CONTENTS Contentsjune 2007

Reader Service Number 1 Reader Service Number 2 CONTENTS CONTENTSJune 2007

Cover Story Toronto Underground 16 Toronto is the largest city in Canada and the provincial capital of Ontario. It is also home to variety of transit, sewer, water and power tunnels that keep this bustiling city up and running. By Boro Lukajic Features RETC Preview 20 A close-up look at 2007’s largest tunneling event in North America, including a Who’s Who of companies and products that will be on the exhibit hall floor. By Katie Fulton 16 Sewer Tunneling in Ontario 28 A joint venture of Aecon and McNally is completing the YDSS Interceptor Sewer in York Region. By Adrian Coombs, Steve Skelhorn and Derek Zoldy

Niagara Tunnel Update 32 TBM checks in on the progress of the world’s largest hard-rock tunnel boring machine. By Desiree Willis

The Owner’s Implied Warranty 36 What you need to know about this crucial and sometimes confusing aspect of construction law. By Peter M. Kutil and Karl Silverberg Columns Editor’s Message ...... 6 Tunneling North of the Border by James W. Rush View From the Hole ...... 6 32 The Truth Shall Set You Free by Bob Pond North American Tunnel Project Update ...... 35 A recap of recently completed, current and future tunnel projects. by Jack Burke My Turn ...... 35 Second Edition of the GBR Yellow Book Is Here by Randy Essex Departments TBM: Tunnel Business Magazine (ISSN 1553-2917) is published six times per year. Copyright 2007, Benjamin Media Inc., P.O. Box 190, Peninsula, OH 44264. USA All rights reserved. No part of this publication may be reproduced or Business Briefs ...... 8 transmitted by any means without written permission from the publisher. One year subscription rates: complimentary in the United States and Canada, and $69 Global Events ...... 12 in other foreign countries. Single copy rate: $10. Subscriptions and classified Calendar ...... 47 advertising should be addressed to the Peninsula office. Postmaster return form 1579 to TBM: Tunnel Business Magazine, P.O. Box 190, Peninsula, OH 44264.USA Business Cards ...... 49

4 Tunnel Business Magazine June 2007 Reader Service Number 3 EDITOREDITOR’S MESSAGE’S MESSAGE Bernard P. Krzys Publisher Tunneling North of the Border In this space last issue, I wrote about the tunnel- Richard J. Krzys Robert D. Krzys ing projects in the Midwest that often don’t get the Associate Publishers attention of their higher-profile brethren on the James W. Rush East and West coasts. But as we prepare to travel Editor to Toronto for the 2007 Rapid Excavation and Nick Zubko Tunneling Conference (RETC), I am reminded of Associate Editor the rich tunneling history in Canada, which also Sharon M. Bueno does not get the recognition of places like Boston, Katherine Fulton New York, Los Angeles, San Francisco or Seattle. Keith Gribbins Brad Kramer Toronto itself has the largest subway system in Jason Morgan Canada, with the completion of the Sheppard Contributing Staff Editors Subway Line being the most recent addition W.M. Conley (opened in November 2002). The subway now comprises 69 stations Creative Director and spans more than 42 miles. The Toronto Transit Commission is Edward A. Haney planning a northward extension that would extend the network even Senior Graphic Designer further into York Region. Sarah E. Hayes Close to Toronto is Niagara Falls, home to the 6.2-mile long Sir Chris Slogar Elizabeth C. Stull Adam Beck tunnel, which is currently under construction using the Graphic Designers world’s largest diameter hard rock TBM (47 ft). Sewer expansion Kelly Dadich tunnels are also in the works in Toronto, which with a population of Marketing Manager more than 5 million people in the greater metropolitan area is one Dan Sisko most populous cities in North America. Greg Thompson Another hotbed of activity is Vancouver, which is playing host to Regional Sales Representatives the 2010 Winter Olympics. Consequently, the city is in the midst of Alexis R. Tarbet building a transit link from the airport to downtown. Additionally, the Circulation Manager Greater Vancouver Water District is building the Seymour-Capilano Filtration Project as a system upgrade, which encompasses more Editorial Council than 4.5 miles of 12-ft diameter rock tunnels. As a side note, Chairman William H. Edgerton Vancouver was recently selected as the site for the 2010 International Gary Brierley, P.E. Jacobs Associates Tunnelling Association’s World Tunnel Congress. Brierley Associates, San Francisco Cities such as Edmonton and Montreal have also had long-stand- Denver Joe Gildner Randy Essex, P.E. Sound Transit ing transit and sewer programs. Mine development and hydropower Hatch Mott MacDonald Seattle projects also play an important role in the development of the Rockville, Md. Boro Lukajic Consulting Engineer underground industry in Canada. Roberto Gonzalez Mississauga, Ont. Izquierdo We will further examine the Canadian tunneling market in Moldequipo Internacional Dru Desai the August issue as we convene a panel of leading contractors, Tepotzotlan, Mexico DMJM+HARRIS Baltimore owners, engineers and equipment manufacturers for the annual Dr. Levent Ozdemir, P.E. Ted Budd TBM Roundtable. Colorado School of Mines Kenny Construction Golden, Colo. Wheeling, Ill. For more information on tunneling in Toronto and Canada, see the Bob Pond David Caiden article by Boro Lukajic on page 16. In this issue there are also Frontier-Kemper Arup project updates on the Sir Adam Beck Tunnel and the YDSS Evansville, Ind. New York, N.Y. Interceptor Sewer Project in Toronto. George Yoggy Rick Switalski, P.E. GCS LLC NEORSD Allentown, Pa. Cleveland, Ohio Regards,

EDITORIAL & ADVERTISING OFFICES MEMBER 1770 Main St., P.O. Box 190 Peninsula, OH 44264 USA James W. Rush Ph: (330) 467-7588 • Fax: (330) 468-2289 Internet home page: http://www.tunnelingonline.com Editor e-mail: [email protected]

6 Tunnel Business Magazine June 2007 Reader Service Number 4 Business Briefs UTRC Meets in Seattle

The Underground Technical Research Committee (UTRC) held its 2007 annual meeting March 23-25 in Seattle. About 100 people were in attendance to visit job- sites in the Seattle area, as well as hear presentations on projects and topics relevant to the tunneling and mining industries. UTRC kicked off with a reception at the Marriott Renaissance Hotel on Friday evening, March 23, followed by visits to Sound Transit’s Beacon Hill tunnel site, the Brightwater project site (East Contract) and the Mt. Baker Ridge Tunnel operations center on Saturday. Mt. Baker Ridge Tunnel: The 1,300-ft long Mt. Baker Ridge Tunnel was constructed by the Guy F. Atkinson Co. in the early 1980s using an adaptation of the stacked-drift tunneling method. Sized for vehicular traffic on two levels, the net interior diameter is 63 ft, requiring an exterior diameter of about 83 ft. The tunnel was excavated from predominately hard clay and constructed under high horizontal stress. It is the largest-diameter tunnel ever The segments for the Beacon Hill running tunnels are on site. attempted in soft ground. The system wide control facili- high groundwater pressures, which necessitate that slurry ty above the west portal enables monitoring of traffic, TBMs be designed to seal up to an 8-bar water pressure. temperatures and control of ventilation and fire suppres- Beacon Hill Underground Station and Tunnels: This sion systems. extension of Sound Transit’s Light Rail System is being Brightwater: The Brightwater conveyance system constructed by Obayashi Corp. Unique elements of this includes 13 miles of tunnels, a 130 mgd pump station, 1.25 project include an underground station constructed using miles of microtunnels, and a 1-mile outfall. The tunnels the Sequential Excavation Method. The 4,200-ft long extend from Woodinville to Puget Sound through varying twin-bore running tunnels with 18-ft, 10-in. internal diam- soils under 1 to 7 bars of hydrostatic pressure and at eter segmental linings are being excavated by a depths up to 459 ft. The tunnel portion of the project is Mitsubishi Earth Pressure Balance TBM. Three cross- divided into three sections. Construction of the eastern passages are included to meet NFPA 130 egress require- section of this soft ground project is being led by ments. The station will be mined from two slurry wall sup- Kenny/Shea/Traylor and includes bowtie slurry shafts. ported shafts; one 46 ft in diameter, the other 26 ft. Acting The middle section has been let to Vinci/Parsons as both entrance/exit and ventilation structures, the RCI/Frontier-Kemper and the tunnel will be exposed to shafts are 185 ft deep. The 380-ft platform tunnels plus connector tunnels, concourse adit, ventilation adits and cross-passage tunnels are being constructed using shotcrete initial linings, which take advantage of ground relax- ation to reduce loading. Sunday presentations included “Deep Shafts for Mine Development,” by Tom Goodell; “Arrowhead Tunnels Update,” by Brian Fulcher; “GBR ‘Gold Book’ Update,” by Randy Essex; “Portland CSO Update,” by Gary Irwin; and a keynote address by Doug MacDonald, Secretary of Transportation, Washington DOT. UTRC is jointly sponsored by the American Society of Civil Engineers (ASCE) and the American Institute of Mining, Metallurgical, and Petroleum Engineers (AIME) through the Society for Mining, Metallurgy, and Participants in the UTRC meeting were (from left) Tom Goodell (UTRC past Exploration, Inc. (SME). ASCE's Construction Institute chairman), Clary Alexander (past chairman), Dave Jurich (chairman), Doug also sponsors UTRC. Staff support is provided by ASCE. MacDonald (keynote presenter), Christopher Hickey (vice chairman), and Red Robinson (technical committee coordinator). For more information visit www.utrc.org.

8 Tunnel Business Magazine June 2007 Microtunneling Program a Success in Colorado

The Colorado School of Mines hosted its annual con- Guest speaker at the Banquet Dinner on Feb. 22 was ference Feb. 19-23, focusing on pilot-tube microtunnel- Lee Abramson, Hatch, Mott MacDonald. A ing and microtunneling through two course programs. Microtunneling Achievement Award was presented to Both the programs were held at the Microtunneling Dr. James Kwong, P.E., principal at Yogi Kwong Research Institute at the Colorado School of Mines in Engineers LLC, Honolulu. Golden, Colo. A total of 95 participants took part in the programs and over the 14 years that the program has been offered, more than 1,500 participants have attended. The two-day pilot-tube course, which took place Feb. 19-20, featured live demos and displays in addition to the course presentations by industry experts. Akkerman Inc. and Bohrtec provided the live demos for the course. The three-day microtunneling short course, which took place Feb. 21-23, featured classroom presentations by leading microtunneling experts on topics such as navigations systems for microtunneling, case histories, solids separations technology and design aspects, soil stabilization and grouting and microtunneling machine innovations. Course instructors were Timothy Coss, Akkerman provided some of the live pilot-tube microtunneling demos. Shown here are (left) Bernie Krzys, Trenchless Technology magazine, Troy Stokes, Microtunneling Inc. director, and Levent Ozdemir, Akkerman Inc., Jeff Boschert, National Clay Pipe Institute, David Gill, Mission Colorado School of Mines course director. Clay Products/No-Dig Pipe,and Don Bergman, Frank Coluccio Construction.

Reader Service Number 6

June 2007 Tunnel Business Magazine 9 Business Briefs Jacobs Associates Acquires Milbor-Pita & Associates

Jacobs Associates (JA), a closely held firm of tunnel management for underground projects, specifically tun- design, construction management and dispute resolution nels, as well as construction analysis and claims/disputes engineers, has acquired selected assets and staff of resolution. JA clients include contractors, public agen- Milbor-Pita & Associates (MPA), specialists in geotech- cies, private owners, attorneys, and surety and insur- nical and rail tunnel engineering. The combined firm ance companies. will have the resources to rival much larger engineering Over the next six months, MPA staff will be relocated firms. into the JA offices at 811 First Ave in Seattle, Wash. MPA’s staff of six includes technical expertise in con- “By combining our firms’ staff, JA will have the struction methods and costing, as well as engineering of resources of a complementary talent pool that will rival rock, soil, groundwater and surface water. Their clients much larger engineering firms. The resulting JA will include major railroads, construction contractors and have more depth in our traditional specialty of under- other engineering firms. ground engineering, while we add new services and JA’s staff of 96 specializes in design and construction clients,” said JA’s President William W. Edgerton.

Mancini Elected President of The Moles Salvatore Mancini of Skanska USA Civil Inc. has been in Syracuse, N.Y., and massive commuter tunnels and elected to serve as president of The Moles for 2007-08. subways in Philadelphia. During this period, he attend- Mancini received the gavel from outgoing president ed college at night, ultimately earning his civil engi- Richard S. Weeks at the annual Business Meeting and neering degree from City College. Dinner on May 2 at the New York Hilton. In 1983, Mancini returned to New York City and over- Other officers elected were Alfred H. Brand, Mueser saw the track work on the Archer Avenue Subway, Rutledge Consulting Engineers, First Vice President; which ran from Parsons Boulevard to the Van Wyck Robert E. Alger, The Lane Construction Corp., Second Expressway. In 1988 he was promoted to Vice President Vice President; Joseph F. Malandro, E.E. Cruz & Co. and in 1990 was elevated to Senior Vice President Inc., Treasurer; Henry E. Adams, Kiewit Constructors responsible for all field operations. Soon afterward, he Inc., Secretary; and Joseph S. Finston, Consultant, was elevated to Executive Vice President and Chief Sergeant-at-Arms. Operating Officer, and in 2001 was appointed President Trustees elected to three-year terms are Kurt G. and Chief Executive Officer of Skanska USA Civil, one Conti, Conti Enterprises Inc.; Val S. McWhorter, Smith, of the four largest heavy civil contractors in the United Pachter, McWhorter PLC; Richard Raczynski, New States. Jersey Turnpike Authority; and Christopher S. Traylor, Recent projects performed by Skanska USA Civil Traylor Brothers Inc. Thomas Gelormino, Vet’s span the country: The Air Train at JFK airport in New Explosives Inc., was elected to a one-year term. York, Cooper River Bridge in Charleston, S.C., Salvatore Mancini’s life is a true Horatio Alger story. Escambia Bridge in Pensacola, Fla., Prado Dam in He was born in a small town outside Rome, Italy, in southern California, the transportation hub at the September 1944 and came to the United States at age World Trade Center, and most recently the Second 13. He grew up in the Bronx and graduated from Avenue Subway in New York. Evander Childs High School and thereupon immediate- As President of The Moles in 2007, Mancini becomes ly got into construction, working for his uncle who had a the third person from Slattery to attain distinction in small construction company. After that, he joined the The Moles. He joins Jim Slattery, recipient of the Moles consulting engineering company Goodkind & O’Dea, Member Award in 1965, and John Saunders, President working in a survey party as an instrument man. of The Moles in 1983 and recipient of the Member After two years, he joined Underpinning & Foundation Award the same year. Co. in 1968, where he worked for seven years as a con- Mancini has been honored by the Concrete Industry struction superintendent before joining Slattery Board in 2001 with its Leader of Industry Award and by Construction Co. the New York Building Congress with its Leadership During his career with Slattery, Mancini was on a Award in Construction in 2006. He is a member of the myriad of projects from the Second Avenue Subway to Construction Round Table; The Beavers; and a long- the foundations for Co-op City. He then moved with his standing member and officer of The General family to manage large water pollution control projects Contractors Association.

10 Tunnel Business Magazine June 2007 People Allentown Equipment Names New President, Sales Manager Allentown Equipment, manufac- Before rejoining Allentown cizers and viscosity modifying addi- turer of the most complete line of Equipment, Allen was the North tives. While at BASF, he won the shotcrete equipment worldwide, American Sales Manager for BASF Master Marketer Award in 1995 announced the promotion of Patrick Construction Polymers, where he from Master Builders Technology. Bridger to President. Bridger, an worked to introduce its line of poly- He will manage and increase 11-year veteran of Allentown, will carboxylate powdered super-plasti- Allentown’s international presence. guide the company’s global operations in tunneling and mining construction, the refractory industry, repair and restoration of infrastructure, and all other areas of the shotcrete industry. Bridger has been in the shotcrete industry for more than 20 years. His career began by building and providing support Patrick Bridger services for dry-process shotcrete equipment and he quickly progressed to Vice President of Operations for a large refractory installer/contractor in the South. He joined Allentown Equipment in 1997, managing equipment sales for concrete repair and restoration. Bridger was promoted to Sales Manager in 2000, overseeing all markets including concrete repair, refractory, underground construction and mining. In 2005, he was promoted to the position of General Manager. In addition, Allentown announced that Bill Allen has been named as Sales and Marketing Manager. Allen is a Bill Allen previous Allentown employee, working with the company as the Sales Manager from 1993-2000. Reader Service Number 7

June 2007 Tunnel Business Magazine 11 Global ITA World Tunnel Congress Held in Prague The International Tunnelling Association held its thirty- third meeting in Prague May 5-10 in conjunction with the World Tunnel Congress 2007 “Underground Space — The 4th Dimension of Metropolises” organized by ITA and the Czech Tunnelling Committee (CTuC). About 1,200 persons participated in the event, which was attended by representatives, delegates, observers and working group members from 43 of the 52 Member Nations of the Association. Among the new members of the executive council is Martin Knights of the United Kingdom, who was elected president of ITA, taking over for Harvey Parker of the United States. Knights will serve a three-year term as president. The new executive council is as follows: Outgoing ITA president Harvey Parker of the United States (left) poses with newly elected president Martin Knights of the United Kingdom. Members — M. Knights, United Kingdom, President (until 2010); A. M. Muir Wood, United Kingdom, Honorary Space Association to better reflect the broader range of President; H. Parker, United States, Past President (until activities with which it is involved. The Assembly also 2010); P. Grasso, Italy, Vice-President (until 2010); E. Grov, announced the creation of two new committees — the Norway, Vice-President (until 2010); Y. Leblais, France, Committee on Education and Training (to be chaired by Vice-President (until 2010); I.-M. Lee, Korea, Vice- past president Andre Assis of Brazil) and the Committee President (until 2010); W. Liu, China (until 2008); S. on Underground Space. Eskesen, Denmark (until 2010); K. Fukumoto, Japan (until The Association has registered the membership of 19 2010); I. Hrdina, Czech Republic (until 2010); M. Thewes, new Affiliate Members (13 Corporate Members and 6 Germany (until 2010); V. Umnov, Russia (until 2010); G. N. Individual Members); the total results to 52 Member Mathur, India-WTC 2008 Host (until 2008); F. Vuilleumier, Nations and 280 Affiliate Members (140 Corporate Switzerland, Treasurer (until 2010); C. Bérenguier, Members and 140 Individual Members) taking into Secretary General (until 2008). Experts — S. Calinescu, account some resignations. Romania, Internal Auditor (until 2008); Pal Kocsonya, Finally, the Association selected Vancouver, Canada, as Hungary-WTC 2009 Host (until 2009). the site for the 2010 conference. For more In addition, the General Assembly voted to change the information on the event, visit http://www.ita- name to the International Tunnelling and Underground aites.org/cms/1599.html. Robbins to Deliver TBM for Chinese Hydropower Project

A Robbins main beam TBM will bore through a steep station will use a 150 km (93 mile) long natural drop in a mountainside on the Jinping-II Hydropower Station in bend of the Yalong River to generate 4,800 megawatts of Sichuan Province, China. Robbins signed the contract on electricity per year. Jinping-II is located 17 km (10.5 mile) March 1, 2007, for the 12.43 m (40.1 ft) diameter TBM, downstream from the Jinping-I Hydropower station, backup, conveyors, cutters and related components. which is slated for completion in 2014 and will have a gen- Robbins and owners Ertan Hydropower Development erating capacity of 3,600 megawatts. Co. Ltd. plan to begin boring on the 16.7 km (10.4 mile) Jinping-II will be the largest power station in an ambi- long headrace tunnel in March 2008 after an onsite assem- tious 21-station project for Ertan Hydropower bly. Engineering and fabrication of key components will Development Co. Ltd. The project will harness up to 25 take place in Robbins’ U.S. locations, while much of the million megawatts per year from the Yalong River for steel structure will be coordinated for fabrication at the China’s West-East Electricity Transmission Project. Robbins China manufacturing facility in Shanghai. Power from these stations and other resources in the west Assembly will take place in January 2008 in an under- will be transmitted to Guangdong, Jiangsu and Zhejiang ground launch chamber pre-excavated by drill-and-blast. Provinces, as well as the cities of Shanghai, Beijing, “Robbins is experienced in onsite assembly — the Tianjin and other eastern locations in short supply. method will save time on the project delivery schedule and The Jinping-II station will use four parallel 16.7 km (10.4 will reduce project costs,” said Biyue Li, Chief Operational mile) headrace tunnels to generate electricity. Robbins will Officer-Far East for Robbins. bore headrace tunnel No. 1, while headraces 2 and 4 will be Once completed in 2010, the Jinping-II Hydropower excavated by drill-and-blast. All four tunnels are located in

12 Tunnel Business Magazine June 2007 a complex geology of marble, shale and limestone with up to 80 MPa (11,600 psi) UCS. The high overburden, up to 2,500 m (8,200 ft) in height, creates a risk of squeezing ground, while faults and fractures as well as karst patterns revealed in the adjacent access tunnel and probe tests indicate the potential for high water inflows. In order to bore successfully in the challenging ground conditions, Robbins designed the machine for a variety of situations. The entire TBM, backup and continuous convey- or setup in the tunnel will be raised in order to allow the expected large water inflow of 5 cubic m/sec (1,300 gallons/sec) to pass under the backup. In addition, a water discharge pump will relay water from the cutterhead support to the end of the backup. Reserve saddles located under the gage area on the TBM cutterhead will allow for overboring if squeezing ground is encountered. Although Ertan’s entire hydropower scheme will not be finished until 2030, the construction of the Jinping-II hydropower station is a feat in its own right. “This is one of the biggest TBM-driven tunneling projects in Chinese history,” said Li. “This is one of many ongoing projects for the country. China is currently one of the leading TBM mar- The mountainous region required specific design modifications to the kets, and will be for at least the next five to 10 years.” TBM in case of squeezing ground and water inflows.

Reader Service Number 5

June 2007 Tunnel Business Magazine 13 The View from the Hole The Truth Shall Set You Free Must have been back in ’76 that my feet in a day had often been done equipment … it by Bob Pond friends at a giant coal company (the when nature, man and machine all was what I would one that starts with “C”) asked me to cooperated and the bonus was gener- have chosen. Ground seemed OK come to Pittsburgh and talk to their ous. It was the twilight of the tramp with just some pattern rock bolts state coal association about high- miners, walkers and hard-headed needed of the old expansion shell speed shaft and slope sinking. “Glad tunnel supers (but that’s another variety. UMWA miners were sort of to,” I responded, and rather giddily story). “Hmm,” I thought, “not real- cantankerous, but if you looked past contemplated the honor of being ly a shaft and not really a tunnel.” the arm-waving and growling and thought an expert in something. When I learned that 80 feet a week treated them like human beings, My experience with such things was outstanding progress in a slope, most of them worked as diligently as was then somewhat abbreviated, any days-pay western miner. Slopes having been in charge on several were just harder to drill, harder to shafts and tunnels but at that load, harder to muck, harder to ven- moment never having actually done If those folks tilate, harder to support, harder to any slope excavation at all, let alone keep dry (water all goes to the face); the fast variety. But if those folks wanted to listen to all in all, a hard way to serve the wanted to listen to me talk about me talk about Lord. Eighty feet a week was pretty something I had no first-hand knowl- good after all. edge of, I didn’t want to disappoint something I had So there I was, anointed expert, them. “Won’t be the first engineer to standing at the dais listening to them commit that sin, or the last,” I no first-hand introduce “Mr. Pond.” I confess at thought, so I accepted. such times, even now, I sneak a I had a few weeks to prepare, it knowledge of, I glance behind me to see if my father, would be a chance to wave the the real Mr. Pond, is behind me. Frontier-Kemper flag, I had the “gift didn’t want to dis- Luckily, I was the last speaker, and of gab” and maybe it would work out. by then the audience had developed If not, a few frosty mugs of Iron City appoint them. a powerful thirst and a severe case of and a “black & blue” rib-eye at “numb-butt’ that can only be cured Christopher’s could palliate the “Won’t be the first by sitting on the edge of a bar stool. deepest shame. I stood, shot my cuffs, thanked my Slopes were a different thing. Up engineer to com- host, and said, “There is no such until then they were unique to under- thing as high-speed slope sinking. ground coal mines. Those days most mit that sin, or the It’ll always be slow, costly, brutish were driven at around 16 degrees work. Anyone who claims otherwise because that was as steep as you last,”I thought. is trying to sell you snake oil. I wish could run a conveyor belt without the I had better news. Thanks for asking coal rolling back on itself. The dilem- me to join you.” I sat. ma was that the deeper the seam, the A roar went up from the audience greater the long-term cost advantage and 50 feet the norm, the desire of that sent a shiver up my spine, until of a belt conveyor, but a slope had to every coal company to find a faster, I realized they were just glad to be be about 4½ times longer than a shaft much faster, way to build a belt slope up and out and racing for a shot and had to be deep to reach the same ele- was obvious. beer. I didn’t lack for refreshments vation. This longer time to first pro- But I was thinking me and my that night. Sometimes, you just duction, so crucial to major facility tomcat could dig one faster all by our- have to get Toto to jerk back the financing, meant shaft hoisting usual- selves. Must be using ancient gear, curtain. Didn’t get asked back, ever. ly won the toss-ups. that United Mine Worker’s labor OK with me. I’d been in Appalachia about four must be as quirky as legend had it, years by then, but for quite a time and the ground wasn’t really rock, See you at RETC. before I’d been a hardrock miner just that weak old sedimentary stuff. SOB and tunnel digger “out West.” Drill- I was wrong. I visited a couple of shoot in a highball tunnel, 40 feet a slopes then under way by our com- Bob Pond is vice president of Frontier Kemper day was no big deal. Upward of 100 petitors. Couldn’t find fault with the Constructors Inc., Evansville, Ind.

14 Tunnel Business Magazine June 2007 Reader Service Number 8 TorontoToronto UndergroundUnderground

AA looklook atat thethe ProjectsProjects ReshapingReshaping GreaterGreater TorontoToronto

By Boro Lukajic he venue for the 2007 Rapid Excavation & Subsurface Geologic Setting Tunneling Conference (RETC) is situated right Since most of the Toronto area tunnels are constructed in the middle of Toronto's business and tourist at relatively shallow depths, it is quite common that they Tdistrict. Here you can find large shopping cen- intersect a variety of soil and groundwater conditions. ters as well as small boutiques. Toronto is the largest city The soil deposits of the Region were formed by succes- in Canada. It is the capital of the province of Ontario, and sive continental glaciations, which can be classified into is the business, financial and cultural centre of the coun- two main categories: — those deposited by the ice itself, try. The city is situated on the northern shore of Lake forming till sheets; and those formed by melt waters in Ontario, which provides part of the border between streams or lakes. The ground conditions in the area vary Canada and the United States. Toronto is a city of the- considerably. Tunnels in the area are often driven below atres, restaurants and excellent entertainment. the groundwater table. This requires careful analyses of It is also no more than 80 km (50 mi) away from one of groundwater impact on tunnel construction. the most spectacular sights in the world: Niagara Falls. The soils are underlain by shale bedrock of the Dundas The CN tower is one of Toronto's landmarks — and by far formations, Ordovician age, consisting of shale and inter- the highest. Take the lift to the top on a clear day, and bedded limestone. Geotechnical sampling within shale you'll be able to see all the way to Niagara Falls and indicates an upper weathered zone of about 3 m (10 ft) Rochester, New York. Toronto has more than 7,000 overlying more competent material. It is well known that restaurants offering well over 100 different cuisines. A high horizontal stresses are prevalent in the rock forma- simple breakfast in an outdoor cafe or a sumptuous din- tions of the Southern Ontario (Lo, 1978). The state of ner in an opulent restaurant: take your pick. horizontal stresses is generally anisotropic. An underground city is a network of tunnels that con- An extensive series of stress measurements were per- nect buildings, usually in the downtown area of a city. formed in the area using the over-coring method with the Beneath the streets of Toronto is such an underground USBM deformation gauge, following the procedure world full of stores, restaurants, and other amenities that described by Palmer and Lo (1976). For example, a mag- allow you to shop, browse, dine, or just explore. It com- nitude of up to 14 MPa was measured at the Darlington prises 27 km of tunnels, walkways and approximately intake tunnel, with the ratio of the horizontal to vertical 1,200 shops. It links many important buildings and initial stresses of about 10 (Lo, Lukajic, 1984). In such attractions downtown to five subway stations and accom- case, a provision of three months between excavation and modates 100,000 pedestrians daily. liner placement was required to accommodate the rock Physiographic Setting squeeze effects. Seen from the air or from the top of the CN Tower, the Tunneling Progress Greater Toronto Area (GTA) presents a surprisingly Large tunnels within the area in soils are primarily green perspective for a region, which is home to more those belonging to the transit system, using three differ- than four million residents. The ravines, valleys and ent lining systems: — reinforced concrete box, circular waterways, which make up the Toronto watershed, tra- cast iron and pre-cast concrete segments. The Toronto verse the region. Much of the geological history in the Transit Commission operates one of Canada’s few full size Toronto area has not only been shaped but also been underground subway networks. Tunneling for subways masked by glaciers. has grown to over 50 kilometers in length, servicing much Geologists claim that there have been several ice ages, of the Metropolitan area. not one, interspersed with warm interglacial periods. Construction of the first subway began in 1949, using Each advancing glacier destroyed most of the evidence of the traditional cut and cover method. The earliest tunnel- earlier ice sheets; however, here and there, deposits from ing techniques also included the application of shield earlier stages have escaped. Excavation for the brick- methods with compressed air. The advent of EPB tunnel works in the Don Valley provides one of those windows boring machines has brought about a fundamental change into the history of the last million years. in tunneling in Toronto area. Most recently in the 1990’s, The most prominent natural feature of Southern the Sheppard Subway line was constructed, using two Ontario is the Niagara Escarpment. The Scarborough pressurized face, EPB tunnel boring machines (Lovat). Bluffs in eastern Toronto exposes a nearly complete Excavating through glacial soil formations under the record of the Pleistocene glaciations. A boundary water table, the machines demonstrated a huge improve- between ancient subcontinents or “terranes” passes ment in advance rates and safety. through the Niagara Peninsula and the Toronto region. Smaller tunnels for sewers, water, and utilities have Fine-banded deposits called “varves” are displaying been constructed throughout the GTA . These have gen- yearly sedimentation layers, thus forming a fine-grained erally been constructed within the shale and tills using record of past conditions. The shoreline of ancient Lake simple tunnel boring machines. More recent tunnels in Iroquois provides a topographical rise that surrounds the more permeable deposits have demanded the use of EPB GTA area. The Oak Ridges Moraine, to the north of the techniques. city, is a terminal moraine left by several glaciations and On the rock side, the largest cut and cover tunnel was represents a regional aquifer. built under the Welland Canal in the mid-sixties. This was

June 2007 Tunnel Business Magazine 17 In the 1990’s, the Sheppard Subway line was constructed, using two pressurized face, EPB tunnel boring machines

followed by construction of five large cooling water rock- will have design life measured in hundreds of tunnels for nuclear generation under Lake Ontario and thousands of years. Lake Huron. All were constructed using drill and blast methods. Lately, there has been a dramatic increase in Tunneling Companies demand for CSO tunnels to address pollution issues in the The Tunneling Association of Canada (TAC) provides GTA. One such storage tunnel was built at the Western a central voice and perspective for all Canadian tunnel- Beaches under Lake Ontario in late nineties. ers. Its corporate members are active in improving and promoting tunneling technology in Canada and interna- Active Projects tionally. On a more difficult and complex projects, it is Currently, a number of small size sewer and utility not uncommon for contractors to form joint ventures in tunnels are under construction in the Metropolitan order to share risks and expertise. There has also been area to support major residential expansion. significant change in consulting practice. In the last ten Programs are in place to build tunnels for new water years, considerable numbers of small specialist compa- intakes, tunnels to carry hydro cables under the city nies have been taken over by larger groups. and tunnels for district heating and cooling. Ontario Power Generation is in process of constructing a ten- Acknowledgement: kilometer long tunnel diversion project at Sir Adam The author would like to thank Brian Garrod, Hatch Beck Generating Station in Niagara Falls, Ontario. Mott MacDonald, for his review and his valuable sug- The tunnel is being constructed by use of a 14.4-m ( 47 gestions while writing this article. ft) diameter TBM. References: Future Programs 1. Toronto Public Library-The Virtual Reference Library Short and medium-term prospects for tunneling in Toronto and surrounding areas are good. Toronto and 2. Lo, Regional distribution of in situ horizontal stresses in the Regions of York, Peel and Halton have ongoing rocks of Southern Ontario, Canadian Geotechnical sewer system expansions driven by residential develop- Journal, Volume 15, No. 3. ment. The plans are underway to expand their sewer 3. Lo & Lukajic, Predicted and measured stresses and dis- systems using tunnel boring machine technology. placement around Darlington Intake Tunnel, Canadian In water and wastewater, a new outfall tunnel is Geotechnical Journal, Volume 21, No. 1, 1984. planned for the Toronto treatment facility. In the trans- 4. Palmer & Lo, 1976, In situ stress measurements in some portation sector, new extensions to the existing subway near surface rock formations, Canadian Geotechnical and commuter rail systems are planned. There are Journal, Volume 13, No. 1. prospects, too, of developing a deep rock repository for the long-term storage of low and intermediate level Boro Lukajic, P. Eng. was president of the Tunneling nuclear waste in Kincardine, Ontario. The repository Association of Canada from 1994-1998.

18 Tunnel Business Magazine June 2007 Reader Service Number 9 Toronto Trek SME’s Biennial Tunnel Conference Heads North

By Katherine Fulton

As the largest city in Canada, the fifth largest city in While there are a number of respected presenters who North America and one of the most diverse cities in the will be in attendance at RETC, there are two speeches world, Toronto has a lot to offer to visitors. When atten- that are eagerly anticipated. The first takes place during dees of the 2007 Rapid Excavation and Tunneling the Welcoming Luncheon as Harjit Dhillon, joint venture Conference (RETC) come to this year’s exhibition, they manager of Aecon Constructors in Toronto, talks about will be treated to the best the city has to offer – as well as his career experience and his company’s recent projects. exciting speakers, informative sessions and excursions to Dhillon started with Aecon Construction in 1963 and sites where they can watch the latest tunneling techniques has been in charge of a number of challenging projects. being put to work. His work in Canada includes the Revelstoke Dam and RETC is held every two years and provides a venue for Powerhouse in British Columbia and Jenpeg, Longspruce industry experts and insiders to network, attend educa- and Kettle Rapids power projects in Manitoba. During his tional sessions about a variety of topics including tunnel- presentation, Dhillon will discuss his role in the Nathpa ing techniques, case studies and new technologies, and Jhakri Hydroelectric project in the Indian state of attend field trips to local tunneling projects. The confer- Himachal Pradesh. The project required tunneling in the ence has seen steady growth, with attendance going from Himalayas and included a number of difficult conditions. 747 attendees in 1999 to 1,411 attendees in 2005. This Tuesday’s speaker may not have experience in the tun- year’s gathering is expected to bring continued success in neling industry, but he does know how to be a leader in his following with the trend. field. At the RETC Dinner on June 12, Darryl Sittler, a RETC is sponsored by the Society for Mining, former center for the Toronto Maple Leafs and an NHL Metallurgy and Exploration (SME). The Society, whose Hall of Fame inductee, will share his experiences both on origins date back to 1871, boasts more than 11,500 mem- and off the ice. After an impressive career as a hockey bers from nearly 100 countries. RETC is one of several player, Sittler went on to become a special consultant to conferences that SME sponsors throughout the year in the president of the Toronto Maple Leafs, concentrating North America. More information about SME and its on marketing, public relations, alumni relations and hock- other conferences can be found at its Web site, ey operations. He is currently a marketing and communi- www.smenet.org. ty consultant. This year’s RETC convenes at The Sheraton Centre For those who like to see technologies and practices put Toronto, conveniently located in the middle of both the into action, this year’s RETC will offer three field trips to entertainment and business districts. The dates of the various tunneling jobs in the region. Prices vary and avail- conference proper are June 10-13; however, pre- and post- ability for the sessions are limited; participants will also be conference events are planned for June 9 and June 14, required to bring safety gear, such as hard hats, reflective respectively. In addition to the recreational tours and field vests and safety boots for some of the excursions. trips, each day of RETC 2007 is packed with sessions and Field trips are not the only opportunities for conference speakers that showcase tunneling projects and break- attendees to get out and about. Four tours scheduled from throughs from around the world. June 9-12 offer the chance to explore the best that Toronto

20 Tunnel Business Magazine June 2007 (and in the case of one tour, Niagara Falls) has to offer. Akkerman Whether it’s a visit to the Falls’ natural splendor, a land and Akkerman Inc. introduced its fifth Guided Boring sea jaunt throughout Toronto, some culture at the Royal Machine (GBM) jacking frame. The 4812 jacking frame Ontario Museum or a retreat to the McMichael Canadian has evolved in design and capability to meet the growing Art Collection, the RETC tour schedule has something for demands of customers, yet maintains the same pipe rate everyone. and distance per shift while accommodating larger pipe. Passport rules for American citizens have recently The 4812 rotational drive is facilitated through a direct changed, and SME stresses the importance of having the hydraulic motor rather than a gear powered motor. The proper documentation. As of press time, American citizens jacking thrust is advanced through a single and continu- are required to carry a passport if they are flying into ous action. The guide rails have been lowered for ease of Canada. Those who are entering by land will need to have pipe placement and require fewer joints to go the same proof of citizenship, such as a birth certificate, and govern- distance. The frame will accommodate pipe up to 2 meters ment-issued photo identification. Before departing for in length. Statistics on the 4812 include its capability for Canada, RETC participants should confirm the type of up to 200 tons of jacking force, up to 100 tons of pull back documentation they will need by visiting the United States force and up to 20,000 ft-lbs of torque (rotational drive), Department of State web site at www.state.gov. almost twice the rotational force of its smaller counter- After this year, the next scheduled RETC is June 14-17, parts. Established in 1973, Akkerman Inc. sells and leas- 2009 in Las Vegas, Nev. For more information about the es microtunneling, pipejacking, tunneling, guided boring 2007 RETC conference, including a schedule and attendee and earth pressure balance and exhibitor information, visit www.retc.org. equipment. Akkerman has built a reputation for supe- rior reliability and service Featured Exhibitors through experienced engineers, technicians and a 1st Global Industrial Services large parts department. For more information, 1st Global Industrial Services specializes in the efficient visit www.akkerman.com. and rapid cleaning of large diameter sewer and storm drain lines while eliminating the need for by-pass pumping. The company offers many solutions to all your large diameter pipe and tunnel cleaning needs. Its large jetter, known as the Tunnel Tiger, operates at 380 gpm, at 2,400 psi, and pumps debris with a 2,800 gpm submersible pump into 30-cy enclosed dewatering system. This equipment will remove stub- born material that may com- promise the performance of a sanitary sewer or storm drain infrastructure. 1st Global’s services also include the cleaning of wastewater system components, such as digesters, clarifiers, and influent channels. In addition, the company uses specialized hazmat divers for certain conditions where access is a problem or where the large jetters are less effective. As problem solvers, 1st Global takes on tough jobs that could pose a challenge to others. The company has the capability to safely clean large diameter sewer and storm drain lines in a manner that saves time and money and eliminates the problem of facing constant issues, such as sanitary sewer overflows. 1st Global has successfully cleaned tunnels up to 22 ft in diameter and 130 ft below ground. For more information, visit www.1stglobalind.com. Reader Service Number 10

June 2007 Tunnel Business Magazine 21 Allentown for all ground conditions means the advance rates of The first steps towards the development of the standard roadheaders can be doubled, thus achieving a process known as “shotcrete” were taken over 100 truly continuous tunneling operation. For more informa- years ago, and Allentown Equipment has been an inte- tion, visit www.alpinecutters.com. gral part of this development from the very beginning. Antraquip Corporation Today, Allentown is a premiere manufacturer of dry and Antraquip continues its history as a leading designer, wet process shotcrete equipment, including pumping manufacturer and supplier of roadheaders, hydraulic and gunning equipment and accessories. The company rock cutting attachments, shaft sinkers, special tracked continues to be an industry leader in the design and man- machines with a variety of boom options, and tunnel sup- ufacturing of pressure tank guns, rotor guns, rotary bowl port systems. Antraquip roadheaders and rock cutting guns, wet process pumps, high pressure pumps and high- attachments, built to the highest technical standards, are quality parts and accessories. For over 95 years being used all over the world in various civil engineering Allentown Equipment has been leading the sprayed and mining projects. concrete industry and today the company can boast of Antraquip offers not having a front office staff with over 125 years of only standardma- combined experience in the shotcrete business. chines in the 12 to 70 Allentown is com- ton weight class but is mitted to having the extremely flexible in industry’s best ser- offering project orient- vice and is constant- ed engineering solu- ly striving towards tions. Based on a profi- the goal of zero downtime for their customers. The heavy- cient and committed duty design and construction of Allentown machines staff of service engi- keeps them up and running even under the most demand- neers and a large parts inventory for its own machines, ing conditions. For more information, visit www.allen- Antraquip continues to be a reliable partner for any min- townequipment.com. ing and tunneling project. To learn more about Antraquip Alpine and its products and services, visit www.antraquip.net. Alpine Sales & Rental Corp., a supplier of roadhead- Cellular Concrete ers since 1968, introduces the Alpine Multi-Tool-Miner Cellular Concrete LLC has been offering low-density (MTM), a novel roadheader with quick-change attach- cellular concrete solutions for the geotechnical construc- ments (cutter head, hammer, and bucket) for all ground tion industry for almost 60 years. The company’s and rock conditions. With TBMs, tunnel excavation is Geofoam liquid concentrate produces stable preformed continuous because boring, muck removal, and support foam able to withstand the vigorous requirements of geot- installation are done concurrently. However, with road- echnical applications and especially those of the under- headers, continuous operation is not possible because ground construction market. Backfills, annular fills, min- the machine has to stop excavation when support is ing applications, abandoned pipes and tanks, replacement being installed. Depending on the support type, this can for poor soils, and bridge approaches are just a few of the be 20 to 60 percent of the available face time. many applications for which Cellular Concrete has found Alpine will introduce a solutions. Cellular Concrete’s latest endeavors are that of new support system for exclusive North American distributor to the shotcrete concurrent support industry for Fibercon Steel Fibers and the development installation and rock cut- of new synthetic concentrates including those able to ting, which will double a develop pervious cellular concrete. To learn more, visit roadheader’s advance per www.cellular-concrete.com. shift. With modification, this new system can also CETCO be used for drill-and-blast CETCO Drilling tunneling. The new sup- Product’s PITDRY HDD port installation system is is an integral part of a not a “bolter miner” as new exclusive process used in coal mining. It has offered by the leader in far more capabilities, such as automated erectors for lat- directional boring prod- tice girders and steel arches, drill-bolters, shotcrete ucts. Using this process, manipulators and pipe umbrellas. The new system can spent liquid drilling fluid also be used with excavator-mounted cutter heads. The can be converted into a combination of automated support installation for con- product suitable for dis- current cutting and the Multi-Tool-Miner attachments posal as a solid. Reduction of overall weight and volume

22 Tunnel Business Magazine June 2007 results in reduced disposal costs. Using a patented prod- graphical format. uct and process, the treated fluid can be pumped directly Functions are into a roll-off box or end-dump for removal to a landfill. included to manip- The processed material is converted to a solid within min- ulate and convert utes. If space permits, it could be spread or backfilled on data and to pro- the project site. The processed product surpasses solid vide for automat- waste disposal criterion in both the United States and ed reports. The Canada. This process may also be applied to numerous db.web.browser is other waste stream products. To find the latest product a database web information or to learn more about CETCO, visit browser which www.cetco.com. allows the user to publish much of the work undertaken in db.data.browser. It includes everything needed to Geokon start web service, create Web Maps and allows service Geokon Inc. recently signed a reseller agreement providers to customize control over data access. For with Vista Engineering of Reykjavik, Iceland, for the more information, visit www.geokon.com. supply of the Vista Data Vision suite of data visualiza- tion software, a complete data management package for Herrenknecht data storage, data browsing and reporting and for pub- Until now, constructing subway stations and under- lishing data to the Web. Data stored in Geokon’s Micro- ground parking garages has been connected with consid- 10, Micro-1000 and Micro-800 Dataloggers is automati- erable problems. On the one hand, construction sites cally imported into the db.robot.c database where it is require space, but on the other hand, the traffic routes available for rapid calculation and formatting for dis- concerned cannot simply be closed. Constructing shafts play and analysis. using drill and blast, as well as excavators, or caissons — Tool kits allow the user to add features such as with all the surface impacts these methods involve — alarms and data validation. Once in the database, data result in high financial costs. The Herrenknecht can be accessed using thedb.data.browser, which allows VSM33000 Shaft Sinking Unit allows the sinking of large users to view and display data from multiple sensors in shafts even under space constraints. As the shaft diame-

Reader Service Number 11 Reader Service Number 12

June 2007 Tunnel Business Magazine 23 ter gets larger and the shaft depth increases, the econom- Digital networks operate at billions of bits per second, ic advantages of the VSM concept also increase in com- allowing real-time transfer of data. No delays in the parison to conventional construction methods. The VSM transfer of voice messages mean conversation is just as Unit is fixed to the ground surface with stabilizers and comfortable were one using the average telephone. The extendable bars. digital network is not limited to a communications func- tion. The same signal can be used to operate video transmission, personnel tracking, device control and monitoring and the acquisition of machine diagnostics and information. For more information, visit www.hard- line.com. Lovat Lovat Inc., is the world leader in the custom design, service, refurbishment/ modification and manufacture of a complete line of tunnel boring machines (TBMs) for the construction of Metro, Railway, Road, Sewer, Water Main, Penstock, Mine Access and Telecommunications tunnels.

During drilling, the telescopic beams of both road headers are swung out over the shaft ground. The excavated soil is fed into a separation plant via a slurry circuit. When the desired depth has been reached, the main beam is turned a further 120 degrees in the shaft and drilling continues. The road header rolls are equipped with round shaft chisels and enables the VSM to be used in varied geologies. After the completion of the shaft construction work, the VSM can be recovered and used in the next shaft project. For more information, visit www.herrenknecht.com. Lovat specialises in rock (single and double shield), soft HLS Hard-Line ground (earth pressure balanced and non-pressurized), HLS Hard-Line Solutions Inc. provides state-of-the- slurry and mixed face TBMs, ranging from 1.5 to 14 art communications systems by deploying a basic meters in diameter. Lovat TBMs are highly versatile and Wireless/Ethernet system into the new Headings in a built to the most rigorous safety and quality standards. mine or providing total coverage throughout an Additionally, Lovat is the only tunnelling equipment entire mine. The system includes Telephone (Voice over manufacturer that fully designs, manufactures, assem- IP) audio communications, both surveillance and real bles and tests under one roof. Web: www.lovat.com. time digital video and high speed hard Moretrench Corporation wired and wireless Founded in 1931 by Thomas F. Moore, the Moretrench data communica- Corporation originally designed, built and installed the tions. It consists of first practical wellpoint dewatering system used in the mini cell sites con- United States. Today, Moretrench American Corporation nected together by a is still recognized as a leader in construction dewatering standards based contracting, although the firm has continuously broadened Ethernet infrastruc- its expertise in engineering and contracting well beyond ture. A digital signal does not easily become degraded, allowing voice information to be transmitted more clearly and over longer distances — mean- ing conversation over a digital network is audible and temporary groundwater removal and hydraulic barriers coherent. Many devices can share the same transmis- Moretrench specializes in design/build solutions for sion medium. Several people can use the system at once, challenging construction requirements and subsurface since a single transmission will not monopolize the conditions. Services include: construction dewatering entire communication system. Hundreds of mining per- and groundwater control; ground/water treatment; sonnel can conduct simultaneous message exchange. ground freezing for deep shafts, tunnels, and under-

24 Tunnel Business Magazine June 2007 ground connections; grouting systems; cut-off and con- out the United States, South America and Asia. tainment systems; earth retention and excavation sup- The company has built a reputation as a leader in port systems; underpinning and foundation support; geotechnical core drilling, providing defensible design and deep foundations. These services are available data for tunnels, bridges, nationwide through full service offices in New Jersey, dams, highways and New York, Florida, Massachusetts, Pennsylvania, other civil projects. Delaware and Washington, D.C. For more information, Specialized services for visit www.moretrench.com. the tunneling industry include helicopter-supported drilling equipment and The Robbins Company the ability to perform continuous horizontal core bor- With more than 50 years of innovation and experi- ings. Current and previous tunnel projects include the ence, The Robbins Company is the world’s foremost Irvington Tunnel; Mt. Olympus Tunnel; Lenihan Dam developer and manufacturer of advanced, underground construction machinery. Since manufacturing the first hard rock TBM in 1951, Robbins has expanded tunneling in new direc-

tions, including the manufacture of the world’s largest hard rock TBM in 2006 for the Niagara Tunnel Project. The machine is impressive not only for its sheer size, but also for its initial onsite assembly. The entire process, from TBM order to launch, took less than 12 months. In 2007, Robbins has taken on even larger projects, such as the AMR project in India, which will be the longest TBM-driven tunnel in the world without intermediate access. Robbins was recently presented with a presti- gious award by the Export-Import Bank of the United States for this project. The Small Business Environmental Project Exporter of the Year Award honored the environmental sensitivity of the tunnel, which is TBM- driven in order to minimize surface dis- turbances as it passes just 1,600 ft under India’s largest tiger reserve. Two 32.8 ft diameter Double Shield TBMs will begin boring the 27 mile long tunnel in September 2007. To learn more, visit www.robbinstbm.com. Ruen Drilling For over thirty years, Ruen Drilling has provided drilling services through- Reader Service Number 13

June 2007 Tunnel Business Magazine 25 Outlet Tunnel; Caldecott Tunnel; San Vicente Tunnel and Pipeline; Devil’s Slide; White Sands Missile Range; Arrowhead and Badland Tunnel Project; Route 9 Tunnel, Hong Kong; and the Highway 53 Tunnel, Puerto Rico. For more information, visit www.ruendrilling.com. TACS GMBH The Tacs Guidance System has been upgraded by a new information window — the Production Report, which now is an integral part of the guidance system. The Production Report is a useful and valuable management tool for project managers and Tunnel Managers, who require quick and easy access of production-related data for decision making. The Production Report provides a quick and easy-to-use overview of the production rate and shows the number of erected rings per day and per week. It comes with an easy and comfortable navigation to move forward and backward between days or weeks. grout. Grout batches are held in an agitation tank until On an additional page, pumped via a high pressure peristaltic pump to a hold- the Production Report ing tank within the TBM. For additional information, gives a summary of sig- visit www.teammixing.com. nificant and character- istic production para- The Underground Construction Group meters like best day The Underground Construction Group (UGC) of production, best week BASF Construction Chemicals offers a complete line of production, average innovative technologies to support mechanized tunnel- daily production and ing and underground construction. MEYCO FIX SLF average weekly production. No spreadsheet program or soil conditioning foams and polymers enhance the per- database system is necessary. The Tacs Guidance formance of tunneling operations in less-than-stable System carries out all required functions like data pro- ground conditions by reducing the wear of machine cessing, data retrieval, calculations and graphical pre- parts while increasing tunnel face stability. MEYCO sentation. You save time and money of developing your FIX TSG tail shield sealants, for use in shielded tunnel own production report presentation. No manual data boring machines, effectively seal the gap between the input is required; your benefits are immediate results TBM shield and concrete segments, preventing the and saved manpower. For more information, visit ingress of soil, water or grout. Rheosoil 211 anti-clay www.tacsgmbh.com. agent, when used in conjunction with the MEYCO FIX SLF foams, combats the problems often encountered Team Mixing Technologies when tunneling through high-clay containing soils. For In response to a customer request, Team Mixing more information, visit www.masterbuilders.com. Technologies Inc. of Abbotsford, British Columbia, has developed an innovative grout batching plant system VMT GmbH incorporating twin horizontal silos, requiring no vertical VMT is dedicated to the supply of goods and services erection by a crane. The fully automated system, with for the machine bored tunneling industry. Specializing batch data collection system, was developed for back- in guidance systems for segmentally lined and extended grouting of the concrete segmental lining on the San distance or curved pipe jacking applications, VMT has Vincente water pipeline project in San Diego. Traylor now enhanced its range to include partial face extrac- Bros Inc. have taken possession of two identical plants tion and support machines (roadheaders, excavators for this project, which combine cement, flyash, ben- and bolters) as well as industrial measurement and tonite and water along with an admix into a high shear deformation measurements. Based on a motorized colloidal mixer. Cement is contained in one horizontal theodolite sighting to shuttered prisms on the body of silo, whereas the second silo is split into two bins to con- the roadheader or excavator and utilizing encoders for tain both flyash and bentonite. These feed directly into monitoring the lift, slew and extension of the boom, a the colloidal mixer situated below. Holding tanks for the continuous display of the cutting tool position is shown admix as well as for a sodium silicate solution are incor- on the machine monitor, in near real time, permitting porated into the plant design. The admix is dispensed the machine driver to execute precise excavation. into the mixer whereas the sodium silicate is pumped Expensive and time-consuming rework is avoided and underground to the TBM as part of a two component production times are shortened significantly. With the

26 Tunnel Business Magazine June 2007 help of the optional profile analysis software, a 3D ability. The company has a team of experienced engi- image of the excavation profile can be calculated from neers and technicians ready to help you with your com- the recorded movements of the cutter arm and dis- munication and automation needs. To learn more about played in the site office immediately. Wholesale Mine Supply’s products and services, visit www.wholesaleminesupply.com.

Wraight Industries Wraight Industries specializes in the purchase and resale of new and used electrical equipment. The company’s inventory consists of new, rebuilt and renewed equipment for mining, contracting and electrical utility companies that require expedient service. Wraight is fully equipped to remove any surplus or used equipment. By providing professional and efficient services, clients receive the full benefit of lower costs and quick response time. The HFC wireless network, provided by Wraight, is easy to install and will provide reliable delivery of voice communication (wired and wireless), The cutter arm’s overbreak and underbreak are doc- asset and personnel tracking and video and data. The umented by easily created reports. With the WLAN system can start small and grow to meet the needs of tunnel data network developed by VMT, the navigation additional services as required. All communication system SLS-TM is integrated in the existing site net- protocols and services are based on current industry work without problems. Constant advancement in standards to support maximum integration of numer- development and the experiences from current and suc- ous vendor products. This saves money by eliminating cessfully completed projects demonstrate that the use the need for multiple communication systems to proof the SLS-TM increases profile quality, accelerates vide all services. To learn more, visit www.wraightin- tunnelling and reduces project costs. For more informa- dustries.com. tion, visit www.vmt-gmbh.de. Wholesale Mine Supply Wholesale Mine Supply LP is the leading supplier of leaky feeder communication systems in North America. The company designs, sells and services underground communications systems and RFID tagging systems for the mining and tunneling industries. Wholesale Mine Supply’s systems are MSHA approved and the components are ISO9001 compliant. The company sells and services Kenwood two way radios as an authorized Kenwood Communications deal- er. It also sells and services its own branded two-way radios by American Radio Communications. The corporate goal of Wholesale Mine Supply is to increase safety and efficiency in the underground mining and tunneling industries by delivering voice, video and data communication systems with unparalleled capacity and reli- Reader Service Number 14

June 2007 Tunnel Business Magazine 27 SewerSewer TunnelingTunneling inin OntarioOntario

YDSS Interceptor Sewer Project

By Adrian Coombs, Steve Skelhorn and Derek Zoldy

28 Tunnel Business Magazine June 2007 n July 2006, McNally/Aecon JV was awarded The liner plate shafts on 19th Avenue were construct- the YDSS Interceptor Sewer Tunnel Project ed with gaskets and combined with neat cement grouts located along 19th Avenue between Yonge and to limit seepage and form sealed shaft. I Leslie Street, within the Town of Richmond In areas of unstable ground (aquifer), two slurry Hill, Ont. This conventional tender project is man- wall shafts were designed and constructed by aged by Earth Tech on behalf of York Region. The Petrifond. Both shafts are octagonal; one is 7.6 m project involves construction of 3,600 m of tunnel on diameter and 18 m deep, the second is 10.6 m diameter 19th Avenue and 500 m on Leslie Street. and 15 m deep. The shaft design does not utilize a Two tunnel drives are currently under way mining keyway to secure the base plug to the slurry wall, but from one shaft at 19th Avenue and Leslie Street: the first relies on friction between the concrete wall and plug. west along 19th Avenue — the TBM was delivered in To ensure proper bond between the plug and shaft February 2007; and the second south on Leslie Street — wall, divers cleaned down the shaft wall prior to the TBM was delivered in April 2007. The tunnels range placing the plug. Both shafts required excavation in depth from 9 m to 18 m and are constructed through under water with tremmie base plugs of 2.4 m and 3.6 boulder-rich glacial tills and sand. The tunnel alignment m thicknesses. crosses through the Oak Ridges Moraine Aquifer (a sig- These slurry walls were constructed between nificant feature for Ontario), as well as other highly sen- November 2006 and March 2007. Jet grouting of sitive environmental features. the tunnel break-in and break-out blocks is now under way. Shaft Sinking This contract has restrictions on groundwater TBMs seepage volumes at shafts. Several of the shafts are To remain on schedule, both tunnels (west and located in geological areas consisting of stable clays south) are set up to drive concurrently from the same and tills with liner plate and rib bracing or soldier pile main launch shaft. To accelerate the launch of the and lagging shoring structures. This includes the main TBMs, starter tunnels approximately 45 m long in mining shafts, Leslie Street recovery shaft and an stable ground were excavated by hand using a steel intermediate shaft at the eastern limit of 19th Avenue. liner plate temporary liner.

Reader Service Number 20

June 2007 Tunnel Business Magazine 29 The McNally/Aecon joint venture prepares the tunneling boring machine.

By combining two York Region projects awarded to maintained with a single, variable speed screw conveyor the joint venture (JV) team, it was possible to sched- with horizontal discharge. An adjustable aperture ule the work utilizing three new Lovat TBMs. exit gate allows for controlled discharge to the All three TBMs are identical full-face earth pres- secondary conveyor. sure balance (EPB) machines. Other components include ground injection system, dewatering dis- Precast Concrete Segmental Tunnel Lining charge tanks, integrated compressors, weld units The tunnels are being constructed using a precast and ventilation fans. reinforced concrete segmental liner. The segments are The TBMs are 3.25 m in diameter and incorporate manufactured in Ottawa by Boucher Precast and the mixed face cutterheads. The face dressing includes JV team. Chris Smith of CRS Consultants was ripper teeth across the full face, scraper teeth on the retained by the JV to provide management and quali- outer two-thirds of the circle and disc cutters on each ty assurance during setup of the plant and casting. blind to provide protection to the gauge. The face is McNally/Aecon procured a total of 18 sets of molds protected with Trimay wear plates and incorporates from CBE in France, as well as all components and grizzly bars to limit cobble and boulder ingress to accessories required for the segment manufacturing. 225 mm. The head incorporates five ground condi- Casting commenced late 2006. tioning injection ports — four on the face and one on The segment design was completed by Halcrow the outer wrap. Group Ltd. in the United Kingdom. The segments are The cutterhead design incorporates an outboard designed as steel reinforced concrete with bolted radi- triple roller bearing with the screw conveyor located al joints and dowels to the circumferential joints. through the bearing, below springline. EPB control is Ring selection was reviewed in detail by the project

30 Tunnel Business Magazine June 2007 A ring placer unit is also incorporated into each system. The ring design allows for six combinations of rotation while preventing cruci- form joints. The unit provides the operator with acceptable ring build positions based on the previous ring build and TBM alignment. The commissioning and the launches of the two TBMs were successful. The construction of the YDSS Interceptor Sewer project is on schedule for completion in February 2008.

The YDSS Interceptor project utilized three identical full-face earth pressure balance tunnel boring machines. Adrian Coombs, P.Eng., Senior Project Manager, Regional Municipality of York. team, with the main focus on need for cables along the tunnel Steve Skelhorn, Project Manager, selecting an arrangement that pro- wall, and surface linked computers McNally Construction Inc. Derek Zoldy, vides ease of ring construction and to allow remote data downloading P.Eng., Senior Project Manager — optimizes build options in curves. and monitoring from the surface. Tunnelling Specialist, Earth Tech Inc. For alignment control, the segments are tapered, and have a maximum length of 1.22 m, minimum of 1.20 m and nominal length of 1.21 m. The rings are designed for a minimum radius of 160 m. There are numerous curves along the tunnel alignments, with the tightest curves having a radius of 210 m. With a universal ring and small key, the ring cannot be rotated about the vertical axis; consequently the counter key must be placed at any location to maintain alignment. This option was not pre- ferred due to safety concerns with building the first segment in the crown of the tunnel. Therefore, in order to maximize ring builds starting with the counter key below spring line, a left and right ring is used. The left and right rings have opposite maximum and minimum lengths at springline when built, while the key position remains constant. TBM Guidance Systems Alignment control is critical, as sealed shaft designs limit the target for TBM entry eyes. ZED tunnel guidance systems were procured including Leica 1103 automated thoedolites with built-in lasers, radio modems to negate the Reader Service Number 16

June 2007 Tunnel Business Magazine 31 Full Speed Ahead World’s Largest Rock TBM Advances Niagara Tunnel

By Desiree Willis

Since September 2006, the world’s largest hard rock supervisory and labor team, while contractor Strabag AG TBM has been excavating a 6.5-mile (10.4-km) tunnel supplied additional labor. The entire time from TBM underneath Niagara Falls. The Niagara Tunnel Project is order to machine launch spanned less than 12 months. an innovative tunneling operation, utilizing new tunneling The 51-month design-build turnkey contract for methods as well as technology to save time and increase Austria-based Strabag AG relies on an aggressive sched- excavation efficiency. ule, with tunnel excavation scheduled for completion by Time-saving techniques began with the initial assembly September 2008. The new hydroelectric tunnel will join onsite of the Robbins 47.5-ft (14.4-m) diameter main beam two pre-existing tunnels that feed into the Sir Adam Beck TBM, finished in September 2006. The TBM was assem- Power Station, owned by Ontario Power Generation bled onsite, rather than in the Robbins manufacturing (OPG). By supplying an additional 132,000 gallons (500 facility, in order to save approximately four to five months m3) of water per second, the new tunnel will generate an on the TBM delivery schedule. Several critical compo- additional 150 MW annually — enough to supply a city of nents were manufactured and pre-assembled in the work- 700,000 people. More power is needed to avoid exceeding shop to ensure fit-up before being transferred to the site, the capacity of the current system during peak summer where the majority of the machine was assembled using months. The tunnel is expected to be operational by operating personnel. Robbins supplied a specialized December 2009.

32 Tunnel Business Magazine June 2007 Time-Saving Operations from the bored tunnel walls and diverted through the con- The TBM, back-up system and conveyor system were all crete form work until they can be reattached to the com- supplied by separate companies and are specially designed pleted tunnel walls farther down. for simultaneous tunneling and lining operations in order “Invert casting and lining will begin in January 2008, to meet the aggressive schedule. The 41-ft (12.5-m) fin- and the arch lining will begin in May or June 2008. We are ished diameter tunnel will require 20-in. (50-cm) thick con- satisfied that the concurrent lining will be a way to move crete lining with a waterproof membrane to prevent water forward and save time on the schedule,” said Robert from leaking out of the tunnel. As the TBM bores, the tun- Goliasch, Equipment Manager for Strabag AG. nel will be concurrently lined with in-situ concrete and Once the lining has been set, contact grouting will be PVC waterproofing membrane. used to fill any voids and to maintain a watertight struc- “The installation of the in-situ concrete liner continuously ture. As a final step, high pressure interface grouting while boring is a first in North America and was initiated (applied at up to 30 bar) will be used to pre-stress the by Strabag in order to reduce the construction schedule lining so that it can withstand internal water pressures and reduce the cost of the tunnel as compared to pre-cast once the tunnel is operational. The compressed lining will segments,” said Doug Harding, Vice President of The eliminate the need for reinforced steel, which can pose a Robbins Company, Solon, Ohio. long-term corrosion risk. The invert structure will be cast and set approximately Other simultaneous tunneling operations include a 1,640 ft (500 m) behind the TBM boring operations, while monorail crane system attached to the crown that allows the arch structure will be separately cast approximately rail to “leap frog” forward as the TBM advances. The rail, 5,000 ft (1,500 m) behind the machine. A 285-ft (87-m) long in 14.8-ft (4.5-m) sections, is removed from behind the bridge will allow rubber-tired supply vehicles to travel back-up in a bored section of tunnel and transported over over the invert concrete installation area. While the arch is the back-up to a new section, leaving behind a smooth cast, the ventilation duct, continuous conveyor, supply tunnel floor. pipes and power lines will need to be temporarily removed “The simultaneous operations result in less rolling stock and materials that must be maintained. The rail does not have to be removed as a separate step after the tunnel LEFT: The 47.5 ft diameter Robbins TBM at Niagara was launched in September 2006 and had bored 836 m as of mid-May 2007. bore is complete,” said Mike Burngasser, Robbins Field Service Manager.

Reader Service Number 17

June 2007 Tunnel Business Magazine 33 ABOVE: 20 inch thick in-situ concrete invert segments will be cast 1,640 ft behind the Robbins TBM.

Robbins 20-in. back-loading cutters are another innova- mixes with water and air. The ground is expected to fur- tion being used on the TBM to bore more efficiently. The ther improve once the TBM hits the 3,280-ft (1-km) mark, cutters have 20 to 25 percent more wear material than where shale should be predominant. their 19-in. diameter counterparts, resulting in a longer Shotcrete is being used throughout the drive as the pri- cutter life, fewer cutter changes, and ultimately less TBM mary means of tunnel support. Rubber-tired tractors downtime. The back-loading design of the cutterhead also transport shotcrete from the onsite batching plant to two reduces cutter change time and improves worker safety by shotcrete robots located on the back-up system. Each keeping workers protected from the rock face. robot has 360-degree coverage and can travel up to 26 ft (8 m) in the longitudinal direction to spray shotcrete at the Excavation In-Progress rate of 66 ft (20 m) per hour. As of mid-May 2007, the TBM had bored ahead approx- Additional rock support includes a ring beam erector imately 2,740 ft (836 m) in varied geology consisting of directly behind the cutterhead support and a total of four limestone, dolostone, sandstone, shale and mudstone at a rock drills on 20 ft (6 m) long slides. Wire mesh is erected 7.28 percent decline. The machine is expected to bore using a material handling cart, known as a “donkey,” locat- through Queenston Shale for the majority of the drive. ed on top of the TBM main beam. The cart transports wire The bore path includes an initial steep downgrade, as well mesh to a hydraulic lifting device for installation at the tun- as a steep upgrade at the intake, in order to avoid a 328 ft nel crown. Rock bolts, wire mesh and ring beams will be (100 m) deep buried gorge. Horizontal realignment of the applied as needed throughout the drive. tunnel was not possible due to existing water diversion The tunneling crew operates the TBM and equipment tunnels already in place. The TBM will pass approximate- 24 hours a day, seven days a week. About 30 crew mem- ly 95 ft (29 m ) below the gorge at its lowest point. “Once bers are onsite in a given shift, with one maintenance we get to this section, we will utilize probe drills to deter- shift each morning to monitor and test the equipment. mine if extra ground support will be needed and which The crew has endured winter conditions reaching below type,” said Goliasch. -4°F (-20°C) at the jobsite, which caused the conveyor The rock encountered so far, up to 26,100 psi (180 MPa) systems to freeze over with ice. Antifreeze was sprayed UCS, has been a combination of mixed face and at times on the affected conveyors and the ice was chipped off in highly fractured rock, requiring various rock support order to keep them running. The continuous conveyor methods. As the tunnel descends, the rock is expected to system is being installed as the back-up advances, and become largely competent with some minor broken will transport 2.2 million cu yd (1.7 million m3) of muck ground. Broken material at the crown has required addi- over three years to a storage area on OPG property. tional roof support including ring beams, wire mesh and “Of course, the sheer size of the tunnel is amazing,” rock bolts in some sections. said Goliasch. “But even more exciting is the fact that A specially designed foam system has also helped we are excavating a tunnel without a mountain over- increase the TBM performance in sticky ground. The head, at a steep gradient and only 328 ft (100 m) underwater spray normally applied to the cutterhead has been neath a famous city.” temporarily replaced with the foam system to assist in the flow of the material through the cutterhead. Five openings in the cutterhead allow the foam to be plumbed in, where it Desiree Willis is a technical writer in Kent, Wash.

34 Tunnel Business Magazine June 2007 Tunnel Business Magazine Webinars turn prospects into qualified leads, giving your sales team the information they need to close more sales. Brand your company as an expert and leader with a one-hour seminar broadcast live on the Web. Participants will have real-time interaction with speakers/moderators throughout the event.

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Educate. Market. Brand. Launch a New Product. Create Interest. Sponsors use Tunnel Business Magazine Webinars for all of these reasons but the #1 reason is to generate qualified leads. Call or e-mail today for more information and to schedule your Webinar. Kelly Dadich [email protected] or Ashley Bonvenuto [email protected] Phone: 330-467-7588 Reader Service Number 18 The Owner’s Implied Warranty — What You Need to Know

By Peter M. Kutil, Esq., and Karl Silverberg, Esq.

It is a basic tenant of construction law that owners rial and location for the relocated sewer. Spearin followed impliedly warrant the plans and specifications provided to the plans and specifications, and the government accept- contractors. This means that if the contractor constructed the work as satisfactory. ed a structure exactly according to the owner’s plans and About a year later heavy rains and a high tide over- specifications, and the resulting structure does not per- loaded the relocated sewer and the sewer broke, flooding form as the owner had intended, the contractor is not the dry-dock. Upon investigation, it was discovered that responsible for such failure. Most contracts, however, also a connecting sewer that should have relieved the pressure contain language that requires the contractor to check the on the relocated sewer was blocked, thus overstressing plans and drawings, and requires the contractor to deliv- the relocated sewer. None of the drawings available er the final product to the owner for its intended use. The showed that the connecting relief sewer was blocked. question then posed is, does the implied warranty survive Spearin thought the government should assume these requirements? responsibility for the damages to the construction site. In other instances if the owner specifies the construc- The government insisted that Spearin was responsible for tion means and methods, and the owner’s specifications or remedying the condition. The government then termi- means and methods do not work, the contractor is not nated Spearin and completed the work with a different responsible for any increased costs of performance. sewer design. Spearin sued for wrongful termination and While it may seem obvious that the contractor should sought his contract balance as well as lost profits. not have to assume the risk for the owner’s faulty plans The Supreme Court determined that whether Spearin and specifications, it took a 1918 U.S. Supreme Court case is entitled to damages depends on whether the govern- to set the precedent. This seminal case was United States ment was justified in terminating Spearin. The court v. Spearin, and the proposition it stands for has become found that the termination was not justified. The court known as the “Spearin doctrine” or the “Owner’s Implied first stated the general rule that, “[w]here one agrees to Warranty.” do, for a fixed sum, a thing possible to be performed, he will not be excused or become entitled to additional com- The Spearin Case pensation, because unforeseen difficulties are encoun- Spearin involved a contract with the U.S. government tered.” “But if the contractor is bound to build according to construct a Navy dry-dock. The site was intersected by to plans and specifications prepared by the owner, the a 6-ft sewer that required relocation. The government’s contractor will not be responsible for the consequences of plans and specifications prescribed the dimensions, mate- defects in the plans and specifications.” The court found

36 Tunnel Business Magazine June 2007 that, “the insertion of the articles prescribing the charac- The court also noted that, “general disclaimers requir- ter, dimensions and location of the sewer imported a war- ing the contractor to check plans and determine project ranty that, if the specifications were complied with, the requirements do not overcome the implied warranty, and sewer would be adequate.” Furthermore, “[t]his implied thus do not shift the risk of design flaws to contractors warranty is not overcome by the general clauses requir- who follow the specifications.” To shift the design risk, the ing the contractor, to examine the site, to check up the disclaimer must be “express and specific.” “The implied plans, and to assume responsibility for the work until warranty, however, does not eliminate the contractor’s completion and acceptance.” “The duty to check plans did duty to investigate or inquire about a patent ambiguity, not impose the obligation to pass upon their adequacy to inconsistency, or mistake when the contractor recognized accomplish the purpose in view.” or should have recognized an error in the specifications or drawings.” Modern Issues of Analyzing the law to the facts in the present case, the Design Specifications vs. court had to determine whether the “three pick-point” system was a design specification, or whether the “three Performance Specifications pick-point” system was merely a suggested system that Spearin is alive and well. In White v. Edsall was a performance specification. If it is a design specifi- Construction, a 2002 case, the issue was whether the con- cation, Edsall can recover its extra costs under the tract shifted responsibility for part of the structure’s Spearin doctrine, but if it is a performance specification, design to the contractor. then Edsall will be judged to have assumed the risk for As described by the court: “In May 1996, the U.S. Army designing the pick-points. awarded Edsall a fixed-price contract for the construction After reviewing the facts, the court concluded that the of a facility to house the Montana National Guard’s heli- “three pick-point” system was a design specification. The copters. The facility specification included two hangars court found that the “canopy door shown in the drawings designed for the Army … The specification and drawings incorporated significant design characteristics.” The called for ‘tilt-up canopy doors’ weighing about 21,000 court further found that, “[b]ecause the disclaimer … pounds each. The design used a complex system of required the contractor to seek clearance for ‘any condi- motors, cables, pulleys, and counterweights to open the tion that will require changes from the plans,’ Edsall could doors. [T]he cables attach to the doors at points called not alter the design without approval of the Army’s archi- ‘pick points.’ … The drawings also show the weight of tect.” The court found this statement inconsistent with each canopy door as distributed equally between three the Army’s argument of a performance specification pick points.” because the performance specification would require the The structural engineer placed a disclaimer on one of contractor to perform the design, as opposed to “not alter- the drawings stating: “Canopy door details … must be ing” the design. verified by the contractor prior to bidding.” Furthermore, The Army also argued that Edsall had a duty to verify the drawings showed a “v” (for “verify”) to indicate the design. But the court disagreed. The court said: schematic details, and asked the contractor to verify the “Although the disclaimer at issue requires the contractor door weight and the weight per pick point. to verify supports, attachments, and loads, it does not After the contract award, it was discovered that the clearly alert the contractor that the design may contain three-pick-point design would not work. Edsall’s subcon- substantive flaws requiring correction and approval tractor redesigned the system for a four-pick-point before bidding. … Like the disclaimer in Spearin, the dis- design. Edsall submitted a request for extra compensa- claimer in this case is only a general disclaimer. It tion associated with the redesign and the contracting offi- required Edsall to verify general details, such as door cer rejected the claim. Edsall appealed to the Armed weight and dimensions, but did not alert Edsall to the Services Board of Contract Appeals and was awarded its prospect that the Army’s design might not work for its extra costs. The Army then appealed the decision to the intended purpose.” U.S. Court of Appeals. The Appeals Court started out by stating the basic Conclusion propositions of law. Citing Spearin, the court noted that, Almost 90 years after the Spearin was decided, it is still “[w]hen the Government provides a contractor with provides the necessary framework for resolving construc- design specifications, such that the contractor is bound by tion disputes such as design vs. performance issues, as contract to build according to the specifications, the con- well as constructability issues. tract carries an implied warranty that the specifications are free from design defects.” The court then contrasted design specification with performance specifications, stating that performance specifications “merely set forth an objective without specifying the method of obtaining the Peter Kutil and Karl Silverberg are attorneys with the firm of objective.” Performance specifications assign the design King & King, LLP in New York and focus their practice on serv- responsibility to the contractor, so Spearin is generally ing the construction industry. More information is available at not applicable. the Web site: www.king-king-law.com.

June 2007 Tunnel Business Magazine 37 Expanding Horizons

Technical Advances Give Pipejacking Added Versatility

By Nod Clarke-Hackston

In the ever-expanding use of the pipejacking tech- In Berlin, Germany, a pipe arch arrangement was nique for creating a conduit from one location to anoth- required for the construction of a metro station. The er, contractors are continually expanding the range and project required 30 drives each with an ID of 47 in., and a complexity of this method of tunnelling. drive length of 295 ft and a horizontal radius of 2,300 ft. To show how far things have progressed in the field of The choice was between a gyro navigation system and a pipejacking, the Seo Cho electricity cable tunnel in Seoul laser theodolite navigation system. gives an indication of type of complex project that can After careful consideration it was decided that either now be constructed. Here a drive of 2,625 ft of 102 in. ID system would be useable, but the gyro system is very sen- with five curves of 656 ft and 820 ft radius was required sitive to vibration, and so for each gyro measurement it for the installation of electricity cables in a densely popu- was necessary to stop the advance for the 10-minute dura- lated area. The use of a curved alignment to keep within tion of the survey, to shut down the separation system on the rights of way of the city street enabled the busy road the surface and the slurry circuit of the TBM. Also, to to be kept open at all times as well as avoiding the achieve the necessary accuracy the gyro system needs construction of six intermediate shafts to depths of 147 ft. more check measurements than the laser theodolite sys- Many factors contributed to the successful completing tem. It was therefore decided that the best choice was the of this project including the choice of pipes and the laser theodolite System. guidance system. To achieve the 656-ft curve radius by For a second project we take the example of a storm pipejacking, the tunnel design consultant worked strict- water tunnel in the Black Forest in Germany where a sin- ly in accordance with design recommendations of the gle drive of 347 ft with an ID of 47 in. was required for the Pipe Jacking Association (PJA) in the United Kingdom. diversion of storm water. Although the horizontal curve of In order to maintain the opening at the pipe joints with- 875 ft radius and a vertical S-curve of radii 810 ft and in an acceptable range for transmitting the jacking 1,312 ft were not exceptional, the whole project was forces around the curves, a pipe length of 60 in. was inclined at a grade of 50 percent. selected, even though this effectively doubled the usual The main criteria for choosing the most suitable system number of pipe joints along the tunnel. Handling time in was the difference in elevation between start and target the 147-ft deep shaft was minimized by assembling two shaft of 164 ft. This differential is too high for the sensors jacking pipes together on the surface. Due to the overall of the electronic hose leveling system, so the best choice length and multiple curves in this project the laser for this project was the laser theodolite system theodolite-based SLS-RV navigation system by VMT For a third project in Stuttgart, Germany, with a single Gmbh was chosen. 574-ft drive with an ID of 31 in. and a horizontal S-curve of 557 ft radius and a vertical S-curve of 1,968 ft radius, the Selecting the Proper deciding factor in was the ID of the pipe. In this case, the pipe did not allow enough space for installation of the laser Navigation System theodolite. The laser theodolite system also needs a line of Choosing the most appropriate navigation system for sight between the components, which is difficult to guar- the project involves detailed knowledge of the align- antee in small diameters and tight curves. Therefore the ment geometry, diameter, technical specifications best choice in this case was the gyro system. (machine type, advance type), geology, specifications in the tender documents and economic considerations. For long distance and curved drives the choice of navigation system is either a laser theodolite-based system or a gyro navigation system. VMT offers both the SLS-RV laser theodolite system and the SLS-G gyro navigation system. The choice of which is the most appropriate system depends on the specific circum- stances of the project. The following are examples of the decision process involved in choosing the most suitable system in several recent projects.

38 Tunnel Business Magazine June 2007 Technical advances will allow complex pipejacking operations to become commonplace.

Continued Developments lation phase to advise the machine By careful planning in the choice in Pipejacking operator on the controlled use of of navigation system to be used, the increased jacking forces where limit inclusion of simulation software, the Having developed these two navi- values may be approached. use of hydraulic joints in the pres- gation systems for complex align- Refinement in the pressure trans- sure transfer ring area and other ments, drives are being further fer ring area by the use of hydraulic advances, complex pipejacking oper- assisted by new developments that joints and a monitoring system ations can be expected in the near are currently in the testing and enables full control of pipe static future that will make the above men- field trial phase. These include a forces in real time to be realized, tioned project look commonplace as pipe joint measurement system for giving stronger durability and a opposed to the exceptions that they controlling pipe deflection by means longer life expectancy for the pipe currently are. of an inclinometer chain system for and significantly reducing the radii the precise calculation of vertical of curvature possible with any given TBM position. This will be used in Nod Clarke-Hackston is international pipe size. sales manager for VMT Gmbh. addition to electronic hose leveling system to increase the accuracy where elevation differences of more than 100 ft are planned. It will also be used in conjunction with a navigation system for extended straight drives where precise vertical navigation is needed. To further enhance the capabilities of curved pipejacking new developments, including the CoJack simulation package, enable a theoretical calculation of the forces encountered by each section of the pipe as it negotiates it way through the designed alignment. A calculation of the deformation on the pressure transfer ring and the placement of interjack stations are also made. These calculations determine of the level of safety and the load reserves at every point in time. When mining is under way, real- time values, together with the values from encoders strategically placed on three joints, augment the theoretical values used in the simu-

Reader Service Number 15

June 2007 Tunnel Business Magazine 39 North American Tunnel Project Update

CALIFORNIA plete and the two-pass tunneling is better than The 8.5-ft Eldorado National Forest expected. Operations Manager: Ross Webb; diameter pipeline Project Manager: Jonathan Wallace; will connect an Middle Fork Surge Shaft Phase 2 by Jack Burke Kiewit Pacific Co. Superintendent: John Wallace; Safety existing aqueduct, Planning and procurement efforts are Manager: Vince Garcia. feeding San Diego under way for the installation of a 550-lf, 96-in. County, to the San Vicente reservoir. The sys- diameter steel liner into an existing surge Montara tem will provide additional storage during shaft in the foothills of the Sierra Nevada. Devil’s Slide Tunnel wet periods, and another water source during Fabrication will begin shortly on the gantry Kiewit Pacific Co. dry periods or when the main aqueduct suf- and headframe, which requires more than 300 Work is commencing on the $272 million fers a catastrophe, such as an earthquake. tons of liner segments and 135 tons of struc- Devil’s Slide Tunnel project in San Mateo West Shaft Site/Reach 1 — Shaft excavation tural steel. Project Manager: Steve Nerby. County between Montara and Pacifica. The is complete to 115 ft. Excavation of starter Project Engineer: Joerg Moser. Information: project involves constructing a new align- tunnel for the rock TBM has been completed (530) 367-2990. ment along State Route 1, consisting of two to 400 ft. The Robbins TBM has been deliv- parallel 4,100-ft tunnels, a north portal ered from Reach 6, and assembled in the Escondido approach adjacent to a bridge currently starter tunnel here. It has recently begun min- Lake Hodges Tunnel under construction by another contractor, ing in granite requiring ribs. Total reach Kiewit Pacific Co. and a south portal approach. The horseshoe- length is 4,400 lf. The contract grouting of the steel liner and shaped tunnels are 30 ft wide by 22 ft high Central Shaft Site/Reach 4West — the seal welding of all 587 grout plugs in the and approximately 59 ft apart, and will be Installation of shaft rail switches and muck pipe were completed in late February 2007. excavated from the south to the north at guides is complete. The CTS digger shield has Following these operations, the epoxy coating about a 2 percent slope. advanced to 7,000 ft through sporadically very subcontractor began sandblasting and coat- Kiewit has mobilized to begin work and is hard, well cemented conglomerate. Ground ing the joint holdbacks and grout ports. Once currently constructing a box culvert drainage support consists of precast concrete segments, this is complete the remaining tasks will be to system at the south portal. Tunnel excavation with backfill grout. install the steel bulkhead, perform the final is scheduled to begin in August 2007. Slaughterhouse Shaft Site/Reach 5 — leakage test on the pipe, and install the pre- Project Sponsor: Ray Backen; Project Reach 5 drill-and-blast/SEM excavation is cast shaft lid. Project Manager: Lyman File. Manager: Sean Menge; Assistant Project complete. Reach 5 west was prepared for Information: (402) 346-8535. Manager: Ryan Sheedy; Tunnel Manager: installation of the second CTS digger shield, Todd Cummings; Concrete Manager: Mark which has been accomplished. Excavation is Los Angeles Ramsey; Equipment Manager: Larry just beginning. Rail was installed in Reach 5 Eastside LRT Andersen. Information: (510) 627-1012. East to support the shield #2 excavation from Traylor-Frontier Kemper JV the eastern Portal. The eastside LRT project for the Los San Bernardino San Vicente Portal Site/Reach 6 — The Angeles County Metropolitan Transit Arrowhead East and West TBM excavation here has been completed. Authority is part of a plan to provide public Shea-Kenny J/V The TBM was driven 1,900 ft into Reach 5, transportation to neighborhoods in East Los Arrowhead East Heading-Strawberry thereby removing many days of activity from Angeles. The project is a 5.9-mile extension of Portal — The Strawberry Tunnel has the schedule. The TBM was backed out, and the current Metro Gold Line, which extends advanced more than 76 percent of the drive shipped to the West shaft for mining of from the city of Pasadena to Union Station in with 16,844 lf mined to date and approximate- Reach 1. Los Angeles. The joint venture is a subcon- ly 5,300 lf left for completion of the mining. Precast Concrete Segments — Manufacture tractor to Eastside Light Rail Constructors Arrowhead West Heading-Waterman by Traylor Shea Ghazi is complete. Project to complete the underground segment of the Canyon Portal — The Waterman Tunnel exca- Manager: Mike Jatczak. Information: (619) 631- project. This includes twin-bored tunnels vation is about 53 percent complete with exca- 0777. from 1st and Boyle to 1st and Lorena. vation of 9,400 lf left to complete TBM mining. Excavation of the two tunnels was success- Project Director: Brian Fulcher; Project Fountain Valley fully completed at the end of last year, with Manager: Bob Gordon; PA: Mike Belcher; Ellis Avenue Trunk Sewer the holing through of the Westbound Tunnel Assistant Project Manager: Stuart Lipofsky; Barnard-Soletanche JV occurring Dec. 9. The TBMs have been Project Engineer: Dana Downs; This project was awarded to the joint ven- removed from the site, and as of the end of Superintendent-Strawberry: Ron Walton; ture of Barnard-Soletanche at $31,232,600.00. March, both the invert and walkway in both Superintendent-Waterman: Bob Leslie; J.F. Shea was the second low bidder followed tunnels is approximately 30 percent complete. Walkers: Danny Sayre, Don Fullmer, Jeff by Kenny Construction. NTP was issued on Five of the six cross passages have been Bright, Bobbie Briggs, Ron Sammeth, Nov. 14, 2006, with final completion scheduled excavated and four of the six have been con- Bradley Leonard, Jim Autry. MWD for May 16, 2008. creted. The excavation of the final one and Construction Manager: John Wallace; The project is a portion of a $2.5 billion concreting of the fifth are in progress. Resident Engineer: Mike Bell; Deputy capital improvement program for the Orange LA MTA contact: Fred Smith Sr., (213) Resident Engineer: Ian Ward-McNally; County Sanitation District. It consists of a 922-7295. Traylor-Frontier Kemper contact: Assistant Resident Engineer: Dan McMaster. 5,437 lf of 9-ft diameter rib-and-board sup- John McDonald, Project Manager, (323) 261- For information contact Brian Fulcher at (909) ported tunnel. A PVC liner is placed behind 0444; Michael Traylor, Operation Manager, 883-3399 or [email protected] the rib and boards to control water inflow. A (310) 524-0044. 66-in. carrier pipe will be installed in the tun- San Diego nel and the annulus between the pipe and Los Angeles San Vicente Pipeline tunnel lining filled with cellular grout. There Joint Outfall H Traylor-Shea JV are a total of eight shafts to be constructed, Affholder Inc. The San Vicente Pipeline Tunnel is an 11- five of which are to be access manholes to the This complex project consists of 11 tunnel mile water conveyance being built for the San pipeline. The other three shafts include a runs split between four different machines Diego County Water Authority. The joint ven- junction structure, a diversion structure and using both jacking and two-pass lining to ture of Traylor-Shea is mobilizing to site, set- an exit shaft for removal of the TBM. The install 84- and 90-in. RCP. Two runs are com- ting up yards, etc. junction structure shaft will serve as the

40 Tunnel Business Magazine June 2007 main shaft for mining operations. CDM and Avenue Tunnel is staged from the R.M. Malcolm Pirnie designed this project. Clayton shaft and will mine 23,600 lf to the As of early May the junction structure North Avenue CSO intake. The Clear Creek shaft has been constructed and the tail and Tunnel is staged from the Rockdale shaft and starter tunnels excavated. The Herrenknecht will mine 20,600 lf to the Clear Creek CSO TBM has been assembled and has mined the intake. The Tanyard CSO intake is connected first 162 ft. Three of the manhole shafts have to the Clear Creek Tunnel through a 400-ft been excavated and the manhole structures long connecting tunnel. The Clear Creek have been built within them. Tunnel joins the North Avenue Tunnel at Project Personnel (Barnard) — Operations Rockdale shaft. The project also includes a Manager: Dan Schall; Project Manager: Ben section of drill-blast tunnel connecting to an Campbell; Project Superintendent: Brad overflow structure. Bush; Safety Manager: Boodie Hurd; Project On April 5 the Clear Creek Tunnel TBM Engineers: Patrick Stump, Jordan Hoover; holed through into the pilot tunnel at the Superintendents: Andy Granger, Bob Cayer; Clear Creek Construction Shaft. As of the Soletanche Tunnel Superintendent: Ismail April 8, the North Avenue Tunnel TBM has Benamar. Information: Shelley Burg (406) progressed 17,740 lf. 586-1995. Drill-and-blast excavation is complete in the Tanyard Chamber and connecting tunnel San Francisco with lining work under way. Surface work is Bernal Hgths Pipeline ongoing for the diversion structures at Clear Affholder Creek, North Avenue and Tanyard. Work on TBM mining was set to begin in April on the 85-mgd pump station is being performed this 1000-ft long soft rock tunnel. It is to be by W.L. Hailey as a subcontractor. Pump sta- mined with a 60-in. Taylor TBM, modified for tion shaft lining is currently nearing comple- rib-and-lagging installation. It will be lined tion.Project Personnel: City of Atlanta — with 42-in. pipe. Operations Manager: Ross Construction Manager: Ken Johnston. Webb; Superintendent: Lenny Dipitino. Atlanta CSO Constructors — Project Manager: Taro Nonaka; Assistant Project Stanford Manager: Darrell Liebno; Project Engineer: Stanford Linear Accelerator Ray Hutton; Safety Manager: Barry Affholder Inc. Jackson; Survey Manager: Bill Currier; This job consists of 1,600 ft of shotcrete- Office Engineer: T.J. Kobayashi; Tunnel lined NATM tunnel. The first tunnel drive is Engineers: Adam Stremcha, James McNally, a curved access tunnel 20 ft by 20 ft and 300 Percy Townsend, Stuart Sullivan, Koichiro ft long that connects to a 40 ft by 40 ft exper- Shimomura; Raj Magam; Arash Sayyar; imental hall 200 ft long. On the opposite end General Superintendent: Jeff Early; of the experimental hall is a 500 ft long X-ray Assistant Superintendent: John Dempsey. tunnel 20 ft by 20 ft. There is a 600-ft long W.L. Hailey & Co. — Project Manager: Don undulator tunnel under the next hillside. Painter; Project Engineers: Mark Palmieri, Mining is started and progressing well on Jake Coibion. JDH Joint Venture — Resident both the Access Tunnel and the Undulator Construction Manager: Mike Robison; tunnel. This job is scheduled for completion Resident Engineer: Ed Kennedy; Project in early 2008 Engineers: Randy Divito, Ron Davis; Project Operations Manager: Ross Webb; Project Controls Engineer: James Talley; Chief Manager: John Forero; Project Engineer: Inspectors: Mark Rhodes, Dave Mundis. Tolga Togan; Safety Manager: Jack Lynch. Information: (404) 352-0701.

COLORADO ILLINOIS Parachute Chicago Wheeler Gulch Calumet Tunnel System Kiewit Western Co. Kenny Construction Co. The scope of work included excavating a The $57,126,600 project was awarded Dec. 3,200-ft long tunnel, measuring 24-ft wide by 2, 2004, and NTP issued Dec. 22, 2004 with a 20-ft high, and hauling 54,789 cu yd of muck. mandated final completion of 2008. Crews holed through on March 7. Tunnel The project involves the splitting of the excavation utilized a roadheader. two pump rooms at the existing Calumet The project also required the development TARP Pump Station. The project includes of a well pad for drilling along the access road the excavation of a 20-ft diameter Valve Shaft to the lower portal. The well pad development for access to a new Valve Isolation Chamber included the excavation of 371,000 cu yd of rock where four 4-ft by 7-ft hydraulically operated by drill-and-blast methods. Project Manager: bonneted gate valves, a canopy system, sump JD Martin. Information: (970) 285-7909. pumps, a ventilation system and a bridge crane will be installed for the separation. A GEORGIA stair and elevator system will be installed in Atlanta the 320-ft deep shaft along with an access West Area CSO building at the surface after the chamber is Atlanta CSO Constructors completed. The existing wet well for the The West Area CSO Storage Tunnel and existing station will be divided by construct- Pumping Station consists of 8.5 miles of 24-ft ing a new dividing wall to full height of wet finished diameter tunnel with three intakes well shaft. and a pumping station. The two sections of In addition to the valve chamber access the main tunnel will be mined using two 27-ft shaft, two 10-ft diameter utility shafts will be diameters Herrenknecht TBMs. The North excavated and lined to each of the two exist- Reader Service Number 21

June 2007 Tunnel Business Magazine 41 ing pump rooms, an additional vent shaft will performing additional work for Vulcan Project Executive: Jose Miguel Gonzalez; be constructed along with another 19-ft diam- Materials in preparation for the installation of Project Manager: Don Hockey; Project eter West Pump Room Access shaft. The new a new crusher that is the major element of the Engineers: Joaquin Fernandez, Julio Velez; access shaft will also include a stairway and new quarry development for a new TARP Job Superintendent: Denis O’Neill; Equipment elevator with an access building at the sur- reservoir. Manager: Louis Sanchez; Survey face. Each of the existing bifurcation legs will Personnel assigned to the project are the Superintendent: Jim Skura; General be isolated with stainless steel inlet and out- following: Ted Budd, Tunnel Division Superintendent: Terry Beesley; Equipment let flumes to/from the new isolation valves. Manager; Bob Rautenberg, Project Manager; Superintendent: Jim Disley. Information The existing pump rooms will be reconfig- Paul Lauricella, Safety Manager; Jack Finn, Contact: Don Hickey, (718) 321-1818. ured and upgraded for larger capacity dewa- Superintendent; Doug Heinz, Project Sponsor. tering pumps. Information: (847) 541-8200 or DHeinz@ken- New York All of the shafts have been excavated and nyconstruction.com. Water Tunnel No. 3, Stage 2 Contract 538C concreted. The access shaft to the TARP Schiavone/Frontier-Kemper/Shea JV Tunnel gives access to the existing TARP tun- KENTUCKY City Tunnel No. 3 involves excavation of nel that flows to the Pump Station. The flow is Frankfort 27,178 lf of 12-ft, 6-in. tunnel, concrete lining currently being diverted to one side of the Holmes Street Drainage Tunnel of 45, 899 lf of tunnel to a finished diameter of existing bifurcation so the new valves and Substantial completion for this 965-ft long, 10 ft, excavation and lining of nine shafts flumes can be installed and encased in the 10-ft diameter rock tunnel was scheduled for approximately 500 ft deep, installation of vacated side. Due to several unseasonable April 30, 2007. The Robbins machine per- stainless steel pipes in the shafts, and building rains and runoff, the existing TARP tunnel has formed well in the Kentucky limestone. distribution chambers at the top of the shafts. been flooded several times hampering access Operations Manager: Ross Webb; The TBM excavation was completed on into the tunnel. Concurrent with this operation Superintendent: Roger Lynch; Project Aug. 4, 2006. Tunnel forms were installed in is the required demolition of the inactive pump Engineer: John Arciszewski; Tunnel the south tunnel and the 10-ft diameter con- room followed by the installation of the new Superintendent: Frank Lynch. crete lining placement started in October TARP pumps. Crews have also been working 2006. Crews have completed the concrete lin- in the existing wet well in preparation for the MASSACHUSETTS ing of the 18,700-ft South Tunnel and are cur- division of wet well into two separate wet wells Dorchester rently in the process of moving the forms to for the new divided station. Dorchester CSO the North Tunnel. Once finished with the Personnel assigned to the project are the Shank/Barletta JV North Tunnel they will move to the East following: Ted Budd, Tunnel Division The joint venture of Shank/Barletta J/V Tunnel. Crews are starting patch and grout Manager; Mike Surman, Project Manager; was the low bidder at $140,000,000.00. J.F. work in the South Tunnel. Shafts 31B, 30B, Christian Heinz, Project Engineer; Don Shea Co. was second at $160,000,000.00. 29B, 28B, 27B and 24B have all been con- Renfro Senior Staff Engineer, Ken Dumas, The project involves the construction of structed. Shaft 25B will be completed this Safety Manager; Richard Dresser, Safety. two miles of 19-ft excavated, 17-ft finished summer and Shafts 32B and 33B will be fin- Information: (847) 541-8200 or tedbudd@ken- segment lined tunnel (one pass lining) from a ished this fall. The stainless steel pipe has nyconstruction.com. single shaft. To date the only work on the pro- been installed in Shafts 29B and 31B. The pipe ject has consisted of submittals to the owner is currently being installed in Shafts 27B, 28B Hodgkins and reviewing and ordering the TBM. and 30B. C.U.P. McCook Reservoir Information: Steve Wardwell (401) 941-1495. Excavation and final lining of five south Kenny Construction shafts is completed and shafts are turned over The $60 million C.U.P. project being built NEW YORK to subcontractor J.P Picone for installation of by Kenny Construction for the Corps of New York City final stainless steel piping and fill concrete. Out Engineers is in the final stages of completion. East Side Access of four north shafts, one shaft remains to be The project consisted of two 11.5-ft and two Dragados/Judlau JV raise bored, while slashing and concrete place- 8.5-ft ID concrete-lined tunnels approximate- This $427 million project is part of the ment operation are taking place at three shafts. ly 3,320 ft and 850 ft in length, respectively; construction program that will allow the Final contract completion is in July 2009. temporary rock plugs and concrete/steel Long Island Railroad system into the Grand Schiavone Project Manager: Anthony Del bulkheads; an 11.5-ft ID concrete-lined Central Terminal on the East Side of Vescovo; General Superintendent: Dale access shaft; a 60 ft by 100 ft underground Manhattan. It consists of 25,200 lf of 22-ft Estus; Project Engineer: Florentino Sison; chamber with a 26-ft ID access shaft approx- diameter hard rock TBM excavated tunnels. J.F. Shea Shaft Manager: Shemek Oginski; imately 340 ft deep; a 12-ft ID shaft approxi- There are four each tunnel runs – two each Shaft Superintendent: Mike Jennings; Shaft mately 320 ft deep for ventilation; six 60-in. are 7,400 lf and two each are 5,200 lf. Project Engineer: Jim Rosteck. Information: conical plug valves; four 5-ft bonneted slide The Dragados/Judlau JV has been installing (212) 564-8552. gates; 4 ft by 60 ft control (service) building the stationary horizontal conveyor along the at the ground surface; and site work includ- existing tunnel. The 36-in. Robbins conveyor NORTH CAROLINA ing excavation, site grading, utilities, mainte- will tram the muck 8,000 ft from both of the Charlotte nance of traffic plan, staging and storage TBMs’ continuous conveyors. The drill-and- Irwin Creek Relief Sewer – Contract II area and project signage. Final testing and blast assembly chambers are being excavated Bradshaw Construction Corp. operations are taking place. prior to the arrival of the TBMs. The 26-ft Bradshaw is completing 21 shafts and 15 Personnel assigned to the project are the diameter horseshoe drill-and-blast work has tunnels as part of a sewer project for following: Ted Budd, Tunnel Division begun in the portal and existing tunnels are Charlotte-Mecklenburg Utilities. The pro- Manager; Bob Rautenberg, Project being excavated 10 ft below an existing live ject, design by CDM, includes 16 tunnels Manager; Paul Lauricella, Safety Manager; subway line. This has been a challenging exca- under various roads, creeks and a railroad Jack Finn, Superintendent; Doug Heinz, vation. The SELI TBM has completed the ranged from 5 to 8.25 ft in diameter and from Project Sponsor. Information: (847) 541-8200 factory test and was disassembled to be ready 10 to 1,308 ft in length. Ductile iron pipe, 36 or [email protected]. for shipment starting in early May. The first and 54 in. in diameter, was installed and TBM should arrive onsite by June. It will be grouted in the tunnels. Subsurface conditions Chicago lowered into the tunnel and transported 9,000 ranged from alluvium to rock and mixed face MWRD McCook Haul Tunnels ft through the existing tunnel and assembled conditions above and below the groundwater Kenny Construction in the drill-blast assembly chambers. The table. Three of the tunnels were mined under The MWRD Haul Tunnel Project associat- second TBM provided by Robbins will be EPA Superfund sites, requiring extensive ed with the reservoir portion of the Tunnel and factory-assembled for the test in early July. safety measures, groundwater treatment Reservoir Plan (TARP) was awarded in The second TBM will be onsite at the end of and extraordinary spoils handling and September 2004 and is completed. Crews are August 2007. disposal procedures.

42 Tunnel Business Magazine June 2007 Tunneling techniques included hand-mine kept diving under the wet and heavy alluvial McNally/Kiewit project, took place Oct. 15 liner plate, compressed air, conventional TBM deposits. The top was supported with spiling and was dismantled and hoisted from the and microtunneling. Drill-and-blast methods boards and each liner plate was installed in shaft together with all the backup gear and were used though most of the rock and mixed unitary fashion. The upper tunnel face was completed. The tunnel has been cleaned and face conditions, including in front of the TBMs supported by breasting boards and the bench crews are mobilizing the Linabond lining through several painful reaches. Shafts for the was drilled and blasted. The 72-in. RCP car- required for the full length. tunnels ranged from 40 ft by 15 ft rectangular rier pipe was installed and blocked in three City of Columbus, Division of Sewerage to 12 ft to 26 ft diameter circular; and ranged shifts. Dewatering was accomplished suc- and Drainage — Gary Gilbert, Tanya Arsh; from 24 to 43 ft deep. Shaft supports consisted cessfully by draining the upper face and from URS (Designer) — Douglas Uhren, Tom of steel piles and ribs, hardwood lagging and sumps in the launch shaft. Some subsidence Richardson; HR Gray (Construction steel liner plate. Dewatering was accomplished occurred in a particularly sensitive reach of Management) — Robert Scott, James Joyce; successfully from sumps in the shafts. There very soft alluvial clay causing settlement at Lachel & Assoc. (Geotechnical Design) — was no damage to any of the roads, utilities or the sidewalk and curb lane of Tyvola Road. David Chapman, Glen Frank; Jay railroad related to tunneling. Traffic was not affected and repairs were Dee/Michels/Traylor JV (Contractor) — Project Manager: Eric Eisold; General completed after tunneling. Michael DiPonio, Project Manager; Jeremy Superintendent: Jerry Simon; Project Project Manager: Eric Eisold; General Theys, Project Engineer; Tim Awald, Project Engineer: Matt Exley; Other key personnel: Superintendent: Robert Welch. Superintendent. Information: (614) 491-9551. Danny Maple, Frank Jones, Jason Lytle, Billy- Joe Riner, Larry Hill. OHIO Columbus Cleveland BWOAS II Charlotte Mill Creek Contract 3 McNally/Kiewit JV Sugar Creek WWTP Pump Station Northeast Regional Sewer District This project consists of 167-in. excavated Bradshaw Construction Corp. KM&M&K JV diameter, 144-in. inside diameter concrete Bradshaw completed a 340-ft long x 112- Concrete lining to a 20-ft ID is 70 percent segment lined 13, 200 lf long excavated 60 ft in. diameter sewer tunnel under Tyvola Road complete and scheduled for completion in July. below surface. One work shaft, four access as part of a major pump station project for Shaft construction and connector sewer shafts, one interconnected structure at the Charlotte-Mecklenburg Utilities. The project installation continues. Project Manager: end. The geology is glacial clay, tills and sands was designed by CDM. Subsurface condi- Robert J. Kassouf; Project Superintendent: with boulders. The project includes 5,000 lf of tions ranged from alluvial deposits of logs Ralph Dodero. Information: (216) 651-3333. surface sewer with two each 400-ft lengths of and stumps to soft clay to silt and sand to pipe jacking included. rock and mixed face conditions below the Columbus The joint venture has completed five shafts groundwater table. Tunnel supports consist- BWARI and one work shaft (39-ft finished diameter, ed of circular steel liner plates. The tunnel Jay Dee/Michels/Traylor JV 77 ft deep with a slurry wall completed by sub- was started using a poling plate shield. This The holing through into the reception shaft, contractor Sole-tanche/Moretrench 99 ft was abandoned early as the poling plates which is also the main working shaft for the deep). A mud slab 15-ft thick was placed at the

Reader Service Number 22

June 2007 Tunnel Business Magazine 43 shaft bottom. A jet grout area 15-ft deep, 30-ft cut-and-cover tunnel including station shell, and WASHINGTON wide and 27-ft high was placed on one side of launch and receiving pits for the tunnel boring Seattle the shaft where the tunnel eye will be placed machine. Work includes utility removal, relo- Beacon Hill Tunnel and a similar jet grout area placed on another cation, support and replacement, mass excava- Obayashi Corporation side where the TBM from BWARI I will break tion, cut-and-cover tunnel and station pits, soil The TBM was re-launched in January after through into this shaft. stabilization (jet grouting, compensation walking across the station on the permanent Mining operations were restarted in early grouting), instrumentation, placement of cast- invert and is making good progress toward December 2006, after installing the in-place (secondary liner), controlled fill and the East Portal. The TBM was on pace to hole redesigned articulation seal. The TBM has site work, removal and replacement of existing through on the southbound running tunnel in completed 44 percent of the drive. The tunnel retaining walls and underpinning State Road the first part of May. The TBM will then be is currently 77 percent complete with 65 viaduct pier bents. The duration of the pro- transported and set up for re-launch on the expected completion in June of this year. ject is 1,030 calendar days. final running tunnel in July. Segment manu- Project Sponsor: Larry Lenahan; Project Work began October 2006. Items of work facturing is substantially complete. Manager: Tom Szaraz; Project Engineer: Gary currently under way include utility reloca- The SEM mining work at the station is 96 Bulla; Project Superintendent: John Herward. tion, jet grouting, CDSM wall installation, percent complete with the platform tunnels Information: Scott Lewis (614) 491-2800. site work, soldier pile and lagging, drilled and cross concourse tunnels having been com- piers and plant setup. A Herrenknecht slurry pleted in February 2007. This leaves only the Columbus TBM will be used to bore the tunnels and is ventilation tunnels left to complete. Work con- Big Walnut Sanitary Trunks Sewer Extension scheduled to be delivered at the site early tinues on waterproofing, permanent lining Site work is under way at the five shaft August 2007. concrete and utilities. sites. Shaft 4 excavation is scheduled to begin Major subcontractors currently working The 1,400 lf aerial structures work at the in May 2007. Project Manager: Robert J. include Nicholson Construction (CDSM and East Portal is substantially complete and work Kassouf; Project Superintendent: Bill slurry walls, jet grouting), Brayman continues on miscellaneous concrete and steel McFadden. Information: (216) 651-3333. Construction (drilled piers, soldier piles and erection for the Mt. Baker station. Aerial lagging) and Moretrench (dewatering). guideway work on the West Portal is under OREGON Site personnel: Asao Nomura, Project way and will be complete in September 2007. Portland Manager; Hiroaki, Deputy Project Manager; Plinth operations and rail works were to begin East Side CSO John Murray, Construction Manager; Shu in May in conjunction with final portal con- Kiewit/Bilfinger Berger (KBB) JV Mino, Project Engineer; Kenji Yamauchi, crete works. The TBM was delivered mid March 2007 Tunnel Engineer; Russ Pollard, Chief Field Major subcontractors/suppliers working and on March 23 it was officially christened by Engineer; Mike Restani, Safety Supervisor; include: Elcon (permanent electrical work), the City of Portland and KBB project staff in Al Duke, QC Manager; Randy Marnhout, Luwa (mechanical work), J. P. Francis (plumb- front of several hundred city residents. General Superintendent; William Gyofi, Shift ing), Thunderbird (temporary electrical work), Assembly of the machine and other equipment Superintendent. Information: Paul Zick, Rebar International (rebar), Technopref (pre- has progressed and the launching of the TBM Project Director (412) 246-0325. cast segments), Wisco (waterproofing) and Apex is scheduled for mid May. Steel (structural steel). The second shaft is well under way with the SOUTH CAROLINA Obayashi Job Site Personnel: Masaki completion of excavation on this 50-ft diame- Charleston Omote, Senior Project Manager; Steve ter, 140-ft deep shaft; underwater excavation Cooper Tunnel/Daniel Island Tunnel Redmond, Project Manager; Jon Kirk, was used to excavate the shaft. Crews also Affholder Business Manager; Richard Boutelle, General completed the diving operations and place- Cooper River — Excavation is complete on Superintendent; Rohit Shetty, SEM Tunneling ment of the tremie slab in April. this project for Charleston Water System. Manager; Neto Jacquez, SEM Tunneling Full production has been achieved at the Pipe placement in tunnel is 85 percent com- Superintendent; Nestor Garavelli, TBM KBB precast plant facility. More than 350 rings plete. Structure work is progressing rapidly Project Engineer; Bob Clucas, Structural (2,800 pieces) of tunnel lining have been fabri- with 60 percent of sites completed. Project is Manager; Gregg Olsen, Project Engineer; cated and stored. This casting operation is one on track for early completion. Billy Hahn, Safety Manager; Leif of the first of its kind in North America — the Daniel Island — Shaft excavation is com- Nordell, Tunnel Concrete Superintendent; use of steel fiber reinforcing for a plete and mining is going well with, the first Duke Wilhite, Surface Superintendent; permanent segment – that is all being batched TBM drive 70% complete and the second TBM Satoshi Akai, SEM Engineer; Yoshi onsite and placed by KBB crews. drive under the Cooper River at 25% com- Sawamoto, Equipment Manager; Tomo Sitework continues along the entire align- plete. This project is also ahead of schedule. Kudo, EPB Tunnel Engineer; Mat ment as future shaft locations are prepared and Operations Manager: Ross Webb; Matsumoto, Structural/Building Engineer; intermediate connection locations are readied Project Manager: John Scheite; General Brent Buzzard, Estimator. Information: Jon for both open-cut pipeline and microtunnel con- Superintendent: Ron Beesley; Structure Kirk, (206) 262-0665. struction. Project personnel are anxiously Superintendent: Harry Gajan; Project Sound Transit Job Site Personnel: Richard awaiting the arrival of the microtunneling Engineer: Jason Tuescher; Field Engineers: Sage, Deputy Construction Manager; Rick machine in May. Dan Swidrak, Rhodes Jordan; Safety Capka, Resident Engineer; Zeph Varley, Project Director: Bill Mariucci; Project Manager: Howard Jones. Station Project Engineer; Clement Wiggins, Manager: Tom Corry; Safety Manager: Paul Tunnel Project Engineer; Roger Smith, Weisheit; Quality Manager: Glen Tomack; Greer Resident Engineer Structures. Engineering Manager: Tony O’Donnell; Site Bushy Creek Trunk Sewer-Tunnels and Shaft Manager: Scott Wimmer; Tunnel Bradshaw Construction Corp. Brightwater Conveyance System — East Manager: Christof Metzger. Information: (503) The project consists of two access shafts and Kenny/Shea/Traylor JV 290-7000. two 120-ft long by 96-in. rock tunnels. The tun- King County awarded the Brightwater nels are being excavated by drill-and-blast and Project to the joint venture of Kenny PENNSYLVANIA lined with steel liner plate per South Carolina Construction (sponsor)/J.F. Shea Co. and Pittsburgh Department of Transportation specifications. Traylor on Dec. 29, 2005, after a lengthy Pittsburgh Light Rail Tunnels The carrier pipe consists of 60-in. ductile iron protest by the second bidder, Jay-Dee/Coluccio North Shore Constructors JV pipe. Both tunnels were excavated and the car- JV. The mobilization for the $130,848,700 pro- Work by the JV of Obayashi and Trumbull rier pipe installed at end of 2006. ject got under way in February 2006 after the includes construction of 2,200 lf twin tube Project Manager: Eric Eisold; Project Jan. 30, 2006, notice to proceed. The scheduled 20-ft inside diameter bored pre-cast lined Superintendent: Frank Jones. Information: completion date is Aug. 28, 2009. The project is tunnels underneath the Allegheny River, (410) 461-4466. in both King and Snohomish Counties.

44 Tunnel Business Magazine June 2007 It is the first of the major projects sched- (2,500 lf of which has a secondary lining of 10 Hiro Uchida, Tunnel Engineer; Andrew Cook, uled by King County to complete the ft diameter piping), 540 ft of 60-in. microtun- Health and Safety Officer; Bill Austell, Brightwater System. The East Contract con- neled effluent sewer, one portal structure for Microtunnel Manager; Renee Halley, Office sists of the following major elements: 14,050 ft launching the EPB TBM and a sampling facil- Manager. Information: (206) 542-2865. of 18-ft, 10-in. EPB TBM mined tunnel using ity with structural, mechanical, electrical, pip- 16-ft, 8-in. ID bolted and gasketed precast ing, landscaping and instrumentation work. Brightwater Conveyance System – Central concrete segments for a primary liner; The project duration is 49 months with com- Vinci/Parsons/FKCI JV installing and grouting 14,200 ft each of 48-, pletion scheduled for March 2011. On July 24, 2006, the joint venture of Vinci 66-, 27- and 84-in. diameter pipes inside the Currently the JV is set up near the site in Construction Grands Projects, Parsons and tunnel along with three runs of fiber optic temporary offices and involved in submittals and Frontier-Kemper was awarded a four-year, cable; 2,430 ft of 72-in. diameter microtunnel project planning. No work has started on site $210 million contract with King County for including three shafts and structures; one but is scheduled for May or June to begin site the Brightwater Central Conveyance Tunnel. intercepting structure (IS) to mine from that mobilization. A Lovat EPB TBM is being manu- Work includes 11,600 lf of 14.33-ft diameter is 74 ft deep and 80 ft in diameter with 130 ft factured for the tunnel drive and scheduled for segmentally lined tunnel between the North deep slurry diaphragm walls, tremie slab and delivery in March 2008. The concrete segments Kenmore Shaft and the North Creek Shaft, final concrete wall lining; one influent pump will be fabricated by CSI/Hanson JV in Tacoma, and 21,100 lf of 14.33-ft diameter segmentally station shell (IPS) 83 ft deep, twin 84-ft inside Wash. All 21,100 lf of tunnel will be from the lined tunnel between the North Kenmore diameter cells, with 160-ft deep slurry shaft portal at Point Wells in Richmond Beach, Shaft and the Ballinger Way Shaft. The pro- diaphragm walls, tremie slab and final lining; very close to the shoreline of Puget Sound. ject also includes 3,400 lf of 3-ft to 5-ft inter- two short 12-ft diameter connector tunnels; Major subcontractors include Delta Technology ceptor work constructed by microtunneling one extraction shaft 40-ft deep by 40-ft wide Corp for HVAC, J.P. Francis & Associates for and cut-and-cover methods. The JV will also and 140-ft long for connection to new treat- plumbing and mechanical, and United States construct the North Kenmore Shaft 54-ft in ment plant piping. Electrical Corp. for both permanent and tempo- diameter and 90-ft deep, and the Ballinger The site utilities and screen/sound wall rary electrical work. Way Shaft 28-ft in diameter and 200-ft deep. fence were completed and the slurry wall con- Project staff includes: Thomas S. DiPonio, The JV will use mixed slurry (slurry and struction for the IS shaft was completed by Managing Partner; Greg Hauser, Project compressed air) TBM, a first for FKCI and Bencor Corp. in spite of a six-week setback Manager; Thomas McMahon, General rarely used in North America until just due to an operator’s strike against the ready- Superintendent; Glen Frank, Project Engineer; recently, but a popular technology in Europe. mix concrete suppliers in King County. Mina Shinouda, Assistant Project Engineer; Maximum operating pressures is expected to Bencor has since completed the binocular twin 84-in. diameter shafts and center wall for the IPS shaft using 160-ft deep by 48-in. thick panels The IS shaft excavation was completed and the 13-ft thick, 2,600 cu yd concrete tremie plug installed. The shaft has been excavated and the lower half of the shaft lined back to final diameter with all the portals installed. Northwest Boring is currently assembling the microtunnel equipment for the first drive out of the IS shaft. The receiving shaft for the first microtunnel drive is complete (80-ft deep caisson) and the second caisson is nearly complete for the second drive. The microtunnel drive from the IS (mining) shaft must be completed before the 19-ft, 4-in. diameter Lovat EPB TBM can be assembled in the same shaft. Delivery of the Lovat TBM is currently scheduled for June 2007. Personnel: Ted Budd, Tunnel Division Manager; John Kennedy, Project Manager; Jake Taylor, Project Engineer; Luminita Calin, Cost and Schedule Manager; Tony Huphauf, QAQC Manager; Mark Saylor, Division Equipment Manager; Rich Mascarello, Site Equipment Manager; Mickey Aliff, General Superintendent; Dale Wold, Electrical Superintendent; Terry Walls, Warehouse Manager; Mike Sarlitto, Safety Manager; Austin Cooney, Home Office Sponsor. Information: (847) 541-8200, tedbudd@kenny- construction.com or jmkennedy@kennycon- struction.com.

Brightwater Conveyance System — West Jay Dee/Coluccio/Taisei JV A joint venture of Jay Dee (sponsor), Coluccio and Taisei is the general contractor for the construction of the Brightwater West Contract for owner King County. The project was bid in October 2006, awarded in January and notice to proceed issued Feb. 20. The project consists of approximately 21,100 lf of 13-ft diameter segment lined tunnel, constructed with an EPB TBM Reader Service Number 23

June 2007 Tunnel Business Magazine 45 be just greater than 5 bar. To retrieve one of Manager; Chuck Hartman, Warehouse refurbished in the Evansville shops of the TBMs, the Ballinger Way Shaft (200-ft Manager; Rich O’Neil, Survey Manager; Matt Frontier-Kemper together with an entirely deep and 30-ft in diameter) will be constructed Hadaway, Site Safety Manager; new backup system and delivered to the site using the freezing technique. The other TBM Phil Harris, Austin Cooney, Home Office and assembled in March 2007 and excavation will be retrieved from the existing North Sponsors. Information: (847) 541-8200, commenced late March. Creek Shaft upon completion of its drive. To [email protected] ora- Personnel: Serge Moalli, Project Manager; date, most major subcontracts and equipment [email protected]. Roger Blankenship, General Superintendent; purchase agreements have been executed. Jonathan Prenger, Project Engineer; Richard Construction of the drilled shaft walls for the Milwaukee Olason, Business Manager. Information: Dave microtunneling jacking pit is complete. The Harbor Siphons Project Rogstad, (812) 426-2741. TBM launch shaft slurry walls are nearing Shea/Kenny JV completion and installation of the cut-and- This project for the Milwaukee Vancouver cover sewer is under way. Metropolitan Sewerage District consists of Seymour-Capilano Information: Dave Rogstad, (206) 766-8106. approximately 2,100 ft and 2,400 ft of 17-ft Bilfinger Berger horseshoe drill-and-blast tunnel, with two 20- The first TBM, the “Seymour TBM,” was WISCONSIN ft drop shafts and one 30-ft riser shaft. set up in the Raw Water Tunnel, which is the Milwaukee The Jones Island shaft has been sunk to the southernmost of the two tunnels. The Elm Road Generating Plant – Cooling Water tunnel invert. The AB and EH tunnels have Seymour TBM commenced Phase 1 on June Intake System been started. These will be drilled and shot. 1, 2006, and stopped after 136 m for a sched- Kenny Construction Co. The AB Tunnel has 2,200 lf to complete and the uled stand down in late July to allow installa- The project is a design-build subcontract EH Tunnel has 1,869 lf to complete. The shaft tion to commence of the second TBM, the for Bechtel Corp., which is the lead contrac- freezing for Jones Island has now been turned “Capilano TBM,” in the Treated Water tor for the $2 billion plant for WE Energies off. The Scott and Barclay Street Shaft is into Tunnel (Wisconsin Electric) consisting of a lake the rock and has 75 lf to go to tunnel invert. TBM #1 Raw Water Tunnel – The third water intake tunnel excavated in rock The shaft freezing at this site is also complete. and final stage of TBM installation complet- approximately 9,200 ft in length, 27-ft, 4-in. in The Erie Street shaft has been grouted and the ed. Excavation has proceeded to 1+633 m diameter of which 930 ft is to be lined to a fin- freeze pipes have been installed. Two of the from Seymour Shaft. Ground support instal- ished diameter of 25 ft. Also included are two nine cells have been completed in the harbor lation to date has been minimal (occasional land-based upshafts at 25-ft and 18-ft fin- and are ready for backfill. spot bolting and shotcreting). Water inflows ished diameters as well as a temporary con- Personnel: Martin (Dutch) Vliegenthart, into tunnel are close to projected from struction shaft at 30 ft in diameter. In addi- Vice President; Carl Christensen, Project detailed design borehole transmissivity tion, there are four offshore water intake Manager; Bonnie Senkowski, Office Manager; results. Two small water-bearing features shafts, 12 ft in diameter, along with ancillary Jerry Straube, Structure Superintendent; were grouted in April 2007. TBM progress is intake piping. These shafts are 8,000 ft out in Darrell Vliegenthart, Shaft Superintendent. below schedule due to equipment issues. Lake Michigan. Information: (414) 258-2510. TBM #2 Treated Water Tunnel — Marine crews have completed the drilling Completing third and final stage of TBM and the installation of the vertical piping in Milwaukee installation. The TBM and backup system the four drilled intake shafts. Dredging and North 27th Street Extension are now 1 + 128 m from the Seymour Shaft. installation of manifold piping is taking place Shea/Kenny JV Ground support installation to date has been when the weather permits. This will be fol- A joint venture of Shea/Kenny has been minimal (occasional spot bolting and shot- lowed by the installation of the intake screens awarded the Inline Storage System, North creting). One small water-bearing feature to complete at least two of the shafts to fill 27th Street ISS Extension, Contract was grouted in November 2006. The TBM the tunnel for test water for the new plant. #C05023C01 that had previously been award- progress is below schedule due to equipment The overburden excavation using a 32-ft ed to Affholder. Information: (414) 258-2510. issues. ID caisson to the rock (80 ft deep) for the first Pipe Supply — Steel pipeline contract of three land-based shafts was completed and CANADA awarded to North West Pipe Company for the rock drilled and shot to the top of the tun- British Columbia $33.6 million Canadian September 2006. The nel and TBM erection chamber. The 200-ft Brackendale pipe will be installed on surface, in shafts and deep shaft was lined followed by the drilling Ashlu Creek Hydro Project at each end of both tunnels. The center por- and shooting of the 30-ft horseshoe erection Frontier-Kemper tion of tunnels (approximately 5 km) will be chamber. The 27-ft, 4-in. diameter TBM was The Ashlu Creek contract is a design- unlined. The project requires up to 4,800 m erected and completed mining in early March build-operate-transfer, run-of-the-river of 3-m internal diameter pipe of between 12 2007. The tunnel has been cleaned and the hydroelectric project. It consists of an upriv- mm to 50 mm wall thickness. The delivery of TBM is currently being cycled back to the er diversion weir, drop shaft, transfer tunnel first pipes is scheduled for December 2007. work shaft for final disassembly and removal. and downriver powerhouse. The weir diverts Vancouver Water District (GVWD) invited The dredging operation in the intake chan- the part of the river into the drop shaft and the tenders, Greater Vancouver Regional nel was completed and followed by steel sheet- tunnel, which then conveys the water 4.3 km District (GVRD) provided supervising engi- ing work in the existing inlet channel that is downstream to a powerhouse, and is finally neers. The project manager is Pacific Liaicon also complete. The excavation for the dyke discharged back in to Ashlu Creek. Frontier- & Associates Inc., a subsidiary of SNC wall construction had to be halted due to fail- Kemper’s portion of the work includes the Lavalin. Design and CM Engineer is Hatch ure of a cofferdam. A remedy has been design and construction of a 130-m deep raise Mott MacDonald (HMM). The tunnel con- designed and the excavation is scheduled to bored shaft and boring 4.3 km of 4.1-m diam- tractor is Bilfinger Berger (Canada) Inc. continue. The second land-based shaft over- eter power tunnel. After a two-year delay, the (BBC). burden utilized a cast-in-place caisson that Provincial Government of British Columbia Personnel: GVRD — Tom Morrison, was landed on rock. The rock portion of the has resolved the land use dispute with the Senior Project Engineer Tunnels; Doug shaft to the tunnel was drilled and blasted. local regulatory body. The developer of the Neden, Manager Water Treatment Personnel: Ted Budd, Tunnel Division project, Ashlu Creek Investments (an Engineering; Goran Oljaca, Senior Engineer. Manager; Paul McDermott, Project Manager; Innergex and Ledcor partnership) issued PLA — Andy Saltis, Area Manager Tunnels; Jon Isaacson, Project Engineer; Tom Frontier-Kemper Constructors a notice to Jeff Spruston, PM; Brian Gardner, Project Plinke, QAQC Manager; Mike Smithson, D/B proceed in August 2006. Mobilization started Director/VP Project Services; HMM — Dean Coordinator; Mark Saylor, Equipment in December 2006. Brox, RE; Joe Rotzien, ARE; Geology — Manager; Joe Johnson, Electrical A 30-m long starter tunnel was excavated Golder as sub to HMM, Grant Bonin; BBC — Superintendent; Tom Peterson, TBM by drill-blast under a subcontract by a local Christian Genschel, PM; Joseph Messner, Specialist; Dave Kuepper, Site Equipment contractor. The Wirth TBM was completely CM. Information: (604) 982-3197.

46 Tunnel Business Magazine June 2007 tunnelingonline.com Web Directory

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Reader Service Number 102 Events Calendar June 2007 10-13 RETC, Toronto, SME, Ph: (303) 973-9550; Fax: (303) 979-3461; E-mail: [email protected]

October 2007 11-13 32nd Annual Conference on Deep Foundations, Washington, D.C., Deep Foundations Institute Ph: (973) 423-4030; Fax: (973) 423-4031 16-19 ICUEE 2007, Louisville, Ky, Ph: (800) 867-6060; Fax: (414) 272-2672; E-mail: [email protected]; Web: www.icuee.com

September 2008 22-27 ITA-AITES World Tunnel Congress 2008, New Delhi, India, ITA, Reader Service Number 26 Web: www.ita-aites.org

June 2007 Tunnel Business Magazine 47 Classifieds

Outside Technical Sales Representative Microtunnel Operator Mid-Atlantic & northeast tunneling, utility and transportation contractor has immediate full time position American Commercial, Inc. offers solutions to civil, foundation and for microtunnel and TBM operator. Experienced candidate must possess extensive experience and under- standing of the microtunneling process. Experience in other types of tunneling and shaft construction is a mining applications and is currently seeking additional experienced, plus. Candidate should possess leadership qualities, desire to work as part of a team and be willing to self motivated Outside Sales Representative to cover various territories. travel the east coast. Salary, transportation and full benefits package commensurate with experience and Responsibilities will be to continually develop and increase sales of knowledge. Relocation costs reimbursable. E-mail resume or C.V. to [email protected]. tunnel and shaft support systems plus a comprehensive range of foundation and slope stabilization equipment including grouting and concreting systems to new and existing customers. Ad Index Advertiser ...... Page ...... RS # Akkerman ...... 25, 37 ...... 13, 103 Requirements: Alpine Sales & Equipment Corp...... 43 ...... 22 American Commercial ...... 3 ...... 2 • Technical knowledge of civil applications, foundation drilling or ARUP ...... 29 ...... 20 tunneling Barbco, Inc...... 47 ...... 102 Benjamin Media Webinars ...... 35 ...... 18 • Proven sales record preferably within the construction industry Bradshaw Construction Corp...... 21 ...... 10 • Excellent communication and presentation skills Brierley Associates LLC ...... 9 ...... 6 Cellular Concrete ...... 31 ...... 16 • Participate in marketing events such as industry trade shows ChemGrout ...... 47 ...... 26 • Proficient in MS Office Suite (Word, Excel) Gilco Group Inc...... 49 ...... 50 Great American Group ...... 15 ...... 8 • Applicants must be authorized to work in the United States & Herrenknecht Tunnelling Systems USA Inc...... 2 ...... 1 travel overseas HOBAS Pipe USA ...... 47 ...... 100 Huxted Tunneling ...... 47 ...... 101 Icon Equipment Distributors, Inc...... 11 ...... 7 Insitu Contractors Inc...... 49 ...... 27 In return we offer a competitive salary, benefits package, and oppor- Jacobs Associates ...... 41 ...... 21 tunity for development and advancement. Messinger Bearings ...... 33 ...... 17 Moretrench American Corporation ...... 27 ...... 14 Mail or fax resume to: Nicholson Construction Co...... 23 ...... 11 No-Dig Sewers Without a Trench ...... 49 ...... 51 Pacific International Grout Co...... 45 ...... 23 Kathy Carrier Palmieri USA ...... 49 ...... 55 American Commercial Inc. Parsons Brinckerhoff ...... 52 ...... 25 Rocscience, Inc...... 13 ...... 5 200 Morrison Blvd. Ruen Drilling Inc...... 23 ...... 12 Bristol, VA 24201 Sekisui SPR Americas ...... 7, 49 ...... 4, 52 Shaft Drillers International ...... 49 ...... 53 FAX: 276-466-1865 Shimahara Illustration ...... 39, 49 ...... 15, 54 email: [email protected] Stein Books Ad ...... 19 ...... 9 The Robbins Co...... 5, 47 ...... 3, 104 Wholesale Mine Supply, LLC ...... 51 ...... 24

48 Tunnel Business Magazine June 2007 Business Cards

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June 2007 Tunnel Business Magazine 49 My Turn

Second Edition of the GBR Yellow Book Is Here By Randall J. Essex

It’s been 10 years since the publica- and the effort of preparing a second participants, guided the preparation tion of the Underground Technology edition was begun. of the final manuscript. That docu- Research Council’s (URTC’s) “Yellow Working with Bart Bartholomew, ment was then subjected to a final Book,” which covers the topic of who chaired the 2004 workshop in review by the Technical Committee, Geotechnical Baseline Reports (GBRs) Atlanta, the author sought members the Executive Committees of the for underground construction. As with for this new Technical Committee on Underground Technology Research other industry practices, there is Geotechnical Reports that would Council and the ASCE’s Construction value to “keeping the pendulum represent a cross-section of owners, Institute. swinging” through open discussion engineers, contractors, dispute reso- In addition to extensive editing, the and the dissemination of new ideas, lution professionals and the legal second edition contains a new and that is what is currently happen- community. The initial charge of the dedication (to James P. Gould) and ing with the impending release of an Committee was to understand the new chapters addressing: the applica- updated Yellow Book. over-riding conclusions that were tion of GBRs within a Design-Build The debate on GBRs has been a agreed at the 2004 workshop, appreci- contracting framework; the applica- spirited one, possibly because there is ate the controversial topics that tion of GBRs for subsurface excava- no silver bullet solution that cuts remained, and then capture these tions other than tunnels and shafts; through all interpretations and dis- perspectives through revisions and and lessons learned derived from the putes and certainly because Mother additions to the first edition. two workshops in 2004 and 2006. Nature will always be subject to multi- As for the first edition, the Comm- As a Committee, we’ve worked long ple interpretations. The one point for ittee felt that a key element in the and hard over the last 24 months sure in the underground business is process was a second industry trying to make this publication a that there will always be room for a workshop where practitioners could worthy second edition to its predeces- better approach to managing risk. provide review comments on a draft sor. The Second Edition, entitled At the moment, the GBR, through manuscript. The Committee’s work Geotechnical Baseline Reports for which parties to a contract agree would then conclude with the Construction — Suggested Guidelines, to share certain risks for subsurface incorporation of comments into a final will be available for sale at the Rapid conditions, appears to be a workable manuscript. Excavation and Tunneling Conference approach. The challenge is to Working through 2005 and into in June in Toronto. If you like what capture the practice — good, bad or 2006, the Committee met its goal of you see, feel free to give us a shout. If otherwise — and share the knowledge. hosting a second industry workshop you don’t, that’s OK too — the pendu- Unfortunately it takes a while for last June at the North American lum will continue to swing. tunnel projects to be designed, bid Tunneling Conference in Chicago. A and constructed, and for any disputes transcript of the workshop proceed- Randall J. Essex, P.E., is Chairman of that may have arisen to be resolved. ings, as well as written comments the UTRC Committee on Geotechnical As a result, the pendulum of our offered by a number of workshop Reports. business swings slowly. Seven years following the initial publication of the Yellow Book, an industry workshop on GBRs was held in conjunction with the North American Tunneling Conference in Atlanta in 2004. The purpose was to explore those aspects about GBRs that were and were not working and attempt to work toward resolving differences of opinion that existed among practitioners. The motivation for a second edition grew from that day-long workshop. The audience was virtually unanimous that a second edition of the Guidelines publication that captured the topics of the day was Committee Members: Back Row: Bob Fitzgerald, Bart Bartholomew, Joe Sperry, Dan Meyer, warranted. Later in the fall and Jim Monsees, Jim Morrison, Ron Heuer, Steve Klein. Front Row: Bob Pond, Randy Essex, winter, a committee was assembled Pete Douglass. Not present: Rich Switalski.

50 Tunnel Business Magazine June 2007 Reader Service Number 24 Reader Service Number 25