10 Tunnelling Market in Tunnel 5/2011

the same period was the long Tunnelling Market in Brazil series of 15 tunnels in what was known as Section 2 of the Dom The following article contains a summary of the history of underground Pedro II Railroad, on the Jape- construction in Brazil as well as a summary of present opportunities in ri-Barra do Piraí line across the Serra do Mar mountain range in the industry when many infrastructure projects are at the planning stage. the state of . Dom This happens not only because of the need due to economic growth, but Pedro II was then the Brazilian also because of the preparation for the coming FIFA World Championship Emperor. He frequently visited the construction works. Figure 1 in 2014 and the Olympic Games in 2016 in Rio de Janeiro. This paper was is a photograph of the visit on held at the IUT’11 – Innovation Underground – the famous trade fair in the the day of a tunnel breakthrough. Hagerbach Test Gallery in Sargans/CH. That was one of Brazil’s most re- markable engineering achieve- ments at the time: a broad gauge Tarcisio B. Celestino, Eng. Civil M.S. Ph.D, Gerente Eng. Civil I, Themag Engenharia, São Paulo/BR; Chairman of the railroad climbed about 400 m in Organizing Committee, WTC 2014 Hugo C. Rocha, Departamento de Concepção Civil, Metrô de São Paulo, São Paulo/BR; President of the Brazilian difficult technical conditions re- Tunnelling Committee www.tuneis.com.br quiring the excavation of 15 tun- nels, their lengths varying from 25 The tunnelling market in Brazil for the excavation of tunnels in only a few decades after inde- to 2,238 m and totaling 5,220 m. started to develop in the second rock. At that stage, only 3 cen- pendence, all the work was plan- Some were excavated in soil or half of the 19th century, even turies after the beginning of the ned and conducted by foreign decomposed rock, so the vault before the advent of dynamite Portuguese colonization, and engineers. Very soon the experti- was lined with masonry, while se of underground construction others were in extremely hard Visit of the Emperor to the Grand Tunnel breakthrough [1] and design started to develop rock. All were 4.2 m wide with a among local professionals. maximum height of 5.8 m. The Since those days, of course highlight was the so called Grand many changes have occurred Tunnel, 2,238 m in length. in the local tunnelling market. Work on the project as a This paper contains a summary whole started in 1858, but exca- of the history of underground vation of the Grand Tunnel was construction in the country as not concluded until June 1864, well as a summary of present op- to be inaugurated in December portunities in the industry when 1865. The contractor was the many infrastructure projects are American Jacob Humbird. The at the planning stage. This hap- tunnels in rock (including the pens not only because of the Grand Tunnel) were excavated need due to economic growth, using sledgehammer and chisel but also because of the prepara- with explosives since there were tion for the coming FIFA World no mechanical drills at that time, Championship in 2014 and the and dynamite was not invented Olympic Games in 2016 in Rio until 1866, hence the apparent de Janeiro. slowness of the works. The Swiss A thorough and interesting scientist Jean-Louis Agassiz (who report about the beginning of visited the site of the Grand Tun- underground construction in nel in April 1865) reported that Brazil was compiled by Silva Tel- the rock was so hard “that the les [1]. Excerpts are shown in the heaviest blows of the diggers following chapters. produced just a little dust”. In The first road and railway tun- order to facilitate excavation, 4 nels in the country were opened vertical shafts were sunk from 1 around 1860. But by far the most the top of the mountain (depth important engineering work at varying from 37 to 101 m) to al- Tunnel 5/2011 Tunnelling Market in Brazil 11

low work to proceed on several ted into a tunnel to avoid railway The introduction of dynamite and several viaducts and bridges faces; one of these shafts was blockages caused by constant brought a significant increase over a stretch of 40 km. Two of subsequently used for ventilati- rock falls. For the tunnel (execut- in underground construction. those bridges were world record on. About 400 laborers worked ed in 1901), the vault was built For the duplication of the Dom holders for their respective types day and night shifts. of reinforced concrete, the oldest Pedro II Railway, the new Grand of structure at that time. Underground construction work with reliable dating to use Tunnel was constructed in 11 The execution of almost all was very active at that time. Work this material in Brazil. months, while the first tunnel the tunnels was supervised by on the so called central line from Between 1877 and 1879, the with the same length had re- the Brazilian engineer Francis- Rio de Janeiro do Belo Horizonte Maritime branch of the D. Pedro quired 7 years. co T. da Silva Telles, who was began in 1865, and there were II Railroad in the city of Rio de In the early 20th century Bra- perhaps Brazil’s leading tunneller 20 tunnels, the longest with 552 Janeiro was built. It was a short zilian engineers were in charge at the time. m. One of those tunnels deserve branch connecting to the port of the major works in tunnelling special attention because it de- and work included the excava- going on in the country. For the Modern Tunnelling notes the beginning of enginee- tion of 2 tunnels, lengths 315 access from São Paulo to the Port Market ring concerns with slope stability and 86 m, to cross a hill (Mor- of Santos, the Mairinque-Santos The development of modern in that area, a problem which is ro de São Diogo). The structure branch of the former Sorocaba- tunnel engineering in Brazil still important in the same zone presented 2 important new fea- na Railroad (São Paulo) was built started in the late 1960s with nowadays. In the João Ayres Gor- tures: the use of compressed air from 1928 to 1937. The adverse the planning and construction ge in the Serra da Mantiqueira drills (the Ingersoll system, driven topographical conditions po- of subway systems in São Paulo mountain range, a cut with very by steam locomotive) and the sed difficult technical problems and Rio de Janeiro. A few under- high slopes was initially cons- use of dynamite (the Emperor and required the excavation of ground hydroelectric schemes tructed; later on it was conver- himself triggered the first blast). 31 tunnels (totaling over 5 km) had already been constructed.

• Backfilling (one or two components) • Pre-excavation grouting • Post/consolidation grouting

• High-Shear Mixers up to 2500 litres • Bentonite modules for microtunnelling • Grout pumps up to 200 bar • Fully automated grout plants • Pressure and flow recording systems • Backfill systems for one or • Compact grout plants two component grouts

Häny AG • Buechstrasse 20 • CH-8645 Jona/Switzerland Stand B 10 Tel. +41 44 925 41 11 • Fax +41 44 923 62 45 • [email protected] • www.haeny.com 12 Tunnelling Market in Brazil Tunnel 5/2011

EPB TBM was used for the exca- million, with a significant pro- 2 vation of the soft ground section rata rate of increase of more of the double-track running tun- than 500 %. The major demand nels. The TBM is shown in Figure 3 for these new tunnels has come as an indication of the techno- from the hydroelectric construc- logical improvements adopted tion industry. Since the market since the 1970s, when compared rules for private investments to Figure 2. About this subject, a for electricity generation have hard rock TBM was used for the been established a large num- recently constructed 5 km long ber of small hydroelectric power Gastau Tunnel to convey natu- plants have been constructed ral gas from the sea level to the with underground works (Fi- economic active Vale do Paraíba gure 4). at 700 m elevation. Advances in A sample of new works to be drill-and-blast constructin have constructed in the near future Single-track open face TBM used for the São Paulo in the 1970s also been significant. is presented next. Then some of A recent partial survey carried the new projects are described. All types of construction me- between Belo Horizonte and Rio out by the Brazilian Tunnelling thods have been used recently. de Janeiro and for the Imigrantes Committee shows that the rate New Projects Line 1 of the São Paulo Metro Highway between São Paulo and of increase in underground A number of underground works was partly excavated with an Santos. Many NATM soft ground construction for civil enginee- are in different stages of develop- open face TBM (Figure 2) asso- tunnels and a few stations were ring purposes is remarkable. The ment in Brazil. This is due to the ciated with dewatering where constructed for the São Paulo total volume constructed in the lasting economic stability, con- necessary. NATM was introduced Subway in the 1980s and 1990s. 1990s was less than 4 million m3; sistent economic growth and in the early 1970s for the cons- For the recently constructed Line in the following 5 years the vo- high rate of urbanization of the truction of the Steel Railway 4 of the same subway, a modern lume jumped to more than 11 population among other factors. Large metropolitan areas have a Project Length [km] Stage backlog of infrastructure which TAV- High Speed Railway, Rio de Janeiro - São Paulo approx. 100.0 Bidding is decreasing. São Paulo State The table 1 presents some of São Paulo Metro Extension 1.5 Final design the projects and their stage of São Paulo Metro Line 5 11.4 Final design/construction development. This list is by no São Paulo Metro Line 6 35.1 Preliminary design means exhaustive and represents São Paulo Metro Line 15 11.5 Functional design just a sample of the current activi- ties. As shown later, underground Roberto Marinho urban highway 4.5 Final design construction for hydroelectric Mario Covas Ring Road North Section 10.0 Preliminary design power plants currently represents Rio de Janeiro State the largest market share, however Rio Metro Line 4, 1st section 9.2 Final design/construction it is very difficult to survey mainly Rio Metro Line 4, 2nd section 4.3 Studies after privatization of the sector. BR101 Highway 3.3 Preliminary design Transolimpica Highway 5.0 Preliminary design Description of a few Highway - Grota Funda Tunnel 2 x 1.1 Construction Projects Ceará State São Paulo Metro Line 5 Metro Line 3 - East 10.5 Preliminary design The southern end of the São Minas Gerais State Paulo Metro Line 5 is already under construction. The line will Highway tunnels 5.0 Preliminary design be fully underground. The total Railway tunnels 7.4 Preliminary design length will be 11.8 km, out of Paraná and Santa Catarina States which 1.5 km will be excavated Highway tunnels 4.7 Preliminary design by NATM; 4.6 km of single-track Railway tunnels 35.0 Studies running tunnels will be exca- Curitiba Metro 20.0 Preliminary design vated by two 6.9 m diameter Tunnel 5/2011 Tunnelling Market in Brazil 13

tions (sandy clays and clayey 3 4 sands; silty clays and silty sands respectively). Most of the experience in tunnel ex- cavation in the City of São Paulo has been accumulated in these formations. • Weathering soil (Gneiss sapro- lite). • Moderately weathered grani- tic gneiss.

An important characteristic of this line is the intense use of TBMs for running tunnels and Double-track EPB TBM recently used Partial survey of volume of different types of under- for the São Paulo Metro Line 4 ground works in 2005 open excavations for stations. Several stations will be exca- earth pressure balance TBM; and constructed with open excava- • Quaternary alluvium sedi- vated using multi-shafts with 5.7 km of double track running tions and 3 by NATM. ments (soft and unconsoli- shotcrete support, such as Luz tunnels will also be excavated by In situ geological investigati- dated organic clays). Station of Line 2, shown in Fi- a 10.6 m diameter TBM. There will on identified the following ho- • Tertiary sediments of the Re- gure 5. For the Adolfo Pinheiro be a total of 11 stations, 8 to be rizons: sende and São Paulo Forma- Station, already under construc- 14 Tunnelling Market in Brazil Tunnel 5/2011

5

Multi-Shaft Luz Station, São Paulo Metro Line 4

tion, a total of 5 secant shafts sediments and a short section The running tunnels will be connecting , at with 30 m diameter are being through weathered gneiss. A excavated with TBM for single the extreme south of the city, excavated. short length of double-track track through sediments of the to the Station, which tunnels will be excavated with Barreiras Formation. All the 12 was at that time Line 1 southern São Paulo Metro Line 6 a TBM through rocks ranging stations will be constructed terminal station. Line 1 links the São Paulo Metro Line 6 is at the from class I to class III. Conven- with open excavation. This is northern and southern zones of preliminary design stage. It will tional excavation methods will favored by the local physiogra- the city through downtown. connect the Brasilândia (north be adopted in a short section of phical condition. An important Since the late 1990s, Line 1 was western part of the city) to granitic rock. aspect is the need to pressuri- successively extended towards São Joaquim (downtown area) ze the TBM in order to minimize south through Copacabana, stations with a total extension Line 3 – East surface impacts due to the thick reaching Ipanema at the Gene- of 15.3 km. Running tunnels Fortaleza is the capital city of sand layers occurring in the re- ral Osório Station. New studies will be mainly excavated with the state of Ceará in northeas- gion. showed importance of connec- TBM through several geologi- tern Brazil. Line 3, currently ting Barra da Tijuca to Ipanema, cal formations. The anticipated under preliminary design, will changing the original alignment demand for this line is 638,000 connect the downtown area Line 4 of the Rio de Janeiro of Line 1. Many important real passengers per day. Most of the to the south eastern part of the Metro was planned in the late estate development projects length will be excavated with a city. The terminal station will be 1990s when the system was have taken place in Barra da Ti- 9.4 m diameter TBM for double- located next to the Campus of transformed into a concession. juca in recent years. Highly con- track tunnels through tertiary the University of Fortaleza. The original project aimed at gested avenues are presently Tunnel 5/2011 Tunnelling Market in Brazil 15

the only possible connection successfully constructed nearby Osório and Gávea Stations are quency air shuttle connecting to the downtown area and trips stations (e.g. Cardeal Arcoverde) currently being prepared. Ex- the cities of Rio de Janeiro and can take as much as 2 h for the with shotcrete for final lining will cavation for the General Osório São Paulo. In 2008, the total esti- 28 km. In addition, may sport be taken into consideration, ac- Station has already started. mated demand between Rio de facilities will be constructed in cording to the practice frequently Line 3 is still at planning stage. Janeiro and São Paulo was 7.3 the Barra da Tijuca area for the adopted in Brazil [3]. It will connect Rio de Janeiro to million trips with a market share 2016 Olympic Games and Ipa- Gavea Station will be exca- Niterói on the west side of the for air of 60 %, 17 % for car and nema and Copacabana are the vated by the cut-and-cover me- through a trans- 23 % for . For the whole sys- zones where most of the hotels thod, using the multi-shaft tech- bay tunnel. From Niterói the tem, studies indicated a demand are located. nique, similar to the one shown line is planned to extend about of 18.0 million trips in 2008 and The new alignment of Line in Figure 5. This technique has 30 km west to Itaboraí. 32.6 million in 2014. The air shutt- 4 will connect General Osório proven to be very safe, cost-ef- le, which has a 15 min frequency, Station in Ipanema to Jardim fective and logistically efficient High Speed Rail System a 55 min gate-to-gate travel time Oceânico Station in Barra da Ti- during construction. It has be- A high speed rail system (HSR) and currently 71 daily flights in juca. The fully underground line come very popular in Brazil and is being planned to operate in each direction, dominates the will be 14 km long with 6 new has been adopted for many mass the most populated and econo- market for time sensitive busi- stations. It will be possible to transit stations. A total of 7 secant mic active region in the country. ness passengers. The system reach downtown in 34 min and shafts are planned to be excava- The National Agency for Land however is sensitive to weather Copacabana in just 15 min. ted to accommodate platforms, Transportation (ANTT) has been conditions and significant delays Running tunnels between Ge- concourse, accesses, operational commissioned by the Federal occur. In addition, Congonhas neral Osório and Gávea Stations and technical rooms. Gavea will Government to conduct the airport in São Paulo located close through the densely constructed be an important station at the TAV Brasil project (www.tavbrasil. to the central business district is Ipanema and Leblon districts will entrance of the Catholic Univer- gov.br). The Consortium Halcrow saturated. The need for a high be excavated with TBM. Between sity Campus. – Sinergia was commissioned to speed rail system is clear. Gávea and Jardim Oceânico the The project is at early cons- conduct the feasibility studies. The HSR will run between construction method will be drill truction stage. The drill-and-blast Excerpts of the feasibility study Campinas, São Paulo and Rio de and blast. The new General Osório tunnel between Jardim Oceâni- are presented below [4]. Janeiro (Figure 6) also connec- Station will be fully constructed co and Gávea is being excavated. Existing transport modes air, ting the airports of Viracopos, underground by the drill and blast Specifications for the TBM which car and bus are well established Guarulhos and Galeão to their method, taking profit of the good will be used to excavate the run- in the market between the 3 metropolitan areas. The system quality rock mass. Experience of ning tunnels between General cities, in particular the high fre- is intended to operate at a maxi-

Packersysteme

Bergbau Felsbau Tunnelbau Spezialtiefbau DESOI GmbH Gewerbestraße 16 36148 Kalbach/Rhön Telefon: +49 6655 9636-0 Injektionstechnik direkt vom Hersteller, 30 Jahre Know-how – wir beraten Sie gern. Internet: www.desoi.de 16 Tunnelling Market in Brazil Tunnel 5/2011

construction of the remaining 3 6 km at-grade avenue. Urbanistic studies however, showed that an underground solution, preserving the surface for a linear park with approx. 3 million m2 would have much further positive impact on the neighborhood. Two twin tunnels for 3 lanes each, 147 m2 cross section area and 15.7 m span are at the final design stage. Lay-bys for emer- gency parking will have 168 m2. The tunnels will be excavated in soft ground, mainly consisting of stiff clay and sand layers from the São Paulo Tertiary Basin and limited length in residual soil re- sulting from the weathering of Pre-Cambrian gneiss. The need for blasting hard rock for bench excavation only will be rare. The excavation scheme will inclu- Alignment of the High Speed Rail project Roberto Marinho Urban Tunnel de side drifts, top-heading and mum speed of 350 km/h The to- on. The total estimate for civil port of Santos) and the Pinheiros bench. The primary support will tal estimated distance between works is US$ 14.5 billion. Those River Marginal Avenue, an area consist or fiber-reinforced shot- Campinas and Rio de Janeiro costs will be reviewed when a which has become an important crete. For the final lining, steel is 511 km; with the distance preliminary engineering design business district in recent years. mesh reinforced shotcrete will between São Paulo and Rio de becomes available. The bidding An urban operation was created be adopted. Janeiro approx. 412 km. Based process for the concession (de- by the City with the purpose of on the alignment developed the sign, build and operate) is cur- generating funds for the project Conclusions non-stop journey time between rently underway. of construction of an avenue The tunnelling market in Brazil is the 2 cities is estimated at ap- The design of this urban tun- along the creek. The first section at clear increase rate of demand. prox. 1 h 33 min. Journey times nel is an example of an important of the avenue has already been Backlog of infrastructure due to with a high speed long distance market share for underground constructed, the so called Rober- recent and continuing growth, service between Rio de Janeiro works in Brazil in the coming to Marinho Avenue. The final 3 km as well as on-going urbanization to Campinas will take up to ap- years. In this case, underground before reaching Imigrantes High- process tends to decrease, but prox. 2.5 h. traffic solutions are being consi- way are irregularly occupied by many works are expected to be The alignment proposed by dered to upgrade the area above. low income housing. About 7,000 contracted in coming years. In ANTT will have 90.9 km of tun- The project is coupled with the families living there will be moved addition to the backlog, demand nels, 46.6 of which will be located real estate market and part of the to new apartments to be built by due to important sport events in urban areas and 44.3 in rural construction cost will be covered a social interest housing program. in the coming years is also ex- areas. In rural areas, the longest by the profit due to the urban re- The original project called for the pected to increase. tunnels will be located at the habilitation. Potential use of this Serra das Araras, an escarpment type of coupled solution is very References [1] Silva Telles, P.C. (2006) Early tunnels in Brazil. In: T.B. Celestino, A. with about 500 m difference in high in many Brazilian cities. Koshima, R.C.A. Telles & A.P. Assis (Eds.) Tunnelling in Brazil. elevation composed of gneis- The City of São Paulo created Brazilian Tunnelling Committee, São Paulo. sic rock. The total construction a program for urban rehabilitati- [2] Metrô de São Paulo – Line 6 – Orange, Public Hearing – cost estimated by ANTT for the on of the area around the Água http://www.metro.sp.gov.br [3] Celestino, T. B.; Rocha, H. C.; Nunes, N. L. (2007) Shotcrete in Brazil. tunnels will be US$ 6.3 billion at Espraiada Creek in the southern Tunnels and Tunnelling International, v. 1, pp. 35-37, 2007. the stage of feasibility studies. part of the city, between Imig- [4] Halcrow – Sinergia Consortium (2009) Brazil TAV Project – Demand For bridges and viaduct the rantes Highway (the most im- and Revenue Forecast, Vol. 1. ANTT Agência Nacional de Transporte estimate reaches US$ 4.2 billi- portant highway to the city and Terrestre. Tunnel 5/2011 Tunnelling Market in Brazil 17

Geprüfte Sicherheit

TROX Tunnelklappen für unterirdische Verkehrsanlagen

TROX bietet projektspezi sche Tunnelklappen mit folgenden Vorteilen:

Ϯ Höchstmaß an Hitze- und Korrosionsbeständigkeit Ϯ Langlebigkeit und Wartungsfreundlichkeit Ϯ Individuelle Planung, Konstruktion und Service Ϯ Weltweites Normen-Know-how und Projektbetreuung

Besuchen Sie uns auf der IUT ’11 Flums (CH), 14.-15. Sept. 2011 Bereich Blau, Stand B16

www.trox.de