CSO reduction program including six deep rock

TBM: TUNNEL BUSINESS MAGAZINE // JUNE 2018 TUNNELINGONLINE.COM TUNNEL UPDATES 45 tunnels totaling over 28 miles. This is the first EPB machine provided by Lovsuns in the United States. ommenced in September 2016 from a 35-ft diameter shaft that The tunnel segments are being manufactured utilizing synthetic fibers. was previously constructed as the retrieval shaft for the Deep Rock Tun- This is the time segments have been constructed in this manner in the nel Connector alignment. After successfully mining the Lower Pogues United States. Run tunnel, backed up and successfully relaunched within Parties Affiliated with the Project:Black & Vetch Corporation – En- the White River T y 2017, mining of the White River Tun- gineer. L er. nel alignment has extended a total of approximately 12,000 ft. Based on Project Personnel: e Garbeth, Senior Proje egg Re- the terms of a federal consent decree, the White River and Lower Pogues hak, Vice President. Run tunnels must be operational by the end of 2021. Key Project Personnel .E.; As- NEVADA sistant Proje oject Engineer: Percy Towns - Las Vegas ager: Kyle Shickles; Equipment Superintendent: Keith Walter; Field En- Lake Mead Low Lake Level Pumping Station (L3PS) Project gineers: Eric Haacke, Zack Heinrich, Kendall G Barnard of Nevada Inc. (Barnard) Engen. Inspe ain, P y 2015, Barnard entered into a $440 million construction man- Gr , P.E.; Supervisor Special ager at risk ( contract with the Sou ada Water Authority Projects: Tim Shutters; Construction Supervis for the L3PS Project. The underground work includes: 525-ft deep x 26-ft. diameter access shaft; bulkhead to allow for future expansion; 80-ft deep MARYLAND x 26-ft diameter Riser Shaft to connect to existing Intak onnector Baltimore tunnel; 33-ft wide x 36-ft high x 400-ft long horseshoe-shaped forebay CSX Transportation Howard Street Tunnel, Camden Street Drain Re- cavern; forebay connector tunnel; and 34 drilled 8-ft diameter x 500-ft placement deep pump well shafts with steel-lined 6-ft diameter casings. Bradshaw Construction Corp. The above-ground pumping station and accompanying appurtenances Bradshaw has begun work on a project in a high-profile area of down- include: 32-each 30-mgd submersible pumps; valves and discharge header town as the tunnel contractor working with Clark Construction’s design- piping; surge tank, concrete valve vaults, electrical controls and starting build team. An existing storm drain is currently located in the invert of equipment for the pumps; electrical control building; electrical feed from the CSX Transportation Howard Street Tunnel and is the cause of fre- an onsite substation; and 5,550 lf of 144-in. discharge aqueducts for con- quent flooding. This project will replace that 48-in. storm drain with a necting the new pumping station to the existing water treatment plants. larger, deeper siphon drain which will eliminate the flooding and eventu- To date, crews have completed the 500-ft excavation and concrete lin- ally allow for CSX to increase the size of the existing tunnel to gain freight ing of the access shaft, the 60-ft connector tunnel and riser shaft (winze capacity through the area. A total of three tunnels will be mined out of a shaft) and all 34-each 500-ft deep x 6-ft diameter well casings, and excava- 55-ft deep shaft at the intersection of Camden Street and Howard Street, tion and lining of the forebay cavern tunnel. in the shadow of Oriole Park at Camden Yards. From the 26-ft diameter shaft, three tunnels will be mined, all starting at different elevations. The first is the Upper Adit Tunnel, 32 ft of 66-in. liner plate, hand-mined tunnel for a 48-in. FRP storm drain. The Upper Adit will connect to the existing storm drain being replaced, bringing those flows back to the Camden Street Shaft. This tunnel in currently be- ing constructed. The second tunnel is 68 ft of 48-in. liner plate, hand-mined tunnel for 18-in. PVC pipe, which will ultimately serve as the drain for the Howard Street Tunnel. The Lower Tunnel consists of a two-pass microtunnel of 73.5-in. steel casing for a 60-in. FRP storm drain. The tunnel will go 122 ft under Howard Street and finish at the footing of the Convention Center and will be the siphon that will reconnect to the existing storm network. Subsurface conditions are expected to be poorly graded sand with silt and gravel and will require extensive grouting prior to tunnel excavation. In- formation: Todd Brown, Proje [email protected].

MISSOURI St. Joseph Black Snake Creek Stormwater Separation Improvement Project – Tunnel Package Super Excavators Inc. The work for this $26.991 million project for the City of St. Joseph De- partment of Public Works generally consists of the construction of 90-in. diameter concrete precast segment lined 6,648-ft long tunnel, 37-ft diam- eter baffle drop shaft, 48 ft of near surface reinforced concrete box cul- vert, 2-ft diameter vent shaft, 181 ft of 90-in. diameter open-cut steel pipe installation, 125 ft of 90-in. jacked steel pipe, an energy dissipation struc- ture, site restoration, and performance of other associated works. Factory acceptance testing on the L omplete, and the machine is in transportation from China. Crews are in the process of finalizing the tunneling site to receiv or onsite assembly. Tun- neling is expected to commence in early June. The concrete work for the energy dissipation structure is being completed, along with steel sheeting removal and final grading to reach the intermediate milestone (October 2018). The secant receiving shaft (drop shaft) is currently under construc- tion, and once complete, excavation will begin along with box culvert in- stallation for the tie in work.

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The upcoming work includes structural the site including the installation of new piping COWI, GPD; Construction – Parsons, concrete of the access shaft bulkhead structure. and valving, associated plumbing, HVAC, and Welty, Thomarios; Subcontractors – Kenmore Concurrent with the underground construc- electrical work. Shaft depth is approximately acting, Brierley tion, the above-ground pumping station work 120 feet under the Great South Bay Associates, Schnabel Foundation Company, continues with the 108- to 144-in. discharge Work b ch 2018. The team is Turn-Key T er – piping installation, concrete valve vaults, pump currently surveying the existing site, prepar- The Robbins Compan e System station pad construction, and electrical/main- ing to build the shaft, and procuring equipment e ement Solutions. tenance building construction. The project and materials needed. This is the largest con- Project Personnel: Bob Rautenberg (Project has also received and stored the 13 of 32-each, struction project in Suffolk County in several Executive), David Chastka (Proje 3,150-hp submersible pumps capable of pump- decades and OHL’s first job on Long Island. The e Quinn (General Superintendent), Brad ing 30 mgd. All work is scheduled to be com- estimated date of completion is summer 2021. oject pleted in 2020. arties Affiliated with the Proj- Engineer), Kentaro Kyo (Lead Tunnel Engineer), Design Engineer: A Joint Ven- ect (Tunnel Designer, Construction , Dirk Chisnell (Surveyor), Greg Cook (Equip- tur arsons Corp. bcontr er, Key Project Personnel: A: Peter esigner; Jauch, Director of Engine o- enknecht; Subcontractors: L.E.B. Cleveland nin, Proje arsons: Kevin Ulrey, Ele etrench, CSI Group. Dugway Storage Tunnel ed Davis Key Project Personnel: OHL: Uday Durg, Salini Impregilo/Healy JV and Steve Hunt, Lead Engineers; Barnard: Op- EVP a, Opera - The $153 million Dugway Storage Tunnel era , Dan Schall; Proje , ager; Sergio Estebanez, Proje . Seli project f egional Sewer Jordan Hoover; Project Superintendent, Andy T co D’Ambrosio, Chief Engi- District consists of 14,750 lf of 24-ft ID tunnel Granger; Underground Sup e neer, Tender & Technical Dept.; Pieluigi Felici, 200 ft deep, 6 deep shafts ranging in size from Gilbertson; Superintendents, Engineers, and Engineer. Posillico: Peter Brindley, SVP, Chief 22 to 58 ft in diameter and 21 other near-sur- Safety: Tracey Chambers, Tyler Askin, c Operating Officer; Robert Hutzler, Superinten- faces shafts and structures. There are four 9-ft la dent; Kirsten Huffer, Engineer; James Scudder, diameter adit connections to the tunnel rang- Alex Casilla, Jeff Porter, Klaus Herbert, Bill Quality Engineer. Suffolk Country Department ing in length from 60 to 800 lf and two sections Kiehl, Pryde Lahr, Jo er, Jake Richard- of Public Works (owner): Gilbert Anderson, P.E., of near surface sewers installed in tunnel and son, Aaron Rustan, Terry Swindle, Peter Turl- Commissioner; John Donovan, P.E., Chief Engi- by open cut. ington, Dan Heroux, Devin Weekly, Leo Wei- neer; Keith Kelley, P.E., Proje The project is currently 80% complete. All thew Jackson, and Shawn Tezak. Smith); Jacek Stypulkowski, P.E., Resident Engi- six deep shafts have been excavated, with the neer ( structures completed in all six shafts. The main NEW YORK tunnel was complete ch 21, 2018. Five West Babylon NORTH CAROLINA of the near-surface structures have been com- Bergen Point Wastewater Outfall Project Charlotte pleted and the four adits have been excavated OHL/Posillico/Seli Overseas JV I-77 HOT Lanes Sewer and lined. The Suffolk County Department of Pub- Bradshaw Construction Corp. Various ground support systems have been lic Works on Feb. 8, 2018, issue TP for the Bradshaw has begun tunneling as part of a utilized. Ribs and liner plate have been used for Bergen Point Wastewater Outfall Project. The I-77 highway expansion project in Charlotte. soft ground support on most of the shaft. Se- $187.78 million job was awarded to a joint ven- The project consists of a 572 lf two-pass micro- cant piles were used to support the overburden ture of OHL/Posillico/Seli Overseas (40% OHL tunnel of steel casing and ductile iron sewer. for one of the deep shaft and two of the near USA, Inc., 40% Posillico Civil, Inc., 20% SELI The casing is 60-in. and the carrier pipe is 24 surface excavations and ground freezing was Overseas USA, Inc.). in. Subsurface conditions are expected to be used to control the ground while excavating The project includes the construction of a highly variable ranging from fine clay to hard the main shaft. 14,200-ft, 120-in. ID tunnel through a mixture rock. Informa e Wanhatalo, Project Final completion is anticipated by Septem- of soft soil materials under the Great South Bay [email protected]. ber 2019. with the use of a tunnel b Parties Affiliated with the Project – Tun- The tunnel will be constructed to replace the OHIO nel designer: Stante JV; Construction existing prestressed concrete cylinder pipe Akron (PCCP) outfall pipe, which carries millions of Ohio Canal Interceptor Tunnel (OCIT) enknecht; Subcontractors: Triad gallons of treated wastewater, connecting the Project Engineering & Contracting Co. – Shaft Exc. & Bergen Point Wastewater Treatment Plant Kenny/Obayashi, a Joint Venture Adit Exc. and Lining; a Service (WWTP) to the Barrier Island under the Great This is a $184 million job for the City of Ak- Inc. – Shaft excavation; Contracting, South Bay. The new tunnel will address the r TP was issue . 4, 2015, with final Inc. – Concrete Structur on Con- concerns of potential failure of the current pipe completion scheduled for June 15, 2019. The struction Company – Se etrench and has a longer lifespan. 27-ft finished inside diameter tunnel, approxi- – Ground Freezing. The tunnel will be excavated and concur- mately 6,200 ft long, will pass through ground Key Project Personnel: Salini Impregilo/ rently lined using precast concrete segment conditions that consist of soft ground, mixed Healy: Proje Jim Kabat; rings. The JV has selecte face soft ground over bedrock, and bedrock. General Superintendent: Willie Flores; Chief most effective and efficient means of tunnel ex- Depth to the invert of the OCIT will range from Engineer: Rob - cavation and elected to use 48-in. wide precast about 40 to 180 ft. A Robbins dual mode type er: Saeed Ta as- segment liners. “Crossover” (XRE) Ro e used so; Electrical Superintendent: TJ Soto; Controls: Shaft construction will be divided into major to excavate the tunnel and install the precast ogram work phases including site preparation, ground segmental lining. a - freezing and excavation of the two shafts both Excavation of the Reach 1 (soft ground) and tion Supervisor: Ryan Sullivan. Information: on the Bergen Point and Barrier Island sites. Reach 2 (mixed face) are complete and Reach 3 John Kennedy, (702)-524-0438. Onc d, tunnel excavation (rock) is underway ently over will proceed, followed by the installation of the 40% complete with excavation. Completion is PENNSYLVANIA permanent tunnel lining. Additionally, the set for Dec. 31, 2018. Wampum team will also complete ancillary work within Project Designer – DLZ, Jacobs, Pennsylvania American Water Ellwood

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Raw Water Facilities and 42-in. upstream and downstream connect- Wanhatalo, Proje wanhatalo@ Bradshaw Construction Corp. ing sewer as well as several junction chambers, bradshawcc.com. Bradshaw is underway on construction on a screening/diversions structures along with project in Wampum that consists of 1,531 ft of odor control facilities. Drop shaft construction WASHINGTON two-pass microtunneling in three tunnels. Cas- commence y 10. Final completion is an- Bellevue ing size is 60- and 75.4-in. with several lines of ticipated by June 26, 2020. Downtown Bellevue Tunnel (E330) carrier pipe installed within. Subsurface condi- The Tunnel Designer/ - Guy F. Atkinson tions are expected to range from alluvium and ager is Black & Veatch. Sound Transit is building the Downtown residual soil to partially and unweathered hard Major Subcontractors and Suppliers: Bellevue Tunnel as part of its $3.7 billion East rock and mixed face. Informa e Wan- L ete (Concrete Link Extension, which adds 14 miles of track hatalo, Proje wanhatalo@brad- Structures), Pacific International Grout (Cellular and 10 stations. In downtown Bellevue, the shawcc.com. Grout), Hobas Pipe – Tunnel Carrier Pipe. alignment goes through a 1,985-lf tunnel, 34- Key Project Personnel: Justin Kolster – ft ID ovaloid, 12 to to 48 ft deep. The project in- SOUTH CAROLINA Senior Proje , Super Excavators / cludes one maintenance shaft 17-ft diameter Greenville e; Greg Rehak – Vice by 50-ft deep located near the midpoint of the Reedy River Basin Sewer Tunnel President, Super Excavators; Stephen O’Connell tunnel, a connecting adit to enlarged tunnel Super Excavators Inc. / Cooperatia Muratori , Black & Veatch; Jason section for permanent ventilation fans, and Cementisti, a Joint Venture Gillespie – Senior Proje , Renewable 250 lf of cut-and-cover structure. Crews are This $33.415 million project for Greenville’s Water Resources. excavating soft ground consisting of glacial Renewable Water Resources comprises 6,000 till and outwash gravel, using the sequential lf of 130-in. ID rock tunnel with 84-in. carrier TEXAS excavation metho pipe (Hobas) grouted in place.; a 40-ft ID by 40- Scurry heading (three headings) as well as single side ft deep launch shaft and 30-ft ID by 130-ft deep Trinity River Main Stem Pump Station drift (6 headings). receiving shaft. Tunnel depth ranges from 40 Bradshaw Construction Corp. Guy F. Atkinson was awarded the tunnel to 130 ft below ground surface. The tunnel is to Bradshaw is resuming the tunneling af- contract a TP was issued Feb. be mined in intact Gneiss bedrock using a dou- ter major site flooding. The project consists of 8, 2016, with substantial completion projected ble shielded rock gripp ed twin 260-lf microtunnels. The casing is 48-in. y 20, 2020. Currently the job is 82% com- by Lovsuns Canada. Shaft construction is to lined and coated to act as a raw water intake. plete, completed excavation and support of first consist of liner plate and rock dowels with wire Subsurface conditions are expected to be pri- 54% using full top heading, bench and invert, mesh. The project also includes 1,600 lf of 60 in. marily lean and fat clay. Informa e currently excavating and supporting using sin-

TUNNELINGONLINE.COM TBM: TUNNEL BUSINESS MAGAZINE // JUNE 2018 48 TUNNEL UPDATES gle side drift. Construction of mid-tunnel main- meets and potentially exceeds current com- of the geotechnical materials to be excavated tenance shaft and adit started mid April 2018. bined sewer overflow (CSO) regulations and were all evaluated. It was also important that Crews are utilizing two Liebherr 950 to ex- guidelines – putting the City of Ottawa at the the tunneling method minimize disruptions cava praymec 8100 forefront of Canada’s leaders in meeting indus- for the general public and daily life in the city. shotcrete robot to place the shotcrete lining. try regulations and guidelines for CSO controls. Sequential Excava was obs Associates are the Stantec and Jac e the adminis- use ovides a high Resident Engineer; trators of the construction contract to ensure degree of flexibility to adjust the excavation ap- unnel Designer; GZ Con- the CSST Project is built in accordance with the proach and support measures for soil and rock unnel Engineer. City’s design with geotechnical support from conditions encountered; it also reduces risks of Key Project Personnel: Sound Transit: Golder. Stantec completed the Environmental tunneling construction. This method also mini- Chad Fre - Assessment and functional design. Stantec and mizes longer term disruptions at surface. er; Atkinson: Archie Kollmorgen, Proje - Jac ompleted the preliminary and Civil works completed in Q1 2018 include: ager, Jake Coibion, Tunnel - detailed design and are now both providing Parliament Station steel erection for mid- len Jacobs Associates: Ted DePooter, Resident contract administration and inspection servic- entrance structure substantially complete; Engineer un Wei Leong, Office Engineer. es through the construction phase. west / mid-entrance site backfill substantially Key Project Personnel: Owner (City of Ot- complete; rock excavation for West Tunnel ta oje - Vent Shaft (TVS) completed; Rideau Station ager - Steve Courtland; Contract Administrator: West Entrance structural lining, excavation CANADA Proje c); and breakthrough of west TVS, mid-entrance ONTARIO Contract Administrator: Sanjay Verma (Jacobs- elevator adit structural lining, station platform Ottawa eviously Clare Humphrey (Jacobs- and track slab concrete pours, and installation Combined Sewage Storage Tunnel (CSST) act Administrator: Co- of west bound track work all completed; Rail Dragados-Tomlinson Joint Venture lin Goodwin (Stantec); Construction Director: installation for the trackwork in the west- The $146 million CSST project for the City Gerald Bauer (Stantec); Jac oject bound direction is complete from Tunney’s of Ottawa includes the construction of two ascal Pitre (Jac ac- Pasture to Blair; In the tunnel, 80% of track inter-connected tunnels: an east-west tun- tor (Dragados-Tomlinson Joint Venture): slab is complete with rail installed for 50% of nel (EWT) through the downtown core from Proje ernando Triana (Draga- the length in the eastbound direction, west- LeBreton Fla dinburgh Park, and dos); Civ - bound track complete. a north-sou ent Street driks (Tomlinson); Project Engineer - Surface Q2 underground work will include: Lyon from Chamberlain Avenue to the Ottawa Riv- Works: Richard Poulin (Tomlinson). Station final finishes, mechanical and electri- er, just behind the Supreme Court of Canada. cal, systems and ventilation, and elevators and The tunnels will be a total length of 6.2 km, Ottawa escalator work; Parliament Station east & west with an inside diameter of 3 m, and will be 10- O-Train Confederation Line Light Rail Tunnel Vent Shafts (TVS) and installation of 31 m below ground level. The CSST project also Transit Project mid-entrance elevators will be underway, and includes the construction of 15 major access Rideau Transit Group work on mechanical and electrical, fire protec- shafts, as well as support buildings such as odor To build the O-Train Confederation Line, tion and HVAC, elevators and escalator work control facilities. the City of Ottawa assembled a strong public- will continue; Rideau Station work will include A double-shield tunnel boring machine private partnership that includes financial staircase concrete pours and escalator installa- eing used to construct the tunnel. commitments from the provincial and fed- tion at west entrance, concrete structural lin- The fully assemble is approximately 250 eral governments, and a proven private-sec- ing of west TVS shaft, mid-entrance elevator m long. Tunneling also makes use of a locomo- tor project team, the Rideau Transit Group. installation, completion of east entrance struc- tive and tracks for the transport of muck cars, A world-class consortium of Canadian and tural lining, elevator and escalator installation precast concrete liner segments and personnel. international companies, the Rideau Transit between concourse and platform levels, and A gantry crane is used at surface to support Group was selected in a highly competitive station service rooms construction and equip- tunneling operations, including removing and process based on the strength of the group’s ment installation. dumping muck cars and lowering liner seg- design, construction and financial proposal, Rideau Transit Group equity partners are: ments for tunnel assembly. and its track record of delivering major trans- ACS Infrastructure C -Lavalin The full length of the CSST tunnels are portation projects on time and on budget. and EllisDon. DBJV is made up of: Dragados anticipated to be excavated in bedrock. The Working closely with the City of Ottawa, the C -Lavalin. bedrock formations that are anticipated to be Rideau Transit Group designed and began Some of the other firms that have worked encountered by the CSST tunnels and shaft building the $2.1 billion Confederation Line on the project include: Thurber Engineering excavations include the Veralum, Lindsay and in 2013 and will maintain the line until 2038. Ltd. (geotechnical); Dr. Sauer & Partners Corpo- Billings formations, which generally consist of Revenue Service begins when the build is ration (tunnel design); Adamson & Associates limestone and shale. completed in 2018. Architects (station design); Alstom – vehicle; Currently, construction is taking place at An integral part of the Rideau Transit Group Thales – systems; bbb Architects (station de- five of the 11 surface locations across the city (RTG) proposal for the Confederation Line was sign); Fast + Epp; Ha and tunneling of the is underway. These the approach to the construction of the tun- Gr oup; Sereca Fire Consulting include, shaft construction, starter and tail nel under Ottawa’s downtown core. The tun- Ltd.; and Scotia Capital. tunnel excavation, existing infrastructure con- nel spans 2.5 km, is on average 15 m below the Key Project Personnel – City of Ottawa/ nections, tunneling support operations, outfall surface and features three of the stations in the O-Train Construction Offic oni, chamber construction, and portal excavation Confederation Line project — Lyon, Parliament Gener , Transportation Services; for receiv and Rideau. Steve Cripps, Director, O-Train Construc- This summer, the tunnel boring machine Following the bid process in 2012, the City’s tion; Gary Craig, , Light Rail Design will complete mining of the north-south experts from around the world worked to de- and Construction. Rideau Transit Group/ tunnel. At which point, it will emerge from termine the tunneling method and equipment OLRTC: Antonio Estrada, CEO, Rideau Tran- a portal in the cliff, behind the Supreme required for the Confederation Line tunnel. sit Group; Peter Lauch, Technical Director, Court of Canada. Proximity to the Rideau C Rideau Transit Group; Eugene Creamer, In constructing the CSST, Ottawa will World Heritage Site, the specific soil condi- OLRTC Project Director; Humberto Ferrer, achieve, by 2020, a level of performance that tions of the downtown core, and the properties OLRTC Deputy Project Director.

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2018 calendar

JUNE 2018 NOVEMBER 2018 JANUARY 2019 24-27 5-7 22 North American Tunneling Chinese Tunnel and Underground Works Confer- George Fox Conference Washington, DC ence/ITA Tunneling Awards New York, NY Web: smenet.org/uca Chuzhou/Nanjing, China Web: www.georgefoxconference.com/ Web: awards.ita-aites.org SEPTEMBER 2018 23 10-12 7-9 The Moles Dinner 11th Annual Tunneling Short Course R2T Global Expo New York, NY Web: Denver, Colorado Las Vegas, NV www.themoles.net Web: tunnelingshortcourse.com/ Web: r2tglobal.com MARCH 2019 8-9 17-21 15-18 TAC/NASTT-NW Tunnelling and Trenchless Confer- NASTT No-Dig Show 61st AEG Annual Meeting/13th IAEG Congress Chicago, IL San Francisco ence Edmonton Web: nodigshow.com Web: aegannualmeeting.org Web: www.tt2018.ca APRIL 2019 18-21 28-29 8-14 InnoTrans Bauma Berlin Risk Management in Underground Construction Marina Del Rey, CA Munich, Germany Web: innotrans.de/en/ Web: undergroundriskmanagement.com Web: bauma.de

OCTOBER 2018 27-30 MAY 2019 24-27 Bauma China 3-9 Deep Foundations Institute 43rd Annual Conference Shanghai, China World Tunnel Congress Anaheim, CA Web: www.bauma-china.com Naples, Italy Web: dfi.org Web: ita-aites.org

ISSUE ad index

COMPANY...... WEBSITE ...... PAGE COMPANY...... WEBSITE ...... PAGE Akkerman...... www.akkerman.com ...... 9 Kenall...... www.kenall.com ...... 52 Arntzen Corporation...... www.arntzenrolling.com...... 49 Loadsensing Webinar ...... www.tunnelingonline.com/webinar...... 37 BASF...... www.master-builders-solutions.com ...... 11 Mapei ...... www.mapei.com ...... 21 Babenderede Engineering ...... www.tunnelsoft.com ...... 43 McDowell Equipment ...... www.bmcdowell.com ...... 49 Benjamin Media Resource Center...... www.edu.benjaminmedia.com ...... 39 & 44 Moretrench...... www.moretrench.com...... 17 Bradshaw Construction Co...... www.bradshawcc.com...... 41 NASTT’s No-Dig 2019 ...... www.nodigshow.com...... 51 BROKK Webinar...... tunnelingonline.com/webinar...... 42 Naylor Pipe...... www.naylorpipe.com...... 27 DSI Underground...... www.dsiunderground.com...... 31 Risk Management Course...... www.undergroundriskmgt.com...... 35 Deep Foundations Institute ...... www.dfi.org/annual2018...... 47 Robbins ...... www.therobbinscompany.com...... 23 Doctor Mole ...... www.drmoleinc.com...... 45 Sandvik...... www.sandvik.com...... 5 Herrenknecht ...... www.herrenknecht.com...... 2 Schnabel - SWS ...... www.schnabel-sws.com...... 19 Hydra-Slide ...... www.hydra-slide.com ...... 15 Strabag...... [email protected]...... 29 InnoTrans 2018...... www.innotrans.com ...... 13 TBM Subscriptions...... tunnelingonline.com/yeti ...... 40 Jennmar ...... www.jennmar.com/civil.com...... 25 Terratec...... www.terratec.co...... 7 Tunneling Short Course...... www.tunnelingshortcourse.com ...... 33

TUNNELINGONLINE.COM TBM: TUNNEL BUSINESS MAGAZINE // JUNE 2018 50 Q&A

Reflections on 25 Years of Microtunneling Q&A with GHD’s Craig Camp

ear in the microtunneling industry, Craig Camp has seen the technology move from its infancy in the United States, to a mature market that is seemingly setting new heights every week. Trenchless Technology sat down with Camp to share his thoughts on the market – past, present, and future. Camp worked for Iseki from 1994 to 2000, and has been closely involved with microtunneling since, as a consultant at various firms, most currently, with GHD.

How did you get started in the systems to pipe manufacturing, has kept joint (Jackcontrol™). When you do a curved microtunneling industry? pace with all the changes. tunnel, you are essentially taking a system Growing up in the mining district of that is set up to build a perfectly straight Coeur d’Alene, Idaho, I always had an What are the most common tunnel, and point loading the tunnel 100 interest in mining. I earned a degree in misconceptions or mistakes you see? percent of the time. To accommodate the ering from the University Some people think the microtunneling change, you must plan for it. The newer of Idaho, and worked in the Gypsum technology to build a tunnel is a ‘silver technology allows this to happen. Curved before joining Iseki, in bullet’, but contrary to popular belief, it’s microtunnels have been slow to take root 1994. At the time, Iseki was a leading not. otunneling has its strengths and in the United States, but are clearly the supplier of microtunneling equipment weaknesses, and there are other methods right solution in some cases. f y that prove more efficient for some ground mining background certainly helped the conditions. Hence why those methods are What other trends are you seeing? transition into the industry. Early on, I still around today. A misconception has Another recent development impacting worked closely with Tom Kusumoto, who been because microtunneling is being the market is the merging of HDD and had long roots with the company, going applied, no issues will arise. False. microtunnling technology. This is the back to the creation of microtunneling system that Herrenknecht calls Direct equipment. He fully understood the trade, How have you have been active Pipe™ erforator calls System and I spent many, many hours under his in the development of educational 2™. The system uses steel casing and an mentorship, learning how the equipment publications for the industry? inverted arc, like HDD, and the slurry was designed and operated. I have been involved in several of the is controlled with microtunneling American Society of Civil Engineers technology. In essence, it is a curved How has the industry evolved since publications, the first being Standard microtunnel with a different thrusting you got involved in microtunneling? Design and Construction Guidelines for method and setup. This is another great The early days of microtunneling felt otunneling (ASCE/CI 36-15). I have tool, for the right ground conditions. like a close-knit, small family; everybody also been involve knew everybody. There were quasi and Reports on Engineering Practice for How can the market be improved? territories, and contractors stayed within e One element that limits the market is their understood areas. The contractors the low bid mentality. With underground at that time had to be committed to the 115), Trenchless Renewal of Culverts and construction, it is crucial to use the right market – one had to be knee deep and up ube and technology, but that can come at a higher to elbows in grease to achieve success, Other Guide initial cost. However, I have seen projects mainly because experienced hires were ciety for with change orders that are greater than scarce, if not impossible, to come by Trenchless Te tion the cost of the tunnel. Let that serve it is more of a mature market, and it is ds Good Practices. as an example - the initial cost should very much a national market. Contractors I believe in trying to improve and not be the focus. The focus should be travel to a greater extent, as there is more grow the industry, and these manuals on implementing the right technology, competition. help provide an educational foundation coupled with engaging the right for successful proje y of these contractor and experienced personnel. How has the equipment changed? documents go through revisions; they are One, if not the, most crucial keys to A big change in the market has been continuously being improved upon, and success is communication. You need to the size of machines. There are a greater build consensus among various parties take the time to discuss the needs of the number of machines on the market today involved in construction. Having an project, as well as the risk factors, before that are greater than 60 inches in diameter, understanding of the various methods is the project commences to ensure the as opposed to in the past, the major portion key, because in underground construction, job is executed properly and correctly. of the market was under 60 inches. With you can only take wha y times in a low-bid environment, bigger machines come more power, more allow. You can have the best method in there is not ample opportunity for torque and durability all positive changes. the world, but if it is used in the wrong open communication before the project Additionally, manufacturers have ground condition, you have nothing. begins. Design-build is a better vehicle developed more effective and compact for allowing that communication, but power units that help equipment excavate How has the use of curved drives often times leaves the owner feeling complex soils. That, in combination with evolved in the United States? as though they are giving up too much improved guidance systems and data Curved drives are a combination of control. Each individual project is unique acquisition, have allowed longer drives many factors. We have had technology and possess its own nuances, but it has and curved drives through a range of changes that have given us better pipe been my experience that the success of a conditions. The support industry, from in some cases, better guidance systems, project is strongly correlated to effective inflatable packers to slurry handling better lubrication and better control of the communication.

TBM: TUNNEL BUSINESS MAGAZINE // JUNE 2018 TUNNELINGONLINE.COM