Thames Water Utilities Ltd Major Projects Thames Tideway Tunnel Programme Lee Tunnel Main Contract Contract No 6LYG/A1 Section 4 PT – Particular Tunnelling Specification Operating Division Waste Water Services August 2008 Lee Tunnel, Contract No. 6LYG/A1 PT – Particular Tunnelling Specification - PT100 PT100 PARTICULAR TUNNELLING SPECIFICATION - INTRODUCTION PT100.1 So far as the Specification for Tunnelling may conflict, or be inconsistent, the specifications shall prevail in the following order of precedence: • Particular Tunnelling Specification • Specification for Tunnelling (BTS/ICE 2000) • Particular Civil Specification • CESWI PT100.2 Clause numbers for 'tunnelling' specifications are prefixed with a 'PT', i.e. PT112.1.4 etc. For consistency, the 'PT' prefix shall be deemed to apply also to all sections and clauses in the Specification for Tunnelling. PT100.3 Clauses for the main tunnel 7200mm diameter are prefixed PT2XX, the 3.05 ID Abbey Mills Connector Tunnel “TBM and Tunnelling” PT3XX, for the precast concrete segmental tunnel linings PT4XX, for the EPDM gaskets to the precast concrete segmental tunnel linings PT5XX and for the segmental shaft linnings PT6XX. PT100.4 This Specification for Tunnelling covers all Tunnelling Works and Segmentally lined Shafts within the scope of Works for this Project . PT100.5 Diaphragm Walls are specified in the Particular Civil Specification:-PC 3.15. PT100.6 The Contractor shall refer to the Particular Civil Specification for the requirements for all structures not specifically referenced in this specification. PT100.7 The Lee Tunnel is a long tunnel drive predominantly in flint laden chalk at high water pressures as described in the Geotechnical Baseline Report. The tunnel route prevents any direct access to the TBM from the surface. For this reason TW considers that the design, performance & operation of the TBM is one of the major risk mitigations on the Lee Tunnel. This specification should be considered as a MINIMUM requirement. Thames Water Utilities Limited August 2008 Page 1 of 1 Lee Tunnel, Contract No. 6LYG/A1 PT – Particular Tunnelling Specification - PT200 TABLE OF CONTENTS PT200 SPECIFICATION FOR NEW TUNNEL BORING MACHINE AND TUNNEL CONSTRUCTION – 7200MM MINIMUM NOMINAL INTERNAL DIAMETER FOR TUNNEL BETWEEN BECKTON STW AND ABBEY MILLS PS. ...................... 2 PT201 SUMMARY........................................................................................................... 2 PT202 REFERENCE STANDARDS ............................................................................... 2 PT203 DEFINITIONS ...................................................................................................... 2 PT204 SUBMITTALS ...................................................................................................... 3 PT205 GENERAL- TUNNEL BORING MACHINE .......................................................... 5 PT206 MINIMUM REQUIREMENTS FOR TBM TUNNELLING EQUIPMENT............... 6 PT207 FINITE ELEMENT (F.E.) ANALYSIS................................................................... 6 PT208 CUTTERS ............................................................................................................ 6 PT209 CUTTER HEAD ................................................................................................... 7 PT210 CUTTER HEAD INTERVENTIONS ..................................................................... 8 PT211 FRONT SHIELD................................................................................................... 8 PT212 THRUST SYSTEM AND STEERING .................................................................. 9 PT213 DRIVE SYSTEM .................................................................................................. 9 PT214 EXCAVATED MATERIAL MUCKING SYSTEM ................................................ 10 PT215 SEALS................................................................................................................ 12 PT216 GROUTING SYSTEM........................................................................................ 13 PT217 SEGMENT ERECTOR....................................................................................... 13 PT218 ERECTOR BRIDGE........................................................................................... 14 PT219 SEGMENT MAGAZINE ..................................................................................... 15 PT220 TBM – LINING INTERFACE.............................................................................. 15 PT221 CONTROL AND INTERLOCKS......................................................................... 15 PT222 TBM OPERATION ............................................................................................. 16 PT223 TBM ELECTRICAL REQUIREMENTS.............................................................. 17 PT224 GUIDANCE SYSTEMS...................................................................................... 18 PT225 TAIL SEAL GREASE INJECTION ..................................................................... 21 PT226 OTHER FEATURES .......................................................................................... 21 PT227 SPARE PARTS.................................................................................................. 22 PT228 FIRE PREVENTION – TBM AND BACK-UP..................................................... 22 PT229 TBM FACTORY TESTING................................................................................. 23 PT230 QUALITY ASSURANCE .................................................................................... 23 PT231 QUALITY PLAN ................................................................................................. 24 PT232 PERSONNEL AND TRAINING.......................................................................... 24 PT233 TUNNEL HEALTH AND SAFETY ASSURANCE .............................................. 24 PT234 REGULATIONS. ................................................................................................ 24 PT235 BORED TUNNEL TEMPORARY FACILITIES................................................... 26 PT236 TUNNEL BORING MACHINE MAINTENANCE. ............................................... 27 PT237 GENERAL TUNNELLING CONSTRUCTION REQUIREMENTS...................... 27 PT238 ELECTRONIC DATA ACQUISITION, VISUALISATION AND REPORTING SYSTEM (DAVARS) .......................................................................................... 27 PT239 GROUTING METHODOLOGY .......................................................................... 29 PT240 INSTALLATION, MONITORING AND CONTROL FOR SEGMENTAL LINING 30 PT241 SURFACE DISPLACEMENT MONITORING .................................................... 31 PT242 DEFECT AND CONDITION SURVEYS ............................................................ 34 PT243 TEMPORARY ELECTRICITY SUPPLY FOR TUNNEL CONSTRUCTION ...... 34 PT244 TREATMENT OF ARISINGS............................................................................. 34 PT245 TBM LAUNCH FROM OVERFLOW SHAFT ..................................................... 36 PT246 CONSTRUCTION TOLERANCES .................................................................... 36 PT247 AS-BUILT TUNNEL SURVEY ........................................................................... 36 PT248 SECONDARY LINING DESIGN AND ISTALLATION ....................................... 37 Thames Water Utilities Limited August 2008 Page 1 of 38 Lee Tunnel, Contract No. 6LYG/A1 PT – Particular Tunnelling Specification - PT200 PT200 SPECIFICATION FOR NEW TUNNEL BORING MACHINE AND TUNNEL CONSTRUCTION – 7200mm MINIMUM NOMINAL INTERNAL DIAMETER FOR TUNNEL BETWEEN BECKTON STW AND ABBEY MILLS PS PT201 SUMMARY PT201.1 The work in this Section includes, but is not limited to, providing all labour, materials, tools, equipment, and incidentals necessary to construct a 7200mm minimum nominal ID finished tunnel (including a primary and secondary lining) in accordance with the Works Information and Site Information. PT201.2 The work in this Section includes, but is not limited to, the following activities: • The provision of a new Tunnel Boring Machine includes, but is not limited to: design, manufacture, supply, maintain and testing of a tunnel boring machine for the express purpose of constructing TBM excavated tunnels between Beckton and Abbey Mills. • Boring Tunnel includes, but is not limited to: mining of tunnels, installation of pre-cast concrete segmental tunnel lining, temporary tunnel facilities, geotechnical monitoring, control of ground loss, settlement and heave, and removal and disposal of excavated material. • As-Built Tunnel Survey PT201.3 This is a performance specification. The Contractor shall be responsible for the selection and complete design of the new tunnel boring machine and tunnel construction systems. The Works Information, Site Information and GBR provides parameters and design criteria for this element of the works. PT202 REFERENCE STANDARDS PT202.1 UK Health and Safety Regulations including but not limited to the Construction, Health, Safety and Welfare Regulation 1996, The Confined Spaces Regulations 1997 and the Approved Code of Practice H.S.E. Document L101. PT202.2 Joint Code of Practice for Risk Management of Tunnel Works in the UK published by the British Tunnelling Society/Association of British Insurers and the International Tunnelling Association/AITES Guidelines to Tunnelling Risk Management: ITA Working Group. PT202.3 BS6164: 2001 Code of