High Speed Railway Systems

ENGINEERING AND CONSTRUCTION PROJECT REFERENCES HIGH SPEED RAILWAY SYSTEMS

HIGH SPEED RAILWAY SYSTEMS 04.2012

eople, Skills, Equipment. eople, Skills,

P saipem.com - A subsidiary of Eni S.p.A. Tel. +39.02.520.1 - Fax +39.02.520.44415 Via Martiri di Cefalonia, 67 - 20097 San Donato Milanese, Milan - Italy Saipem S.p.A. HIGH SPEED RAILWAY SYSTEMS

INDEX

SAIPEM TODAY 4

SAIPEM ENGINEERING & CONSTRUCTION 6

THE HIGH SPEED RAILWAY SYSTEM IN ITALY 8

INFRASTRUCTURES CENTER OF EXCELLENCE IN MILAN 10

THE MILAN-BOLOGNA HIGH SPEED RAILWAY LINE: AN ENORMOUSLY COMPLEX PROJECT 12

THE HIGH SPEED RAILWAY PROJECT: AN EXAMPLE OF COMPLEX AND INTEGRATED INFRASTRUCTURAL ACTIVITIES 14

MILAN-BOLOGNA RAILWAY SYSTEM 16

A JOURNEY ALONG THE RAILWAY TRACK, FROM MILAN TO BOLOGNA 22

THE NEXT CHALLENGE: THE HIGH SPEED RAILWAY MILAN-VERONA 46

MILAN–BRESCIA RAILWAY SECTION 48 3 SAIPEM TODAY SAIPEM TODAY IS A WORLD LEADER IN THE GLOBAL SUPPLY OF ENGINEERING, PROCUREMENT, PROJECT MANAGEMENT, CONSTRUCTION AND DRILLING SERVICES WITH DISTINCTIVE CAPABILITIES IN THE DESIGN AND EXECUTION OF LARGE-SCALE OFFSHORE AND ONSHORE PROJECTS.

Saipem has a strong bias towards oil and gas frontiers, namely activities in harsh and remote areas, in deep waters as well as in extremely cold and hot environments, applying significant technological competences in many diverse fields such as gas monetization and heavy oil exploitation.

Saipem is organized in two Business Units: Engineering & Construction and Drilling.

4 5 SAIPEM ENGINEERING & CONSTRUCTION FOLLOWING AN AGGRESSIVE GROWTH STRATEGY, WHICH INCLUDED IN THE LAST DECADE THE ACQUISITION OF MANY CONSTRUCTION, TECHNOLOGY AND ENGINEERING COMPANIES, MOST PROMINENTLY OF SNAMPROGETTI, BOUYGUES OFFSHORE, SOFRESID AND MOSS MARITIME, SAIPEM HAS BECOME ONE OF THE WORLD LARGEST AND MOST COMPLETE ENGINEERING AND CONSTRUCTION COMPANIES IN THE GLOBAL OIL AND GAS MARKETS, ONSHORE AND OFFSHORE.

6 SAIPEM ENGINEERING & CONSTRUCTION

Ever since its initial steps in the fifties and numerous project execution installation; also revamps, upgradings, as the construction division of Snam, centres around the globe, and with maintenance, decommissionings, the pipeline company of the Eni Group yearly revenues exceeding 10 billion €/y; reclamations and decontaminations. in Italy, Saipem has pursued all held together by outstanding project a systematic growth strategy, based management skills. Saipem today operates in virtually every on the development of internal assets, world market, often in remote locations expertise and skilled resources, as well Through the involvement of our global with harsh environmental conditions as on the acquisition of other players EP(I)C hubs in Milan, Rome and Fano and challenging logistics, leveraging with their own asset bases, such as (Italy), P aris (France) and Chennai on its proven experience across the Micoperi in late eighties, and many (India), which operate in connection most significant product lines in the others. with a growing number of medium size oil and gas production onshore, and smaller regional engineering offshore, in deepwater; gas and oil In the last decade, Saipem has and project execution centres transportation via offshore and onshore continued its growth by acquiring employing altogether over 7,000 pipeline systems; midstream, refining, Bouygues Offshore and Sofresid in engineers, Saipem balances high chemicals, power generation from fossil France, Moss Maritime in Norway, IDPE project execution quality with a as well as from renewable sources; in India and Snamprogetti in Italy, competitive cost and - most importantly environmental industries, maritime and by carrying out a multibillion - with a major emphasis on local works and infrastructure. investment program into the expansion know-how and content. of its offshore construction and drilling This new series, therefore, outlines fleets. Since the year 2000, Saipem’s This well-integrated multicenter Saipem’s integrated references market capitalization has grown more approach provides a consistent design in engineering and construction than sixfold and its revenues tenfold.(*) and robust execution philosophy markets offshore and onshore, on all our projects worldwide. according to individual business The organizational integration of Top priority is provided throughout and technology lines. this considerable asset base, namely to all HSEQ aspects. the network of engineering centres, fabrication and support yards in several Saipem therefore offers a complete continents as well as the offshore range of project definition construction fleet, has been completed and execution services, offshore gradually over the years - most recently and onshore, particularly for with the creation of a unified Business the complex “mega-projects” required Unit Engineering & Construction, by the market today: from feasibility an entity with over 30,000 employees and conceptual studies to complex (excluding corporate and BU Drilling integrated solutions combining design, staff) from over 100 nationalities, engineering, procurement, field with over 60 permanent establishments construction, fabrication and offshore

(*) Until Dec. 31, 2010 7 THE HIGH SPEED RAILWAY SYSTEM IN ITALY WITH THE ADVENT OF HIGH SPEED RAILWAYS IN EUROPE, A NATIONAL PROGRAM WAS INAUGURATED IN 1977 UNDER THE AUSPICES OF THE ITALIAN GOVERNMENT TO DEVELOP A HIGH SPEED RAILWAY SYSTEM FOR RFI (RETE FERROVIARIA ITALIANA), A COMPANY OF FS (FERROVIE DELLO STATO GROUP).

Within the context of that program, For the Milan-Verona (142 km) track, Snamprogetti – subsequently integrated the legal entity “Consorzio Cepav into Saipem – has been assigned two Due” (Saipem, Condotte d’Acqua, tracks under an Eni financial guarantee: Maltauro, Pizzarotti) completed the Front End Design. Milan-Bologna (182 km), was In April 2011 the construction designed and built by Saipem in a activities have been started with the JV with Italian civil E&C companies contract signature between the (Consorzio Coperative Costruzioni, JV / Consortium Cepav Due and Rete Grandi Lavori-Fincosit, Pizzarotti). Ferroviaria Italiana (RFI). This legal entity was named “Consorzio Cepav Uno” under a The Milan-Turin, the Bologna-Rome mixed contractual scheme including and the Rome-Naples rail tracks both JV and consortium elements. were assigned to other national E&C The Milan-Bologna railway track companies. The earliest high speed was built starting in the year 2000 track, Rome to Florence (254 km) had and completed and inaugurated in been completed in 1977, using the December 2008. technologies available at that time.

8 Trento Trieste Aosta Milano Padova LEGENDA Verona Saipem Cepav Uno Project Venezia Saipem Cepav Due Project Torino Other High Speed tracks Genova Other High Speed tracks Bologna under construction Firenze Ancona Perugia

L’Aquila Roma Campobasso

Napoli Bari Potenza

Cagliari Catanzaro

Palermo

9 INFRASTRUCTURES CENTER OF EXCELLENCE IN MILAN SAIPEM HAS DEVELOPED COMPLETE IN-HOUSE CAPABILITIES TO DESIGN AND MANAGE THE LARGEST AND MOST COMPLEX INTEGRATED INFRASTRUCTURAL PROJECTS.

The staff dedicated to this business line includes more than 100 people in Engineering, Construction and Project management services, covering the main specialized diciplines:

Geometric alignment, soil modelling and hydraulic systems.

Geotechnics and structural modelling.

Underground special works.

Environmental mitigation.

Plant technology systems.

Construction services.

Project management services.

Logistics and transport systems.

10 Saipem Infrastructures Operations offices in San Giuliano Milanese, very close to Saipem’s headquarters in San Donato Milanese (Milan, Italy).

11 THE MILAN-BOLOGNA HIGH SPEED RAILWAY LINE: AN ENORMOUSLY COMPLEX PROJECT HIGHLIGHTS:

182 km long high speed railway track. Maximum speed of 300km/h. Single EPC contract, worth more than 6 billion e with Treno Alta Velocità SpA, an RFI company dedicated to the development of the High Speed Railway System in Italy. Saipem has been the Leader of “Consorzio Cepav uno” (Saipem, Consorzio Coperative Costruzioni, Grandi Lavori-Fincosit, Pizzarotti). First application of ERTMS (European Rail Traffic Management System) level 2 signalling system in Europe, implemented in partnership with Saturno Consortium (ABB, Alstom, Ansaldo, Balfour Beatty Rail, Sirti) for Power Line, Substations and Signalling Systems. Complete system inaugurated on December 13, 2008. The scope of Work for “Consorzio Cepav Uno” had been to design, build, install, commission and start up the full railways line with a “lump sum/turn key” contractual scheme.

12 13 PUBLIC SERVICES INTERFERENCES RESOLUTION ROADS & HIGHWAYS ENVIRONMENTAL MITIGATION

RAILWAY SYSTEMS BRIDGES

BUILDINGS

RESIDENTIAL CAMPS AIRPORTS

VIADUCTS

PUBLIC SERVICES ROADS INTERFERENCES RESOLUTION & HIGHWAYS ENVIRONMENTAL MITIGATION RAILWAY SYSTEMS BRIDGES

RESIDENTIAL CAMPS BUILDINGS

THE HIGH SPEED RAILWAY AIRPORTS PROJECT: AN EXAMPLE OF COMPLEX AND INTEGRATED VIADUCTS INFRASTRUCTURAL ACTIVITIES THE HIGH SPEED RAILWAY PROJECT ILLUSTRATED IN DETAIL IN THIS BROCHURE IS A GREAT EXAMPLE OF A MAJOR EXTENSIVE INFRASTRUCTURAL PROJECT, WHICH INCLUDES A SIGNIFICANT SET OF COMPLEX PUBLIC SERVICES AND INTEGRATED ACTIVITIES, WAY BEYOND INTERFERENCES RESOLUTION THE MAIN FOCUS ON DESIGNING AND ROADS BUILDING THE RAILWAY SYSTEM ITSELF. & HIGHWAYS ENVIRONMENTAL MITIGATION One of the main reasons for the complexity of this Railway project was the track positioning in a relatively densely populated area along the RAILWAY SYSTEMS Milan-Bologna highway. RESIDENTIAL CAMPS

This required: Relocation of vital public services, such as schools, buildings, etc. Re-stitching and rearranging the connection of many transversal roads, including the repositioning of certain sections of the 200 km long Milan-Bologna 6 lanes motorway, BUILDINGS since the motorway is adjacent to the railtrack for 75% of its length. BRIDGES

In addition: A complex environmental mitigation AIRPORTS of the scar caused by the new railway line. A number of bridges over many roads, other railways and particularly waterways, including the Italian longest river Po. VIADUCTS Throughout, the reduction of the project’s visual impact on the territory, to the extent this was possible, was one of the main design objectives. 14 PUBLIC SERVICES INTERFERENCES RESOLUTION ROADS & HIGHWAYS ENVIRONMENTAL MITIGATION

RAILWAY SYSTEMS BRIDGES

BUILDINGS

RESIDENTIAL CAMPS AIRPORTS

VIADUCTS

PUBLIC SERVICES ROADS INTERFERENCES RESOLUTION & HIGHWAYS ENVIRONMENTAL MITIGATION RAILWAY SYSTEMS BRIDGES

RESIDENTIAL CAMPS BUILDINGS

AIRPORTS

VIADUCTS

PUBLIC SERVICES INTERFERENCES RESOLUTION ROADS & HIGHWAYS ENVIRONMENTAL MITIGATION

RAILWAY SYSTEMS RESIDENTIAL CAMPS

BUILDINGS BRIDGES AIRPORTS

VIADUCTS

15 MILAN-BOLOGNA RAILWAY SYSTEM CONSTRUCTION DETAILS: 50 DIFFERENT PRODUCTION SITES. MORE THAN 40,000,000 CONSTRUCTION MANHOURS PERFORMED. 3,150 WORKERS EMPLOYED, ON THE AVERAGE. A MANPOWER PEAK OF 4,800 WORKERS. OVER 450,000 TONS OF STEEL UTILIZED.

16 Bulk Materials Utilized [M.cu.m.]

Concrete Bitumen Aggregates Aggregates Aggregates for Embankment for Concrete for Ballast

Main Lengths [km]

300

250

200

150

100

High Speed Relocated Traditional Embankments Artificial Interchanges Railroad Railway Line /New Rail Road and Tunnels between High Viaducts Roads Tracks Cuttings Speed and Traditional Tracks Systems

17 Impact on the Territory Land Usage (M.sq.m.)

Expropriation [m2] Temporary Land Occupation for Yards and Diversions [m2]

• Expropriated more than 90,000 incompatible buildings • More than 1,100 pieces of equipment were working simultaneously on the project during 5 years of peak operations

Geographical Distribution of 450 Contracts or Agreements with Individual Stakeholders

150

120

Milan Lodi Piacenza Parma Reggio Modena Bologna Emilia

• More than 1,500 service items to be relocated along the route • Managed 58 different stakeholders: Municipalities, Public Service Entities, etc.

18 19 20 Engineering & HSEQ Documents Production

80,000

70,000

60,000

50,000

40,000

30,000

20,000

10,000

Project Documents HSE Documents Quality Documents

Environmental Tests during Construction, by 60 Independent Laboratories

10,000

8,000 80000

700006,000

60000 4,000 50000

400002,000

30000 0 20000 Environmental Measurement Environmental Preservation Inspections Campaigns on Working Places 10000

Project Documents HSE Documents Quality Documents

21 A JOURNEY ALONG THE RAILWAY TRACK FROM MILAN TO BOLOGNA THIS 182 KM JOURNEY WILL TAKE US THROUGH: 2 REGIONS (LOMBARDY AND EMILIA ROMAGNA). 8 PROVINCES. 44 MUNICIPALITIES.

Milano Melegnano Interchange

Lodi Piacenza West Interchange Piacenza East Interchange Piacenza Fidenza Interchange Parma Interchange Modena West Interchange Parma Modena East Interchange Modena Lavino Interchange Bologna

22 Milano Melegnano Interchange

Lodi Piacenza West Interchange Piacenza East Interchange Piacenza Fidenza Interchange Parma Interchange Modena West Interchange Parma Modena East Interchange Modena Lavino Interchange Bologna

23 MELEGNANO INTERCONNECTION BETWEEN THE HIGH SPEED AND THE TRADITIONAL LINES

Built through a relatively densely inhabited area, close to the borders of Melegnano, the interchange linking the existing Milan-Bologna line with the new high speed track consists of 2 artificial galleries overlapping the existing railway. Their separation and interoperability are crucial because of high traffic volume: most goods and passengers from the central and southern part of Italy will go trough this interchange. Removing the bottleneck related to the previous “at grade” dangerous crossing improved existing railway line efficiency, even before the full completion of the new high speed line.

24 Melegnano Railway Interchange during construction

25 UPGRADING OF MOTORWAY TOLL PLAZAS AT LODI, CASALPUSTERLENGO AND REGGIO EMILIA

For the new high speed train line, the Client RFI selected the path alongside a relatively straight Milan-Bologna motorway. Indeed about 140 out of 182 total km of the new railway line are placed just next to the motorway, so much so that in certain places the motorway had to be repositioned and rebuilt in a new location. Many existing interchanges, toll plazas and other structures were upgraded and rebuilt, as well as 59 bridges across the motorway.

New ramps and new artificial galleries construction close to Lodi Station, very close to the existing motorway

26 Casalpusterlengo station: existing cloverleaf clearly interfering with the railway path, and part of the new ramps (on the right/bottom corner)

Reggio Emilia motorway exit: new ramps, as well as the existing ones in the background

27 SOMAGLIA ARTIFICIAL POLICENTRICAL GALLERY

The medieval city of Somaglia is located on a geomorphological step. In order not to alter the landscape and to reduce the noise, it was agreed with the Municipality to build the new railway line underground through a polycentric artificial gallery.

A park was built above the gallery, a solution that provides: Better landscaping. Environmental mitigation for the new line. Environmental mitigation for the existing motorway.

Somaglia’s artificial gallery concept and construction phases

28 29 CABLE STAYED RAILWAY BRIDGE OVER PO RIVER

The viaduct across the Po river is a system crossing Italy’s largest river, connecting the two regions of Lombardia and Emila Romagna: Full viaduct extension of around 1,350 m. The cable stayed viaduct, 400 m long, with central bay and lateral bays, respectively of 192 m and 104 m, with foundations on 2 artificial islands. The bridge, built with pre-stressed reinforced concrete, sustained with 72 stays connected to two towers 60 m above the foundations. The towers foundations designed to resist to heavy erosion, each one built on 28 piles 2 m wide and 65 m long.

Po viaduct central bay – artificial island north – foundation 30 31 PIACENZA RAILWAY VIADUCT SYSTEM

The viaduct system close to Piacenza, connecting the Po river crossing with the Emilia Romagna region, contains: 2 viaducts, made of double box girder precast beams. Full extension is 5,103 m. The precast pre-stressed reinforced concrete beams have a medium length of 33 m. Each beam weighs 990 t. There are more than 150 beams.

32 Piacenza viaduct system extension

33 THE SYSTEM OF SUSPENDED ARCH BRIDGES AT REGGIO EMILIA DESIGNED BY SANTIAGO CALATRAVA

3 cable stayed bridges connecting northern to southern parts of the city of Reggio Emilia, designed by Santiago Calatrava: Full extension is around 1,000 m. Main bridge crosses over: - The highway. - The high speed railway. - Ordinary roads. The main structure is a longitudinal steel arch over 220 m long, over 50 m high, with 50 steel wires couples. The 2 lateral stayed bridges main structure is a transversal steel arch, 70 m high, with 26 steel wires couples.

Lateral arch bridge

34 Main bridge over the motorway and new railway

35 THE SYSTEM OF OMEGA BRIDGES

This kind of viaduct system, named Precast pre-stressed reinforced “Omega” for the peculiar shape of its concrete isostatic beams with section, crosses the Modena-Brennero medium length of 31.5 m. motorway and Secchia and Panaro Each beam 689 t. rivers: More than 750 isostatic beams. Total bridges extension around 9 hyperstatic beams caste on site, 24,000 m. 136 m long.

Modena viaduct system typical section

Modena viaduct system girders transport and launching system

Modena viaduct system in final configuration

36 Hyperstatic beams crossing the Secchia river

37 SEVEN INTERCHANGE SYSTEMS INTERCONNECTING THE HIGH SPEED RAILWAY LINE WITH THE TRADITIONAL LINE

Interchanges have been designed To build the interchanges of Parma, and built to comply with the existing Fidenza and Piacenza East it was traditional railway lines, in order to necessary to: give the opportunity to each railway Build artificial motorway tunnels station to be connected, when needed, underneath the new rail track. with the High Speed Train System. This Build artificial galleries underneath implied designing and building: the existing motorway. Viaducts. Diverge provisionally the motorway, Embankments. with special care to cause the Tracks and Sleepers. minimum disruption on motorway A complex system of signaling. traffic (Milan-Bologna is the Different power lines to shift from motorway section with the largest the 25kV AC power line of the High traffic flow in Italy): Speed track to the 3kV CC power - 2 sequential diversions, moving line used on the traditional track. 1 carriageway at a time. - Diverging all the carriageways at the same time.

Parma interchange under construction. The motorway tunnel was built under the new railway line. The motorway was temporarily diverted to the left side of the picture during contruction. 38 Piacenza West interchange, while under construction

39 FONTANELLATO ARTIFICIAL GALLERY

Fontanellato is a remarkable medieval village that needed to be preserved from any environmental impact caused by the new railway line. For this reason an artificial gallery had been built to mitigate the visual and other potentially negative effects.

The artificial gallery main features are: Over 3 km long. Floating foundations, made of caissons, due to the water table really close to the ground level. A project designed and built to ensure safe transit of a High Speed train at 300 km/h, even with relevant fluctuations of the waterbed. A township park was built on top of the artifical gallery to provide better landscaping and environmental mitigation.

Fontanellato’s artificial gallery physical model

40 Fontanellato’s artificial gallery under construction

41 VIADUCTS WITH PRECAST GIRDER BOXES SYSTEM

Standard design viaducts had been erected every time it was possible, according to Italian railway standards: Cross section assembled setting 4 box girders together. On cast in situ piers.

One of the best examples is the viaduct located in Paradigna near Parma: 3 km long. 25 m span.

Paradigna viaduct at completion 42 Paradigna viaduct during installation

43 SERVICE FACILITIES

Several service and support facilities trains circulation along the tracks were also designed and built: (ref. ERTMS lev.2 for High Speed line High Voltage electrical power Milan-Bologna, first application in lines to supply electricity to the Europe). electrical substations and Medium Control buildings and installations Voltage power lines to the Feeder housing all traffic monitoring devices distribution system line. and the safety/signalling systems. Electrical substations to revert the Monitoring systems to provide High Voltage, needed for efficient continuous knowledge of the status long distance power transfer, into of sensitive artworks and areas of feeding voltage for trains. potential attention. Signalling systems to supply safety

44 Typical electrical/signalling infrastructure along the track

Electrical substation high voltage to medium voltage 45 THE NEXT CHALLENGE: THE HIGH SPEED RAILWAY MILAN-VERONA

Further to the original agreement, Saipem had been awarded the new high speed 142 km long track between Milan and Verona, a project ultimately worth over 4 billion e.

So far, Saipem - as the leader of the “Consorzio Cepav due”, namely the JV with other Italian civil construction Treviglio East Brescia West Interchange Interchange companies - has successfully completed Brescia East Verona Merci the frontend design. Milano Interchange Interchange Furthermore, following the recent agreement with the Italian Government Treviglio in April 2011, Saipem was given the Verona EPC award for the first project portion Brescia from Milan to Brescia, approximately 53 km long.

Mincio viaduct simulation

46 Milan to Verona railway track

Treviglio East Brescia West Interchange Interchange Brescia East Verona Merci Milano Interchange Interchange Treviglio Brescia Verona

47 MILAN–BRESCIA RAILWAY SECTION HIGHLIGHTS:

Crossing 27 Municipalities and the Provinces of Milan, Bergamo and Brescia. 46.2 km of embankments. 7 railway viaducts. 5 bridges crossing the railway section. 602 utilities and waterways to be relocated. 94 third party organizations to deal with. 84% of the track will be positioned alongside the new BRE-BE-MI motorway, simultaneously under construction. More than 300 measurment points for more than 10 environmental parameters, to be customized depending on the results of the first environmental monitoring activities.

Serio viaduct, railway side view (photo simulation of the-Bre-Be-Mi motorway viaduct on the background)

48 Typical embankment configuration

49 MILAN-BRESCIA LOVERNATO ARTIFICIAL GALLERY

The Lovernato artificial railway gallery in This technology has the advantage that the Treviglio-Brescia section is designed after the top slab is ready, completion to protect the Madonna di Lovernato of the works doesn’t cause any other monumental sanctuary and the town recstrictions into the area, apart from of Ospitaletto. trucks removing the excavation’s earth Its full extension will be around 530 m. from the yard. It will be built according to the “Milano methodology”, because of the peculiar area in which the gallery will located: Diaphragm walls construction. Top slab concreting. Inside terrain removal and lower slab construction.

50 The artificial gallery built according to the Milano Methodology: a typical section

51 MILAN-BRESCIA 1P VIADUCT – BRESCIA WEST INTERCHANGE

This viaduct will be part of Brescia West Interchange system: Full extension: 349.50 m. 14 isostatic spans of 25 m long each. Coupled pre-stressed reinforced concrete box girders.

52 Interchanges viaducts typical section

53 MILAN-BRESCIA OGLIO AND SERIO VIADUCTS

The Oglio and Serio rivers are the most important waterways interfering with the Milan-Brescia pathway. New viaducts will be built to cross them. The Serio viaduct, the longest one, will have the following dimensions: Full extension will be 1,286.60 m. 43 isostatic spans 30 m long. 4 box girders pre-stressed reinforced concrete section.

Oglio viaduct simulation

54 Oglio viaduct section simulation

55 NOTES

ENGINEERING AND CONSTRUCTION PROJECT REFERENCES HIGH SPEED RAILWAY SYSTEMS

HIGH SPEED RAILWAY SYSTEMS 04.2012

eople, Skills, Equipment. eople, Skills,

P saipem.com - A subsidiary of Eni S.p.A. Tel. +39.02.520.1 - Fax +39.02.520.44415 Via Martiri di Cefalonia, 67 - 20097 San Donato Milanese, Milan - Italy Saipem S.p.A.