North America
Inspection standards to improve infrastructure health
Shaft sinking & raiseboring
Dealing with problematic passageways
Waterproofing
How technology can ensure integrity
ISSN 1756-4107 CovI_WT1509.indd 2
September 2015
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Contents
1
EDITOR’S COMMENT
STEMming the flow
T
he younger generation is more likely to actively engage in social media. They may be more easily influenced on such platforms, such as Twitter, especially when it concerns their future.
The hashtag #ILookLikeAnEngineer is gaining momentum in the Twitterverse with many female engineers from a broad range of disciplines tweeting pictures of themselves in their work fatigues, some from major tunnelling projects. Earlier this summer a software engineer retaliated to sexist criticism of her appearance in an advert to help promote a recruitment campaign.
News
Isis Wenger received remarks that she didn’t “look like an engineer”. Since then, Wenger set up the Twitter hashtag #ILookLikeAnEngineer to break the stereotypes women working in science, technology, engineering and mathematics (STEM) face. The hashtag is being circulated in more than 50 countries, with over 75,000 connected tweets. Despite an abundance of international awareness campaigns, the civil-engineering sector is still not appealing to young women at a time of career discussion. It is results time for UK schools with many 17 and 18 year-olds learning if the grades they achieved at A-level will meet entry requirements for higher education at university or elsewhere.
“Unless a new generation of engineers is trained, 27,000 construction projects a year could be at risk by 2019”
Regional focus: North America The long road to now Super ships and storm surges New promise for Peel
Clever sinking
Home and dry
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Contacts
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Classified advertising
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Next month
It is clearly a time when more should be thrown at the campaign, but the pot seems to be running out.
Will those young female tweeters be posting images of themselves as tunnellers in the future or will this image-conscious generation lack the confidence (and cash) to bloom? LUKE BUXTON, EDITOR luke.buxton@aspermontmedia.com
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Best practice: waterproofing
“This gender gap is then reflected in the numbers entering the technical professions, which is an issue industry is urgently trying to address.”
Unless a new generation of engineers is trained, 27,000 construction projects a year could be at risk by 2019, according to the Royal Institution of Chartered Surveyors.
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Equipment in action: shaft sinking & raiseboring
“While this year’s A-level results show rising numbers of students attracted to STEM subjects, there is still a significant gender gap,” Aecom’s chief executive for civil infrastructure for EMEA and India, Richard Robinson, said.
“Funding for the sciences is crucial for the qualifications and skills required for our future engineers,” Julia Evans, chief executive of the Building Services Research and Information Association, said. “Government needs to think proactively and longterm about this – which doesn’t appear to be the case right now. A reduction in such funding is certainly a false economy when businesses are struggling to find the talent they need.”
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Regional focus: Australasia
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Best practice: drilling muds
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Equipment in action: TBMs
America North standards to
Cover
Inspection health improve infrastructure
Shaft-sinking / raise-boring problematic Dealing with passageways
ng Waterproofi can ensure How technology integrity
A cutting drum is lowered into position for a shaftsinking project on the Moscow metro. This equipment is part of the Herrenknecht VSM system ISSN 1756-4107
September 2015
.com
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See page 12
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WT September 2015
News REGULATION
Chinese whispers on tunnels to cut construction din Chinese authorities are putting in place measures to reduce the impact of construction works, including plans for new utility tunnels. The underground pipes for power, water, heating, telecommunication, gas and other systems will be in place by 2020, the State Council announced. The scheme will remove overhead lines and stop traffic and noise pollution from open-pit works, while improving pipeline safety and disaster resistance. From this year, the government will make sure that underground utility tunnels are developed at the same time as the construction of roads in new districts, industrial parks and development zones, a State Council document decreed on August 10. In the older areas of a city, the authorities must plan underground tunnels at the same time as projects such as road reconstruction and river regulation, so as to reduce disruption. “The construction of utility tunnels is a special priority in urban areas – and concerns infrastructure related to roads, rail transit and underground complexes that involve high traffic volumes and many pipelines,” the government said. “It is also a priority in intensive development zones, public spaces, road intersections, railways and rivers, as well as in narrow road sections that cannot sustain multiple pipelines.” The government will arrange financial support through current channels, while local administrations should pump more funds into the construction of the utility tunnels. The private sector is also encouraged to invest in the building and operation of such tunnels.
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CONSULTANCY
Costain acquires Rhead consultancy Major engineering player Costain has purchased infrastructure, construction and assetmanagement programme company Rhead Group for £36 million (US$56.5 million). Rhead employs over 550 people primarily in the UK, for clients including National Grid and Wales & West Utilities. Costain’s strategy is to focus on major customers spending billions of pounds addressing national needs in energy, water and transportation, the company said: “Customers are consolidating their supply chains and are seeking an increasingly integrated service
offering from their Tier 1 service providers through larger, longer-term collaborative contracts.” Rhead Group will enhance Costain’s programmemanagement and advisory capability as part of that integrated service offering.
In the year ended July 31, 2014, Rhead Group generated revenues of £63.5 million and EBITDA of £5.2 million (before exceptional administrative expenses of £0.7 million). Rhead Group will be fully integrated into Costain this financial year; the acquisition is expected to be earningsenhancing from 2016. Rhead’s senior management team, including Nigel Curry, its CEO, will remain with the business. “This transaction accelerates the development of Costain and further broadens our range of capabilities to meet the requirements of major blue-chip customers, providing greater ability to deliver integrated solutions across the full lifecycle of a project,” Andrew Wyllie, Costain chief executive, said.
CONSULTANCY
CONSULTANCY
Arup has put its confidence in the growing transport infrastructure business in Colombia by opening an office in the capital, Bogotá. The company’s design and planning engineers, consultants and technical specialists have worked on projects in the nation for some time, with notable works including El Dorado International Airport and the Bogotá convention centre. “Our major interest is working on infrastructure projects in partnership with the national government, which includes highways, airports and railway reactivation,” Federico Torres, Arup’s CEO in Colombia, said. The government and businesses have invested billions over the last few years, with no signs of slowing down. “Infrastructure is one of the five engines established by the Colombian govern ment to boost the country’s economy,” María Claudia Lacouture, president of
Metro and rail projects in Brazil could benefit from engineering and consulting group Systra’s takeover of national ‘top-five’ engineering consultant Tectran. Tectran, which employs 80 professional staff, is active in urban planning and logistics studies and in transport infrastructure engineering for metro, rail and road. “We have worked with Tectran since 2013 on passenger rail projects in the Belo Horizonte region,” Systra’s Latin America regional director Colas Martinet Martinet said. “[Tectran’s] expertise is recognised by major private concession operators and civilengineering groups, as well as with major public bodies.” “This acquisition reinforces Systra’s presence in a country with considerable transport infrastructure needs,” Systra CEO Pierre Verzat added. “We are able to anticipate the recovery of Brazil’s economy, which we expect to occur in the coming years.”
Arup enters Colombian civil-engineering market
ProColombia (a government agency promoting exports and foreign investment), said. From 2010 to 2013 there was an accumulated investment of CoP22.4 trillion (US$7.49 billion) in transport infrastructure. Changes to legislation in recent years have allowed for more publicprivate partnerships and the process of granting licences and acquiring property has been simplified. “Bogotá has a highly skilled workforce with experience in infrastructure development,” Juan Gabriel Pérez, executive director of Invest in Bogotá, commented. Notable projects in the capital city have included the expansion of the Bogotá metro and works on the Avenida Boyacá main road.
Tectran sale could boost rail work in Brazil
21/08/2015 09:57
WT September 2015 •
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News TECHNOLOGY
Spanish tunnel work for Thales and Siemens Thales and Siemens will work on the AtochaChamartín tunnel in Madrid, Spain, as part a contract for railway operator Adif. The joint venture is embarking on a larger contract for the Chamartín Torrejón de Velasco high speed section of network to introduce their trafficcontrol and security technologies. Works on the €34.8 million (US$38.4 million) scheme include signalling facilities, train protection systems, fixed telecommunications and centralised traffic control, with a maintenance period of 36 months. The project will connect the MadridValladolidNorth highspeed lines with the
MadridSevilleSoutheast Spain highspeed lines; totalling 37km, of which 7.3km run through the new AtochaChamartín tunnel. Siemens Rail Automation will be responsible for modernising the Trackguard Westrace technology electrical interlocking located at Chamartín station and its
Thales and Siemens will provide communication, control and safety systems for Adif
extension as far as the new southern head of Chamartín station, and will undertake adjustments to the Centralised Traffic Centre (CTC) responsible for the MadridValladolid and MadridSoutheast Spain highspeed lines. Furthermore, it will provide its ASFA train
3
protection system in the AtochaChamartín tunnel and on the track section up to Torrejón de Velasco. Finally, Siemens Rail Automation will install its Clearguard FS3000 line circuits along with LED signals and associated cabling, and will carry out auxiliary civilengineering works as well as the construction of a technical building in Chamartín. Thales will take responsibility for extending and adapting the existing level 1 and level 2 ERTMS protection system in Chamartín station, including modifying two control centres. It will also provide LockTrac electronic inter lockings, ERMTS L1 AlTrac trainprotection equipment, security systems (CCTV) and fixed telecommunications to the ChamartínTorrejón de Velasco section to facilitate the circulation of trains.
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NORTH AMERICA
The long road to now This August, the Federal Highway Administration (FHWA) introduced a standardised inspection programme for tunnels in the US. World Tunnelling finds out what it means for the industry
I
t was a fatal accident that could have been avoided. In mid-December 1967, the Silver Bridge, carrying rush-hour traffic between Point Pleasant, West Virginia, and Gallipolis, Ohio, collapsed killing 46 people. The investigation concluded that a 0.1in (2.5mm)-deep defect in one single eyebar on a suspension chain, combined with poor maintenance and loads exceeding design limitations, caused the collapse. Following this, the US Congress passed the Federal-Aid Highway Act of 1968, which set forth requirements for establishing the National Bridge Inspection Standards (NBIS). Like the NBIS, the genesis of the new The need for inspection National Tunnel Inspection Standards Until now, FHWA has provided tunnel(NTIS) had its own tragic trigger. In July inspection guidance but tunnel owners, 2006 four three-ton sections of a concrete such as state departments of transportadrop ceiling inside the I-90 Fort Point tion or other transport agencies, were not Channel Tunnel in Boston, Massachusetts, legally obliged to inspect tunnels. fell onto a car, killing the passenger and “To date there have only been guideinjuring the driver. lines and recommendations for methods Investigators found that the adhesives of inspection and reporting, resulting in connecting a steel tieback suspending the infrequent inspections and degree of concrete drop ceiling to the main ceiling accuracy, quality of the inspectors and above had failed. extent of what is reported,” On July 6, 2012, US PresRaymond Blanchard and “About 40% of US Bassi Baljinder say. ident Barack Obama signed the Moving Ahead for ProNTIS will also provide a tunnels are now gress in the 21st Century database to keep track of more half a century the tunnel ratings for deterAct (MAP-21), which requires the establishment old; with about 5% mining priority of tunnels to of national standards for or repair based on already exceeding renovate tunnel inspections. limited funds. 100 years of As a result of the legisla“Some [technical assets] tive mandate in MAP-21, need more inspection and service” the Federal Highway Adminservice [more often], such istration (FHWA) formed the as machinery and equipNTIS and corresponding manuals and ment; and some need maintenance with a guides to accomplish the inspections. lower frequency, such as concrete struc-
Experts in this article Raymond Blanchard, P.E. Bassi Baljinder Shay Burrows Roland Leucker Ben van den Horn
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senior principal engineer and project manager, CH2M senior principal FLS engineer, CH2M office of bridges and structures, FHWA chairman of ITA COSUF, and CEO of STUVA ITA COSUF secretary, and senior consultant at Arcadis
In July 2006 four three-ton sections of concrete ceiling inside the I-90 Fort Point Channel Tunnel in Boston, fell on a car; this collapse triggered the establishment of the US National Tunnel Inspection Standards
tures,” Roland Leucker notes. “If some concrete spalling is going to take place, or if steel corrosion is appearing, an early intervention can prevent severe accidents. To ensure safe operation of infrastructure, a regular inspection is mandatory.” Based on preliminary information obtained from an initial tunnel inventory conducted jointly by both the FHWA and the Federal Transit Administration (FTA), more than 350 highway tunnels have been identified in the country. About 40% of these are now more half a century old; with about 5% already exceeding 100 years of service. “Like many places, the number of vehicles using roads is up, mileage is going up. Trucks have the biggest impact to the structure, as they’re getting heavier, causing more damage to roads,” Shay Burrows explains. “Although tunnels have expected lifetimes of 100 to 130 years, degradation can occur and has to be repaired,” Leucker adds.
Deadlines for data
This NTIS will be a nationwide rollout. The regulations were published on July 14, and became effective August 13. “This doesn’t require tunnels to be inspected for two years – until August 2017, but state federal agencies should be gearing up development procedures and staff training,” Burrows explains. FHWA will sponsor eight training sessions across the country over the next four months. The first one is at the end of August in Sacramento, California, the state estimated to have the most road
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Regional focus
tunnels, owing to its expanse, diverse geology, and mountainous and urban areas. All tunnel owners are required to submit preliminary information by December. This informs of details such as where tunnels are, what type they are, and how many lanes they have. It is a call for inspection or condition data, a count of how many there are around the country. The full data should be ready by early 2018.
After the ceiling collapse, an inspection of the Fort Point Channel Tunnel revealed that some of the hanger plates holding the ceiling were coming loose
Fire and freezing conditions
“I think that from a safety point of view, spalling of concrete”, Raymond Blanchard the risks of dynamic mechanical ‘overand Bassi Baljinder point out. loading’ on bridges (fatigue) have been “From a fire and life-safety equipment assessed as higher than the risks related perspective, [inspections] are needed to to tunnel fire safety,” Ben van den Horn ensure that any equipment installed, such says. as emergency ventilation fans or fire“The collapse of the Tacoma Narrows detection equipment, is maintained and Bridge is a famous example to put in good working order.” bridges on the inspection The inspection should calendar.” The main safety concern “In many instances, not be limited to just equipment. heard in the news over the the institution of any “This inspection should years and from inspecting existing tunnels is the type of inspection has include all aspects of including ensurpotential for ceiling and been reactionary, as response, ing that there is a current wall tiles to break loose, mainly due to freezing and a result of a specific response strategy in place, the local fire thawing cycles, causing a incident” department is involved in potential hazard to motor response strategy develvehicles. opment, and ongoing training for all first Another risk is “damage to concrete responders and any operations and conportal structures and concrete linings within the first 30m, again due to freezing trol staff. “Inspections can also ensure that and thawing cycles causing cracking and
Global standards Structural, fire and life safety inspection requirements vary around the world. They are common in the Australia, Japan, the UK and parts of mainland Europe. “Visual inspection was adequate in Japan until 2012 when more than 300 structural precast concrete ceiling panels killed nine people and caused significant property damage in the Sasago Tunnel,” Raymond Blanchard and Bassi Baljinder comment. “Visual inspections are now being considered inadequate. In many instances, the institution of any type inspection has been reactionary, as a result of a specific incident.” There is not a void of literature on the topic, but more could be done. “The World Road Association, PIARC, issued recommendations in 2012 for the maintenance and technical inspection of road tunnels, especially when it comes to technical equipment,” Ben van den Horn says.
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“These recommendations are recognising the fact that standard (highway) tunnels do not exist and a proper inspection strategy depends on the characteristics.” In Germany, for example, inspection of civil-engineering structure along roads has to be carried out according to German standard DIN 1076, ‘Engineering structures in connection with roads – inspection and test’. This standard gives some basic rules for bridges and tunnels; however, some additional information for each type of structure does exist. The structural integrity of the building must also be considered, due to water ingress and corrosion degradation, which can occur and must be investigated as soon as possible. “However, as these processes take place considerably slower so that the inspection intervals are much longer (in Germany – between three and six years),” Roland Leucker reveals.
changes to the physical geometry or operation of the tunnel are made in compliance with local and national code requirements,” say Blanchard and Baljinder.
Future trends
In the short term there are quite a few road tunnels being built in the US. One has just been completed in Miami, Florida; one is being built in Kentucky, one in Virginia and one in Colorado, to name a few. “The demand for road tunnels will most likely increase mainly in urban areas due to limited and expensive real estate required for new bridges and infrastructure,” Blanchard and Baljinder state. Tunnels will provide for new, shorter, faster travel options, and better traffic routing and flow of cars, trucks and other commercial vehicles, resulting in reduced neighbourhood impact, controlled service conditions, and reduced congestion. With respect to fire and life safety, the future trends for highway tunnels will greatly depend on two key aspects: • Design fire sizes: the trend over the last 10 years or so since the Runnehammer tests for larger fire sizes will increase both capital and maintenance costs of ventilation and fire/life-safety equipment, having a negative impact on constructing new tunnels. • Vehicle emissions: these are trending down, which will have a positive impact on maintenance costs. Sometimes age is just a number. The oldest road tunnel in Germany was built in 1834, in Austria in 1765, and in Switzerland in 1708. “STUVA has already prepared a ‘Progress Report on Rehabilitation of Rail Tunnels’ in 2011, which shows the urgent need for rehabilitation in such tunnels in Germany, Austria, and Switzerland,” Roland Leucker says. Currently, a similar report for road tunnels is under development that will be released during the STUVA Conference in December 2015.
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NORTH AMERICA
Super ships and storm surges A joint venture (JV) of Hatch Mott MacDonald and CDM helped safeguard a water-supply connection underneath New York City’s harbour – twice By David Watson
W
hen Hurricane Sandy disrupted a tunnelling project in 2012, it threatened the future of a back-up water-supply link that is key to New York City’s resilience. Following rehabilitation of the flood-damaged tunnel boring machine (TBM), the project is back on track. The story begins thousands of miles away at the Panama Canal, which is being expanded to provide some of the world’s largest ships with a new path to the US east coast. The US’s third largest port, the Port of New York and New Jersey, had to be deepened to 15m to accommodate this new generation of ships. However, this would leave too little ground cover – less than 1m in places – for two water-main ‘siphons’ buried below the harbour. To enable the harbour deepening, these historic siphons – built in 1917 and 1925 as essential water mains, and used as back-up mains since the 1970s to ensure the resilience of Staten Island’s water supply – had to be replaced by a single, larger siphon at a safer depth.
“This is the first EPB TBM used in New York City and the first cross-harbour tunnel in decades”
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The New York City Economic Development Corporation appointed Hatch Mott MacDonald as designer in a JV with consultant CDM, and Tully/OHL JV as general contractor. The JV designed the new siphon tunnel, shafts and associated infrastructure including a chlorination station, microtunnel railway crossings and onshore water-transmission mains and sewers. The Caterpillar TBM was the first EPB machine in New York City
A first for NYC
Due to variable ground, it was recommended to lay the new siphon inside a 3.8m-diameter tunnel, excavated by an earth-pressure balance (EPB) TBM through soft ground at depths in excess of 37m. This is the first EPB TBM used in New York City and the first cross-harbour tunnel in many decades. The Caterpillar TBM has a 12ft 4in (3.76m) excavated diameter with tion following flooding proved valuable 10ft 4in precast concrete lining. in evaluating the crisis and navigating the The ability to monitor and adjust pressure within the cutting chamber, to achieve path to recovery. Both Hatch Mott MacDonald and CDM gathered their experts a balance with the pressure at the tunnel and convened a strategic workshop with face, makes an EPB TBM suitable for varythe client, construction manager, contracing soil types. tor and TBM manufacturer. The launch shaft’s proximity to the A boroscopic inspection and analysis Staten Island waterfront posed a flood risk, determined that the TBM’s main bearing so a flood barrier was incorporated into had sustained only limited immersion and the temporary works design, setting it damage, and could continue operating. almost 1m above the necessary elevation However, the rear components of the TBM to protect against a 1 in 100-year flood backup system, including the trailing ganelevation. The JV then provided design tries and belt conveyor, had to be dismanservices during construction. tled, removed and shipped off site for a Dewatering wells were installed at the complete rebuild. Staten Island shaft. These included wells Meanwhile, the forward portions of the outside the shaft to relieve artesian presback-up system and the TBM sures in the bedrock, and shield itself could not be dewatering wells inside the excavation. Wells were drilled “The TBM and its removed from the tunnel and had to be cleaned, evaluated in a few weeks. trailing parts and repaired in place. A full-time presence on site were totally It was recommended to the created a key link between submerged in facility’s owner, the New York construction and design, and City Department of Environimproved understanding of saltwater” mental Protection, that the field conditions. Risks were siphon’s permanent onshore proactively identified and infrastructure be raised further above the addressed, while immediate advice could revised 100-year flood-plain elevations. be supplied on critical issues. This was agreed and redesigned. This role came to the fore in October 2012 when Hurricane Sandy was forecast, forcing suspension of tunnelling just 460m Balancing act into the 2.9km-long drive. After almost 18 months’ delay, tunnelling The flood barrier, supplemented by sand on the NY Harbour Siphon resumed bags and pumps at the mouth of the tunin April 2014. The rest of the drive was nel, significantly limited storm surge floodnot without challenges. As the TBM ing but could not fully prevent it. Approxiapproached its destination at the Brooklyn mately 50% of the tunnel was inundated shaft, ground conditions required a careful and its 2.6% downward grade meant the balance of foam and slurry to maintain TBM and its trailing parts were totally subpressure when tunnelling through sand merged in saltwater. with cobbles and boulders, and heavy Various hydraulic components and the wear on the cutterhead meant it had to entire electrical system were corroded be maintained mid-drive. The TBM was beyond repair. Hatch Mott MacDonald’s backed up and workers entered the chamexpertise in tunnelling and TBM rehabilitaber under 4 bars of pressure.
Waterfront work site
The tunnel drive was completed at last in January 2015 and installation of the new 1.8m-diameter steel siphon pipe in the tunnel should be installed and grouted by the end of 2015, with overall project completion including the Siphon Chlorination Station by the third quarter of 2016. The project is expected cost US$200 million, including $141 million for the tunnel and shafts. On completion, the scheme will ensure Staten Island’s resilience to any events that threaten its water supply. Finally, decommissioning and removal of the two historic siphons will allow completion of the harbour deepening, and facilitate the economic benefits of finally welcoming larger ships to New York City.
What’s under NYC? Geology varies from decomposed to highly weathered rock at the Staten Island shaft, through glacial soils with cobbles and boulders, plastic silts and clays, and interlayered clays, silts and sands. The most challenging conditions were glacial soils without fines, which required careful control of soil conditioning to achieve a more paste-like material that could form a plug in the screw conveyor and allow the TBM to operate in EPB mode. A combination of foam injected at the cutterhead with bentonite injection in the plenum chamber proved the most effective. Cobbles and boulders along with abrasive soils required two hyperbaric interventions to change cutting tools. One of these interventions had to be performed at a pressure of up to 4 bar in granular soils with high permeability.
David Watson is a senior project engineer at Hatch Mott MacDonald
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NORTH AMERICA
New promise for Peel Two small tunnels could make a big difference for one region in Canada
T
he population of Peel in Ontario, Canada, is growing. Since 2009 over 125,000 more people are living in the municipality, a growth rate of over 10% in five years. Extra demand for businesses and residences is an extra burden on the ageing water network. The Hanlan Water Project is designed to meet the future needs of the region, with the installation of the 2.4m-diameter Hanlan Feedermain and the 1.5m Mississauga City Centre (MCC) Subtransmission Watermain. The feedermain will run approximately 14.5km from the Lakeview Water Treatment Plant on Lake Ontario to the Hanlan Reservoir and Pumping Station at Tomken Road and Britannia Road East. The subtransmission main will stretch about 6km from the Hanlan Reservoir and Pumping Station to the intersection of
Cawthra Road and Burnhamthorpe Road. Work also includes local distribution works, road improvements and wastewater collection improvements along the route. Construction began in 2011 and is scheduled to be completed by mid-2017. Construction methods will be split two ways: open-cut trenches to lay the water pipe; and tunnelling, via two shafts to excavate beneath the surface of the road to install the pipe. This will help preserve environmentally sensitive areas, such as the Etobicoke Creek.
Interlocking Styrofoam sections ensure all the caissons are in the right place
2.4m TBM breaking through at Shaft 3
A touch of TDD
All tunnelling activity for the Hanlan Feedermain and MCC Subtransmission Watermain is through shale rock with swelling and creeping characteristics once exposed to atmospheric conditions.
“This condition, known as timedependent deformation (TDD), occurs for up to six months following exposure to the atmosphere along tunnel and shaft
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Regional focus
Above: welding pipe restraints Main picture: aligning the 2.4m TBM with the rails
walls,” the Hanlan project team tells WT. “Newly formed stresses formed by this rock swelling behaviour are integrated into our design, and have led to the use of cautionary rock support in the form of ribs and lagging along much of the tunnelled route.” There are also mandated minimum waiting durations before grout works can be placed following mining and pipe installation. “It is these unique design and construction considerations that permit the 2.4m Hanlan Feedermain to be tunnelled through the distinctive shale rock along its route.”
Hanlan Feedermain
Hanlan Feedermain Contract 1 was the first contract to start tunnelling operations in the spring of 2014. Contract 1 covers 5,850m, all tunnelled. Contract 2 is 2,510m, all open cut. Contract 3 comprises 5,500m total (tunnel: 4,330m; open: 1,170m). 640m was previously completed via open cut. Overall, 70% of the Hanlan Feedermain length will be completed by tunnelling. The contractor on Contract 1 is McNally Construction, with tunnel works costing C$98 million (US$74.88 million). A Robbins 3.65m-diameter hard-rock TBM, manufactured in 1980, is being used on Contract 1. T2DMP Hanlan Infrastructure is undertaking Contract 2 open-cut efforts. Contract 3, the combination of tunnel
and open cut, is overseen by the Southland Technicore Mole JV. The tunnelled portion of this contract is approximately C$185 million. Here, a Lovat Tunnel Equipment 3.25m-diameter hard-rock TBM, manufactured in 1991, is tunnelling away. “One particular challenge on the Hanlan Water Project has been co-ordinating the three general contractors’ work activities at the intersecting points of their respective feedermain contracts so that sufficient time and space separation is always maintained,” the Hanlan project team explains. “A watchful eye on their critical-path activities near these locations, in combination with the co-operative support of our general contractors, and regular communication has thus far successfully mitigated any risk of delay.
Inside the 1.5m TBM, tunnelling the MCC watermain under Tomken Rd
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“It is evident that by segmenting the feedermain into multiple contracts we have mandated a greater degree of project-management services. “We are confident that despite the challenge of additional co-ordination, the benefit of leveraging three separate contractors working simultaneously to complete the feedermain far outweighs the hurdles of working in a different way.” All contracts are on or ahead of schedule, and are expected to meet their required substantial completion date of mid-2017.
MCC Subtransmission Watermain
As with the feedermain, tunnelling here began in spring 2014. 3,930m of the MCC Subtransmission Watermain is tunnelled, and 2,070m will be installed via open-cut methods. Altogether, the MCC Subtransmission main is 6km in length: 34% open-cut and 66% tunnelled. “A significant value engineering change proposal was introduced by the contractor, which involved increasing the portion of MCC installation by tunnelling and reducing the amount of open-cut construction,” the Hanlan project team comments. “This thought-provoking change in design so late in such a complex project posed unique and demanding challenges to our project team. Ultimately, with the support of our elected officials and project advisory group the proposal was accepted and we are extremely happy with more tunnelling and less surface disruption for the community surrounding the project.” The general contractor of the 1.5m MCC Subtransmission Watermain is the Southland Technicore Mole JV. On Contract 3 a Terra Form 2.74m-diameter hard-rock TBM, manufactured in 1991, is being used. A Technicore Underground Corp 2.66m-diameter hard-rock TBM, aged 10 years, is also boring through. The MCC Subtransmission Watermain is currently on schedule and expected to be completed on time. Total cost of all tunnelling works from Contract 1 and Contract 3 Feedermain and Subtransmission Main works are approximately C$274 million. It will not be last time the region sees a TBM. “We’ve used tunnelling on many previous and current projects. We will likely be much more dependent on tunnelling future infrastructure projects due to our congested urban environment both from a utility and traffic standpoint,” the Hanlan project team adds.
World Tunnelling would like to thank Scott Durdle and Dave Abreu, Hanlan ambassadors, and Anthony Parente, Hanlan project director, for their input into this article
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WT September 2015
Equipment in action: shaft sinking & raiseboring
TECHNOLOGY
Clever sinking On tunnel projects in Hong Kong and Malaysia engineers were put to the test in inconsistent ground while trying to maintain an eye for accuracy By George Demetri
S
hafts play a crucial role in tunnelling, as they form the passageways for supplying equipment and materials, and also provide access and ventilation. A circular shaft in ring compression is self-stable and does not normally require any additional strutting during
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excavation. Firstly, this is a safer way to excavate, as crew and equipment do not have to work under any heavy support assemblies, and there is no need for anyone to work at height. Secondly, as there is no need to install strutting, there is no need to halt the work below, making for a faster and smoother excavation. Third, the high level of compression in the wall means that the
concrete is working in an optimal condition, so the design of reinforcing steel can be minimised. With these benefits in mind, Intrafor – a subsidiary of VSL International and part of Bouygues Construction Group – recently completed a 48m-deep circular ventilation shaft on the Tuen Mun – Chek Lap Kok Link – Northern Connection Sub-Sea Tunnel Section in Hong Kong.
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Equipment Equipmentininaction: action:shaft shaftsinking sinking&&raiseboring raiseboring 13 is to toe the diaphragm wall inside a 300mm socket of rock category 1c, but we were in a fault area, resulting in panel toes varying from 48m to 68m.” The fault meant Intrafor faced a high angle of dip, which sometimes resulted in having to excavate though 3m of 1c-category rock in order to reach the designed founding level. Due to the formation level being very low (46m deep), Intrafor opted for milled joints to ensure water-tightness in the wall joints. The shaft working in compression also helps reduce the risk of joint leakage. A bentonite slurry’s properties decrease significantly with cement contamination. To counter this, polymer and soda ash were used to maintain properties and allow re-use of the slurry. Maciszewski adds: “When constructing a circular shaft, the panels have to be perfectly aligned in order to spread the load evenly, so we had to comply with a 1/200 tolerance, whereas we normally work with a 1/100 tolerance. This required special attention in order to complete on time, as well as achieving high quality on a project that isn’t, by any means, common.” Only one ring beam was used to support the shaft during construction. No water ingress was encountered throughout the work and grouting was not necessary. The project also had a further benefit: spoil was taken from the site by barge to be used as landfill at other projects in Hong Kong.
Completed in March 2015, the 56m-diameter shaft was constructed using diaphragm walls up to 70m deep under a bentonite slurry using milled joints (see case points below).
Unstable geology
Photos: Derek M. Allan
Excavation went through 20m of recent landfill, 6m of alluvium and from there downwards comprising completely decomposed granite (CDG) – basically silty sand ranging from soft to hard. “We usually stopped the cable grab at 30m as the CDG at this level was less silty and started to be difficult to excavate by cable grab,” states Nicolas Maciszewski, superintendent at Tuen Mun – Chek Lap Kok. “In Hong Kong the current practice
Completed 56m-diameter ventilation shaft at the Tuen Mun-Chek Lap Kok Link – Northern Connection Sub-Sea Tunnel Section in Hong Kong; left inset: diaphragm-wall panels in the shaft; right inset: cable-grab excavator used on the project
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Graphic showing the concept of Herrenknecht’s VSM system
Herrenknecht claims that using VSM allows shafts to be completed quickly, safely and in difficult ground conditions, without affecting groundwater levels or the surrounding soil. Initially, a 1m- to 2m-deep launch shaft is formed and a support concrete ring beam is installed around its perimeter. The shaft-boring machine is lowered into the slurry water-filled shaft, its three machine arms gripping the sides for stability. Shaft excavation is achieved by a telescopic boom armed with a rotating cutting drum and attached chisels tools – similar to a traditional roadheader. New developments The swivelling and rotating action of Recent years have seen some pretty the boom assembly excavates the shaft inspiring technology introduced for shaftbase over the entire cross-section plus sinking and raiseboring, as well as refineovercut. During excavation, the slurry ments to existing technology. At the forewater balances the ground-water presfront of numerous significant sure in the surrounding soil. Spoil is transdevelopments is Herrenknecht. ported by a slurry circuit to a separating The company recently introduced its plant on the surface. Shaft Boring Machine for Shaft EnlargeAt the same time as excavation proment (SBE) – conceptually a hard-rock ceeds, jacks and steel cables TBM acting vertically (see WT supported on the concrete September 2014, pp 18-19). “Recent years ring structure at the surface But it has also introduced the Vertical Shaft Sinking have seen some lower the shaft’s entire conlining structure while Machine (VSM), which excapretty inspiring crete ring-building at the top end vates and lines the shaft technology continues with the bolting of simultaneously, whether by concrete rings or sprayed introduced for rubber-casketed precast concrete segments. concrete. Aimed at soft and shaftsinking and Lowering the shaft lining stable soils (especially below is facilitated by reducing fricgroundwater) with compresraiseboring” tional forces in two ways: sion strengths of up to first, an integral steel edge 80MPA, the system features a on the lowest concrete ring cuts through shaft-boring unit and a lowering mechathe soil; second, a bentonite solution is nism that can produce shafts from 4.5m injected into the annular gap. ID to 11m OD.
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WT September 2015
Equipment in action: shaft sinking & raiseboring
The VSM is removed when the shaft reaches the desired depth, allowing the base plug to be cast. Once the concrete has reached its required strength, the water is pumped out of the shaft. Daily sink rates are claimed to be around 1m-5m, although this depends on the shaft diameter, geology and hours worked. In a variation, dry excavation of shafts is possible in soft to medium-hard rock and can incorporate rockbolting and shotcrete-spraying systems. VSM has been used to excavate 10 ventilation shafts between 34m and 45m deep for metro Line 1 in Naples, Italy. Inside/outside diameters are 4.5m/5.2m. Four vent shafts are also planned on the city’s new metro Line 6. Also, in late 2014, six ventilation shafts up to 73m deep (5.7m ID/6.4m OD) were sunk on Moscow Metro’s Lublinskaya line through a geology comprising sand and clay (max. 60 MPa). Progress of up to 8m/day was achieved.
Ule Jelai Hydropower, Malaysia
Located on the Bertam River in Pahang State, Malaysia, the US$400 million Ule Jelai Hydropower project will comprise an 80m-high dam, an underground power station and 22km of tunnels. On site since 2011, it will be completed in mid-2016 with an installed power of 382MW. Italy-based raiseboring specialist Edilmac has been commissioned to construct a series of shafts, including a 16.5m-diam-
eter, 35m-high upper surge shaft supported by 150mm of shotcrete and 4.5m-long type RI rockbolts; a lower surge shaft (160m high, 7.5m diameter); a 25m-high junction surge and power shaft, and a power shaft (107m high, 6.5m diameter). Excavation is through
Fig 1: excavation sequence used by Edilmac at the Ule Jelai Hydropower project
The specialist for tunnelling equipment and logistic systems
good-quality granite (UCS 115 MPa). Edilmac’s Giulio Maccabelli tells WT: “Since November 2013, our staff have been involved in building two vertical wells, 17m in length and 1.84m in diameter; and a subsequent 337m piezometric well of the same diameter using raiseboring technology, and its later enlargement and safety implementation from an initial diameter of 6.5m up to 16.5m.” Due to the large diameters involved, excavation begins by drilling a 310mm (12.25in)-diameter pilot hole down to the bottom of the proposed shaft; a Tricon bit with tungsten carbide inserts is used and drilling waste is carried away by water. Micon’s RVDS (rotary vertical drilling system) tool for directional drilling controls the borehole’s verticality and is said to have an accuracy better than 0.2m/500m.
Maschinen Stahlbau and
Dresden Branch of Herrenknecht AG www.msd-dresden.de | info@msd-dresden.de
• High-performance rolling stock • Jobsite logistics • Customized back-up systems • Shaft installations MSD_08_2015 WT.indd 1 Shaft_WT1509.indd 14
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WT September 2015
Equipment in action 15
InnoTrans 2016 20 – 23 SEPTEMBER • BERLIN
International Trade Fair for Transport Technology Innovative Components • Vehicles • Systems
innotrans.com
According to Edilmac, the accuracy of the 310mm pilot hole using this method is in the region of 0.5%-1.5% of the total shaft length but cannot be guaranteed. Following completion of the pilot hole, the bit is removed and a 1.84m-diameter Robbins RR6 reaming head (weighing 5,000kg) is attached to the drill string. Raiseboring begins using an Ingersoll RBM7 and ends when the head has reached the top of the shaft. The pilot shaft is later enlarged to the final diameter by drill and blast. Throughout these operations, spoil is removed from the base of the shaft (see Fig 1). A specially designed travelling crane handles all equipment and materials into the shaft. Lining the shaft walls will comprise R1 rockbolts (25mm-diameter deformed bar embedded with resin or cement grout), a layer of shotcrete according to expected support type, and if required, steel ribs and wire mesh. Typical timescales for construction of the surge and power shaft (total length 337m) are around 13 days for site installation, assembly and disassembly; 15 days for pilot drilling (assuming an advance rate of around 1.3m/h); and 40 days for reaming, assuming an average of 0.52m/h. “To solve the issues related to the large and varied enlargement diameters and safety implementation, Edilmac is using a new G18 CG 30/15 gantry crane specifically built for this project,” says Maccabelli.
Main picture: lowering VSM cutting drum into shaft at Moscow metro project Top inset: on the Ule Jelai project, Edilmac used a grantry crane to handle components Lower inset: a completed shaft at Ule Jelai
“According to Edilmac, the accuracy of the 310mm pilot hole is in the region of 0.5%-1.5% of the total shaft length”
Contact Messe Berlin GmbH Messedamm 22 · 14055 Berlin Germany T +49 30 3038 2376 F +49 30 3038 2190 innotrans@messe-berlin.de
George Demetri is a journalist and technical writer on underground construction and can be reached at geo@graphyk.com
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Best practice: waterproofing TECHNOLOGY
Home and dry How can companies ensure the integrity of waterproofing solutions in the fast-growing immersed-tunnels market? By George Demetri
P
olymeric geomembranes have been used in tunnelling for many years with great success. But problems can occur if the inner lining is damaged during the installation process. Once the concrete lining is in place, it can be very difficult to locate the source of the leak, often requiring complex remedial repairs, perhaps even involving injection and backfilling. Some of the more innovative tunnel waterproofing technology to emerge in the past three to four years has come from Austria-based Agru. It has two systems worthy of note. The first begs the question: “How can
you be certain of the integrity of a waterproofing membrane once it has been installed, and how can testing verify this?” Agru’s Geomembrane with Integrated Electronic Leak Detection appears to provide an answer. The waterproofing method was
17
designed to meet the problems associated with the construction of the 10.6km Niagara Tunnel in Ontario, Canada. Conveying water to the Sir Adam Beck hydropower complex, the tunnel alignment runs through Queenston Shale, a rock that expands when continually saturated. However, extensive saturation could disturb the geological formations and lead to potential uplift above the tunnels and even minor tremors. It was therefore crucial to ensure that the tunnels could be totally sealed, and to ensure that the technology was available to detect whether and where any damage had occurred to the waterproofing liner.
Above: cross-section through multi-layer, laminated geomembrane liner
Two-coat Stirling Lloyd spray system of contrasting colours
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WT September 2015
Best practice: waterproofing Photo: The Elizabeth River Tunnels Project
To meet these objectives, Agru, in association with Strabag and ProGeo, developed a patented, multi-layer, laminated geomembrane that can reveal (after liner placement) where liner damage has occurred. The tunnel liner (attached with Velcro discs to the tunnel wall) comprises a flexible polyolefin waterproofing membrane sandwiched between electro-conductive layers connected to a monitoring device (see diagram). A high voltage is passed through this assembly. If the liner is damaged at any point, current will flow between the electro-conductive layers at the point where the damage has occurred, thereby causing an increase in local temperature. An infra-red camera is then used to reveal where the increased temperature has occurred, locating the leak. Thus, the entire tunnel liner can be inspected for proper installation before the final concrete lining works begin. More recently, Agru introduced its Induktofix system, which allows the mechanical fixing of a thermoplastic liner to a concrete substrate without puncturing the liner. Its main application is the renovation of existing concrete structures and tunnels, especially the temporary fixing of geomembranes, particularly to seal nel; the latter is also being rehabilitated the tunnel crown. and currently carries around a million Welding discs are first attached to the vehicles each month between Portsmouth concrete structure without, it is claimed, and Norfolk. the need for any extensive surface prepaThe SKW joint venture – comprising ration. To install the lining, the Induktofix Skanska USA Civil, Kiewit and Weeks welding discs are mechanically fixed to Marine – is constructing the scheme with the existing concrete structure, either in a Parsons Brinckerhoff as lead designer. grid or variable pattern, thereby avoiding Designed to increase capacity and the problem of fixing into steel reinforcereduce congestion, the new 1,280m-long, ment. Once the anchor studs two-lane immersed tube is have been removed, the proexpected to increase road “Clients are now, safety by eliminating oppostective liner can be positioned and induction-welded more than ever, ing traffic flows in the tunto the discs. it will extend under the buying into the nels; Agru claims the benefits of Elizabeth River and is notable the system include non-pene- idea of whole-life for being North America’s tration of the lining system; first deep-water concrete costing” reduced welding when comimmersed tube. pared with conventional sysThe majority of immersed tems; flexibility in the positioning of the tubes in the US have been steel-shell condiscs, faster installation; and reduced crete tunnels but at Midtown concrete costs from not having to fill the annular tunnel elements are being used for their gap with concrete. cost savings and flexibility of design. The new tunnel will comprise 11 reinforced concrete elements weighing Working in tandem 16,000t each with temporary bulkheads Virginia Department of Transportation’s (VDOT) second Midtown tunnel scheme is to allow them to float. In cross-section, each element has two chambers – a large, being constructed under a public-private two-lane road chamber and a smaller partnership and is part of an agreement egress corridor for emergency escape with Elizabeth River Crossings (ERC). and maintenance access. Located in the Hampton Roads area Waterproofing between the concrete between Norfolk and Portsmouth, Virelements is being achieved by the installaginia, US, the US$2.1 billion scheme tion of Trelleborg’s Gina and Omega sealincludes a new immersed tunnel that will ing gaskets between the bulkheads at run parallel to the existing Midtown Tun-
Waterproofing_WT1509.indd 18
the ends of the individual tunnel elements. Both gaskets work in tandem. The Gina is attached to each end of a tunnel element before immersion. When the immersed tunnel elements are pulled together, the Gina profile compresses and seals the joint due to the pressure differential between the bulkheads and the hydrostatic pressure on the outside of the tunnel. Once the water has been pumped out and the temporary bulkheads removed, the Omega seal is installed on the inside of the tunnel element across the joint. André de Graaf, sales manager for Trelleborg Engineered Products, tells World Tunnelling: “The Gina gasket is made from natural rubber and is supplied as a closed rectangular frame to seal each sectional element.” Each gasket will have a hardness to suit both the intended depth and the hydrostatic pressure to be encountered: the deeper the application, the harder the compound must be. “The Omega seal connects each segment together and is made from multiple layers of SBR and nylon to improve durability,” adds de Graaf. “The combination of the two seals enables the transfer of hydrostatic loads and movements between the tunnel ends, generally caused by soil settlement, creep of concrete, temperature effects and earthquakes.” The final element was lowered into
21/08/2015 10:17
WT September 2015 •
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Best practice: waterproofing Main picture: crews at Sparrows Point, Maryland, installing bulkheads and Gina gaskets onto tunnel elements for the Midtown immersed tunnel Left inset: detection of liner damage using infrared camera Below: spray application of waterproofing first coat onto walls of a cut-and-cover tunnel outside the Emirates Palace Hotel, Abu Dhabi
position in July and the tunnel is scheduled for completion in early 2017.
Spray policy
Stirling Lloyd offers waterproofing products for a variety of construction applications. For tunnelling, its Integritank HF is a two-coat, spray-applied system aimed
at shotcreted and cast concrete tunnels. It has been used to waterproof numerous high-profile tunnel projects, including the Yas Island Southern Crossing in Abu Dhabi. This tunnel runs beneath a 25m-deep sea channel and links the Abu Dhabi mainland with Yas Island. Integritank is formulated to be a sprayapplied, seamless elastomeric waterproofing system that, according to Stirling Lloyd, fully bonds to the structure to provide a seamless system behind which water cannot track – as can happen with traditional loose-laid sheets. Two of its stated benefits are speed of application and curing. The company claims a design life in excess of 100 years. “Clients are now, more than ever, buying into the idea of whole-life costing and ensuring that the correct and best-value solution is provided at the outset by selecting a proven bonded technology,” says James Hopper, Middle East regional sales manager for Stirling Lloyd. “In the long term, this ensures that their significant investment in infrastructure will serve future generations rather than burden them.” Integritank has been used extensively on immersed tunnels and marine crossings. It is said that it can be repaired underwater if the need ever arises. Application is by spraying between primary and secondary shotcrete layers or used between cast concrete layers. On-site quality control is facilitated by the product being applied in two colour-coded coats. A render coat is recommended on steel-fibre-reinforced primary linings.
George Demetri is a journalist and technical writer on underground construction and can be reached at geo@graphyk.com
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North America
Success from five applications on one site
Microtunnelling
Sewer installation by the Mad River
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Plenty in the pipeline for Turkey
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September 2015
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Contents
1
EDITOR’S COMMENT
The animal instinct of engineering
Y
our grandmother probably told you that if you eat more rabbit food – carrots, in particular – you can see in the dark. While we’re still waiting for solid proof of this, we’ll look back down the food chain and see what we can learn from the hunger games of other species. The humble bat can tell how far away something is by how long it takes the sounds it emits to return to it. This echolocation provides the bat with a sonic map with which to navigate the dark.
News Regional focus: North America
Coast-to-coast rebuilding drive for contractors Linking communities with trenchless technologies
The same creature’s wings inspired Da Vinci’s flying machine idea in about 1488. Now, in 2015, engineers are once again drawing from the bat to make big changes to utilities. Enter the SewerBatt, an acoustic pipe inspection device, which uses the same echo location principles that allow these mammals to fly at night. Lanes Group, in partnership with Thames Water, has become the first wastewater network contractor in the UK to commercially deploy the technology. It works by sending multi-frequency sound waves along sewer lines. The sound echoes off of chambers, lateral connections, cracks, deformities or blockages, feeding engineers with distinct notes, which are displayed on a digital graph.
“The longeared owl could help reduce sound on construction sites”
6
Small site and stubborn slate Putting the coat on Life under the third lane
What other ideas can we pluck from the sky? You’ll probably see a bat as often as you’ll see an owl. But when do you hear it? Research published in the journal Bioinspired, Biomimetic and Nanobiomaterials, has revealed how the feathers of the long-eared owl could help reduce sound on construction sites. During flight, the owl’s feather structures are able to extract the mechanical energy from the vibrations and convert it into heat – enabling the creature to remain stable and quiet. In engineering, the process used to eliminate this mechanical noise is called ‘damping’ – the extraction of mechanical energy from a vibrating system, usually by converting it into heat and allowing it to remain steady. Owls, bats… personally, ‘pigging’ still remains my favourite.
10 12 14
Special report: No-Dig Istanbul Construction under the crossroads Talking Turkey
17 18
Special report: ICUEE preview
Take tomorrow for a test drive
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Contacts
21
Next month
The trials, during which a CCTV drainage survey was carried out to back up each SewerBatt inspection, showed the system was 97% accurate.
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4
Best practice: Microtunnelling
Within 30 seconds, the system’s software analyses the data from each length of pipe, and provides a simple output assessment of its condition as being green (clear), amber (requires further analysis), or red (requires remedial action).
LUKE BUXTON, EDITOR luke.buxton@aspermontmedia.com
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Regional focus: Australasia
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Best practice: HDD Equipment in action: Lining
Cover Customers learn about the all-new 2015 DD-110 at American Augers’ annual Customer Day held this past June. The rig was unveiled to guests at this special event and is now available for customers looking for the perfect HDD rig in the 100,000lb (50t) class. n Pipe rehabilitatio during the cold snap CIPP works
Europe Western the market share Expanding
Augerbyboring the Boeing plant Take-off
September 2015
.com
www.trenchless-world
ISSN 1756-4093
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News SEWERAGE SERVICES
Amey secures water contract Regulated services provider Amey will become responsible for the network repair and maintenance of UK utility Yorkshire Water’s 55,000km of sewerage pipes from September. The contract, worth in excess of £113 million (US$177 million), will improve response and resolution times when dealing with customer issues, Yorkshire Water said. The deal will expire in 2020 with almost 2.5 million properties and over 600 waste-water treatment works covered. Amey will also support Yorkshire Water in protecting homes from sewer flooding and pollution incidents, which equates to over 100,000 jobs a year. The company has been involved with the water sector for more than four decades, working in partnership with some of the largest water-utility asset owners in the world to offer a full range of clean and waste-water services. This includes network design and installation, repair and maintenance and civil engineering on both infrastructure and noninfrastructure works. Every year, the company installs, upgrades and repairs 300km of water pipes and undertakes over 250,000 clean- and wastewater repair and maintenance jobs across the UK.
TECHNOLOGY
Sykes primes market for pump sales Sykes Pumps’ six-month R&D programme has produced a new range of bentonite pumps for construction, civilengineering and utility projects. The pumps are aimed for flooded suction or automatic priming applications. The launch of the B150 range, which includes both electric and diesel units, was the result of customer feedback to incorporate features and benefits. The pumps have been designed for faster and easier set-up on site. Sykes Pumps’ rotary-vane vacuum pump-
priming system delivers fully automatic self-priming from dry and rapid re-priming where required, while the innovative priming shut-off valve enables configuration without the use of a blanking plate, with a simple lever to
ASSOCIATIONS
New chapter for NASTT Seven US states have been included in a new trenchless association merger. The Northeast Trenchless Association (NTA) and the North American Society for Trenchless Technology (NASTT) are joining together to form the NASTT Northeast Chapter.
An expanding family: NASTT staff members
This chapter will cover Connecticut, Maine, Massachusetts, New Hampshire, New York, Rhode Island and Vermont. The new chapter will be celebrated at a launch event on November 12 at the Springfield Marriott in Massachusetts. Members will outline the goals of the new association, including a call for nomination of officers. The event is open to all stakeholders including municipal utility owners and operators, consulting engineers, contractors, suppliers and students. The next NASTT show will take place at the Gaylord Texan Hotel & Convention Center in Dallas, Texas, from March 20 to 24, 2016.
TECHNOLOGY
Milliken podcast focuses on geopolymers Each week, listeners can learn of solutions for storm and sanitary markets from Milliken Infrastructure’s new series of five weekly podcasts. The ‘Industry Insights: Geopolymers’ series of podcasts are led by development manager Joe Royer, offering a detailed look at common infrastructure repair problems and how to address challenges with new technology. The podcasts focus on the increased demand and adoption of geopolymer mortar systems,
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techniques and more. Additionally, Royer walks listeners through two pipe-repair projects. “Geopolymers are known to have advantageous chemical resistant and physical properties, but are not typically industrially used,” Royer said. “We recognised that handling and mixing highly concentrated, alkaline solutions on a jobsite comes many risks, and focused on addressing those problems by developing a just-add-water geopolymer solution.”
switch off the automatic priming function and enable safe and efficient floodedsuction operation direct from a silo, the company said. Capable of heads of up to 38m, a flow rate up to 90L/s and handling solids, the pumps have a weatherproof control panel that enables site set-up in automated or manual configuration, with an emergency stop button for safety. Sykes Pumps has fitted the lightweight B150 pumps with an oil-bath mechanical seal for efficient performance and abrasion resistance, while a three-way valve on the vacuum pump and six flushing points per unit ensure easy cleaning, flushing and draining, saving time on site.
SAFETY
New portable gas detector Water and waste-treatment facilities and utility companies now have more choice of gasdetection gear. Crowcon has launched the T4 portable multigas detector, which it said will enable companies to ensure compliance to safety standards by protecting employees against unsafe levels of carbon monoxide, oxygen, hydrogen sulphide and flammable gases. Among the key features of the T4 are Crowcon’s +ve Safety status indicator; easy one-button operation; clip-on filter plates; and a novel timeweighted average (TWA) resume facility. +ve Safety is a ‘traffic light’ status indicator that allows the user to check compliance status without having to read and interpret data. TWA resume ensures that TWA logged doses of toxic gases are not reset when the unit is shut down, for example during a break.
21/08/2015 09:23
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TW September 2015
Regional focus
4
NORTH AMERICA
Coast-to-coast rebuilding drive for contractors
In this edition’s regional focus we look at trenchless activity on a handful of underground construction projects from across North America. This month’s selection highlights installation and rehab of pipes and sewers for water, wastewater and gas utilities, with drought and damage posing problems for some
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Gas line on Highway 29
Project location: St Helena, California, US Type of work: Gas-pipe installation Trenchless techniques: HDD
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Pacific Gas and Electric Company is moving on to the second stage of its Highway 29 Channelization project, with contractors preparing to install two sections of gas pipeline. An HDD rig will complete the pilot hole, being drilled at Dowdell Lane. A further investigation of the project site revealed that a second HDD rig is boring a similar pilot-hole further up near Charter Oak. Along this section of Highway 29, where there are several driveways and road crossings, the use of HDD will reduce the need to close streets or repave crossings. The California Department of Transportation (Caltrans) says the project should be finalised by 2017.
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Works in Willow Hill
Project location: Folsom, California, US Type of work: Pipe rehab Trenchless techniques: Unknown
Trenchless underground-construction company Mountain Cascade is undertaking phase one of the Willow Hill Pipeline Rehabilitation project. As California suffers from drought, the city is co-operating in planning through the Regional Water Authority for long-term water-supply needs. In 2009, Folsom began to assess ways to increase efficiencies in the city’s waterdelivery systems and to develop a programme that would comply with the Sacramento-San Joaquin Delta Reform Act of the same year. A city review and leak-detection and repair programme took place. The system diverts raw surface water from the Folsom Dam-Water Treatment Plant delivery system and conveys this raw water through 22,000 linear feet of pipe to the Willow Hill Reservoir to serve nearby aerospace and defence-market company Aerojet’s nonpotable industrial needs.
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Regional focus
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Dealing with a decayed sewer line
Project location: Adrian, Michigan, US Type of work: Pipe lining Trenchless techniques: CIPP
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Layne Inliner is wrapping up rehab works on a US$103,255 contract to line approximately 1,000ft (304.8m) of a deteriorated 24in (609.6mm) stormwater sewer line. The sewer beneath Michigan Avenue had decayed to a thickness of about 3/8in from an original thickness of at least 2.5in. Over the years the concentration of hydrogen sulphide gas has eaten away at the concrete sewer pipes. Slusarski Excavating performed repairs on the 10ft-deep sewer. Once the collapse was excavated and inspected, it was found that the concrete had deteriorated.
4 •
Project location: Ottawa, Ontario, Canada Type of work: Water-main installation Trenchless techniques: HDD; auger boring; CIPP; pipe lining; pipe rehab
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5 • • •
The fabulous five (see page 6)
Contractors are installing 8,000m of multi-diameter water main to connect the growing area of Orléans to the city of Ottawa. A unique solution was required for the Orléans Watermain Link (OWL) project, taking into account the significant operational challenges, the need to minimise disruption to the community and the need to cross many environmentally sensitive features. Teams executed five different trenchless applications. See the Trenchless World focus on this project on page 6.
Shifting bridges: the hazards of HDD
Did you know?
•
Between 2014 and 2060, the US population is projected to increase from 319 million to 417 million, reaching 400 million in 2051
•
Canada’s medium-growth scenario forecasts the nation’s population would reach 51 million in 2063, from about 35 million today
•
Mexico’s population is expected to rise by about 30 million by 2050 – from approximately 125 million today
Project location: Longboat Key, Florida, US Type of work: Pipe installation Trenchless techniques: HDD
Construction works to install a pipeline have been blamed as the cause of damage to the Longboat Pass Bridge, which became stuck in the down position in October 2014. The Florida Department of Transportation’s contractor, Infrastructure Corp. of America (ICA), discovered that the gap between the bascule and the roadway has widened from 1.5in (38.1mm) to 4in. Repairs could cost up to US$2 million. Last year, Spectrum Underground, a general contractor for the town, had its subcontractor, TB Landmark, install a 16in pipeline in Longboat Pass to supply the town with drinking water from Manatee County. ICA suspects that horizontal drilling to bury the pipeline caused the bridge to shift by destabilising subsurface soils, including soils that support the bridge.
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NORTH AMERICA
Linking communities with trenchless technologies
The trenchless aspect of most construction schemes is sometimes minimal. On one unique project in Ottawa, Ontario, Canada, no less than five trenchless applications took place By Jeffrey Waara and Gerald Bauer
O
n the eastern edge of the city of Ottawa, along the Ottawa River, lies the suburban community of Orléans, with a population of over 110,000 residents. This growing area is serviced by only one large feeder main. A failure of this critical infrastructure linking Orléans to the rest of the city would have serious impacts on the city’s ability to meet daily water demands. Recognising the importance of improving the reliability of water delivery, the city embarked on a major initiative to install over 8,000m of multi-diameter water main. A unique solution was required for the Orléans Watermain Link (OWL) project taking into account the operational challenges, the need to minimise disruptions to the community and the need to cross many environmentally sensitive features. The city first completed a study to determine the best option to significantly strengthen the water-supply system while also meeting future demands. Maximising short- and long-term operational flexibility, determining how best to connect to
the existing piping, minimising impacts on the surrounding community and maximising construction costeffectiveness were key goals.
Pushing scope
Above: the use of traditional open-cut construction would have caused a significant impact to the public, utilities, traffic and environmental areas such as Greens Creek
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“A unique solution was • required for the Orléans Watermain Link” •
The study indicated that using traditional open-cut construction would significantly impact on environmental, public, utility and traffic, including: • A crossing of the environmentally sensitive Greens Creek, with steep sides and a creek bed well below the surrounding lands; • A crossing of the Rockcliffe Parkway, which is several metres above the surrounding grades and owned by a federal agency; • A crossing of Ottawa Regional Road 174 (OR 174), a critical transportation link between Orléans and the rest of the city; • Construction on major arteries and roadways with a number of business owners and major utility infrastructure;
Culvert rehabilitation needs and replacement along OR 174; An alignment on private lands that required both temporary and permanent easements; Difficult soil conditions in some areas.
Making the project more complicated was the realisation that a single trenchless installation method was not appropriate for all areas of concern. A Value Engineering (VE) session was held with
The project in numbers 590m
HDD drive
110m
casing on auger-bore crossing
1,300m 16
watermain lining stretch number of culverts renewed
A Vermeer HDD machine installed more than 0.5km of pipe under sensitive and difficult terrain
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infrastructure experts and city staff to validate or modify the proposed solution based on specific location features and constraints. The selected solution brought together a combination of traditional open-cut and various trenchless technologies. The trenchless installations included: • Horizontal directional drilling (HDD) crossing under Greens Creek and the Rockcliffe Parkway (590m-long pull); • Auger-bore crossing under OR 174 (110-metre long steel casing); • Water main lining of existing connecting water mains (1,300 metres); • Renewal of 14 corrugated steel culverts along OR 174 using cured-in-place pipe (CIPP) liners; • Renewal of two concrete box culverts along OR 174. The following provides details on each of the trenchless technologies used.
Horizontal directional drilling
The features that led to HDD being preferred for installing 590m of pipe under the environmentally sensitive Greens Creek and Rockliffe Parkway included crossing a smaller secondary creek and significant erosion and slope-stability Top & above: 1,178m of 406mmmeasures that had previously taken place. diameter and 179m of 300mmThe high groundwater along the route diameter water main were lined and homogenous soft clay soil were also of concern. The elevation along the Avoiding cuts to the artery route varied by over 23m vertically. OR 174 is a critical link to the Orléans An alignment along OR 174 with parts community, having two east-bound and of the embankment was at almost a 1:1 two west-bound lanes with a designated slope with a 15m vertical variation. In bus lane in each direction. addition to this, there were minimal Jack and bore was determined to be areas for staging construction activities. the preferred solution here and was used Contractors had to consider carefully to install 110m of pipe under the freethe bending radius along the bore path way. Installation of the casing and pipe to minimise the length of was at a depth of about HDD on installation of a 4.5m below the travel “The OWL project 914mm-diameter DR11 lanes through a soft high-density polyethylene is the first in Ottawa clay soil. (HDPE) pipe. The allowed The water main was to use this many bending radius at entry a 914mm-diameter pits was 100m and at concrete pressure trenchless other below-ground locainstalled inside technologies as part of pipe tions had to be 330m. a 1,650mm-diameter one comprehensive Installation took place steel casing through a 11m below the bottom of clay stratum with minisolution” the creek, which was 20m mal groundwater issues. to 23m below the entry Open-cut construcand exit pit elevations. As with all contion or pipe installation at this major struction jobs, the contractors needed artery would have caused significant trafto minimise impacts to privately owned fic-management and social impacts to land surrounding this location. the community. Using HDD installation significantly reduced the impact to the environment Lining the water main and reduced the requirements and During the design process, one of the duration for the approval process. This area’s water feeder mains was deterallowed the installation of the infrastrucmined to need rehabilitation. The team ture to occur earlier, reducing the risk of assessed various options and decided to a critical pipe failure. line the main using a CIPP liner due to
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its location, surface features, the limited number of services in the area, and cost. Lining also maximised the life of the existing infrastructure. A total of 1,178m of 406mm-diameter and 179m of 300mm-diameter water main were lined. The CIPP lining required a number of access pits, which were strategically located where valves or tees already required replacement and at any significant horizontal or vertical changes in direction. Before lining, the water main was decommissioned, cleaned and reassessed for suitability. Using CIPP technology minimised impacts to the transportation network and natural environment. The shorter construction period than for open cutting also reduced the impact to the community.
Rehabilitating the pipes
The corrugated steel pipe culverts along OR 174 had varying degrees of corrosion and build-up of debris. Cured-in-place lining was used to rehabilitate a total of 14 culverts ranging from 300mm to 1,150mm in diameter for a total length of 414m. Before lining the culverts, they were cleaned, and in locations where parts of the bottom of the culvert had major corrosion, grouting was completed to fill
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The culverts were renewed using a combination of crack injection, removal of loose and deteriorated concrete, abrasive blast cleaning, concrete patching, installation of reinforcing steel and welded wire mesh, and formed concrete repairs. The two culverts were 1.22m wide by 0.94m high and 28m long, and 1.22m wide by 1.22m high and 30.5m long respectively.
Perfect match
Left: overhead view of auger boring under the OR 174 freeway Above: two con crete box culverts were renewed using crack inject ion, removal of deteriorated con crete and abrasive blast cleaning
voids around the base of the culvert. Open cutting to install these 14 culverts would have caused traffic disruptions to the community for months.
Renewal of concrete box culverts
Due to varying degrees of concrete spalling and cracks, a renewal option was developed for two concrete box culverts.
With only one feeder main supplying water to more than 110,000 people, the community of Orléans required a unique solution to ensure a continued reliable and safe supply. Traditional open-cut construction was simply not an option for many areas on this project due to significant associated impacts. The Orléans Watermain Link project is the first in Ottawa to use this many different trenchless technologies as part of one comprehensive solution. Each technology proposed had been individually and successfully implemented in other projects, giving the city the confidence to use multiple trenchless technologies at once. This cost-effective approach reduced environmental, social and stakeholder impacts, while a streamlined approval process provided a redundant water main system that allows for operational flexibility, and met the long-term development needs of the community.
This article is an edited version of a paper of the same name, authored by Jeffrey Waara, P.Eng., senior project manager, City of Ottawa, and Gerald Bauer, P.Eng., principal, Stantec Consulting. Original presentation given at NASTT’s 2015 No-Dig Show. © North American Society for Trenchless Technology. All rights reserved. www.nastt.org
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Best practice: microtunnelling
SEWER
Small site and stubborn slate Walls, cottages and a sewer: some of the structures microtunnelling subcontractors had to avoid on a flood-alleviation scheme on the southwest coast of the UK
Fast facts Partnership
Microtunnelling subcontractor Job
South West Water, Environment Agency, Plymouth City Council Active Tunnelling 2 x 90m-long tunnels, 1,200mm diameter
A
t the end of April, UK utility South West Water’s delivery alliance H5O completed a floodalleviation scheme in Plymouth. The project aim was to reduce the risk of surface water, river and combined-sewer flooding in the Colebrook area. The £2 million (US$3.125 million) scheme, which began in May 2014, was jointly funded by South West Water, the Environment Agency and Plymouth City Council. Completion of the work means that almost 50 houses are now protected. Work on the scheme included building two 90m-long, 1,200mm-diameter sewers beneath Newnham Road using a microtunnel boring machine. The twin tunnels take sewage from the Golden Green area, surface water from Boringdon Hill and the culverted Boringdon stream. H5O Alliance main contractor Balfour Beatty also installed a new 450mm combined sewer in the industrial estate and a new 1,050mm-diameter combined sewer overflow. “The two tunnels were installed using the tunnelling machine and the combined sewer and overflow were installed using traditional open-cut techniques,” South West Water project manager Steve Cross told Trenchless World. Further works included: a reinforced concrete headwall to allow flow from Boringdon stream and the combined sewer overflow into Tory Brook. H5O also diverted 30 metres of gas mains to permit new drainage and upgraded 24 metres of foul sewer on Boringdon Hill. Additional duties comprised the installation of five storm gullies, two surfacewater road gullies and associated pipework on Boringdon Hill.
Fitting in Main picture: aerial view of the MTBM; top inset: the Decon 1200 being lowered into the launch pit; bottom row: jacking pipes being assembled
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Microtunnel subcontractor Active Tunnelling (ATL) began boring operations on October 20, 2014, and finished just over
21/08/2015 09:45
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A Charles Machine Works Company
18/08/2015 10:11
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Best practice: microtunnelling
The machine took just over two months to tunnel 180m
Microtunnelling_Trench1509.indd 12
two months later, on December 23. The machine was a Decon 1200, modified in-house by Trenchless Plant (a sister company of ATL). It consisted of a fullface cutting head with a cutting tooth set up to break the hard slate, but also to be set with a minimum over-break, allowing careful extraction of sands and gravels. ATL hired the machine from Trenchless Plant and was able to keep the hire charges to a minimum, typically £6,000 to £9,000 per week. The microtunnel was pipe-jacked and the 1,200mm-diameter jacking pipes came from F P McCann. The total tunnel length combined was 190 linear metres, which equates to 76 jacking pipes at 2.5m long. They were shipped from F P McCann’s distribution yard in Alnwick, Northumberland. “The site footprint was extremely small,” Cross explains. “The ground content varied every metre, so the operator had to use all his experience and training to keep constant face pressure. “We twin-tunnelled approximately 45m under an extremely old retaining wall and alongside cottages with limited ground cover. We also had to jack through an existing concrete sewer that needed to
be over-pumped during the tunnelling. “The geology posed a challenge as it was predominantly local grey slate, sands and gravels. Both the tunnels had to be driven from the same launch pit with only a 500mm gap from the tunnel sides and limited cover.”
Promising plans
In October/November 2014, ATL also installed a 1.2m-diameter tunnel, 150m long and 8m deep, beneath the A38 dual carriageway to connect a new 1,500m3 storm storage tank at Ivybridge Sewage Treatment Works into the sewerage network on the other side of the dual carriageway. The work was part of South West Water’s £7 million investment to improve the quality of the River Erme and bathingwater quality at Mothecombe beach. “South West Water will be delivering further improvements to bathing and shellfish waters over the next three years, which may include further microtunnelling,” comments Cross. “We also have another supply-and-demand project in Ivybridge at the design stage to be delivered this year, which is more than likely to involve a microtunnel.”
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Best practice: microtunnelling
13
GAS PIPE
Putting the coat on How a specific pipe coating helped reduce risk on a pipe-jacking project in Germany
E
ngineering and pipeline construction company Vorwerk recently installed two 30m-long gas pipelines with a diameter of 800mm in Schoenefeld near Berlin using the pipe-jacking method. To protect the corrosion-resistant layer of polyethylene (PE), the pipes were coated with the BWB system. The BWB system (Berolina Wickelrohr Beschichtung – Berolina spirally wound pipe coating) is a glass-fibre reinforced plastic (GRP) coating, which prevents mechanical damage to the corrosion-protection layer during trenchless installation methods. The BWB system was applied to five gas pipes, each with an individual length of 12 metres, at the BKP Berolina Polyester plant in Velten near Berlin. The 5mmthick coating is made of resin-impregnated glass fibres, which were tangentially and axially applied around the PE-sheathed steel pipe in a winding process. The styrene-free vinyl ester (VE) resin used for this application is particularly environmentally compatible and is cured
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Main picture: overview of the start pit (section I) showing road still open Far left insets: weld cleaned for re-insulation, and curing the GRP protective layer Bottom right inset: storage area showing some pipes with BWB surface protection (greenish)
by UV light. All pipes were coated after the shortest possible lead time, a 20 tonne overhead crane loaded them onto low-loaders widened especially for them and they were delivered directly to the construction site.
Making it work
In its fleet, Vorwerk has microtunnelling equipment in sizes from DN 300 to DN 1000. The pipe-jacking method was chosen due to the circumstances on site. The connecting pipelines for a newly re-built compressor station lay directly under the B197 federal trunk road. A 25m-long and 5m-wide start pit with a depth of 4m was excavated for the pipe-jacking. After the first 12m-long pipe had been pressed into the ground, the second pipe could be welded on. The weld was insulated by applying PE adhesive tape and then covering it with
handmade laminate (glass-fibre mats in conjunction with resin) and curing this on site using UV light. In the third step contractor Vorwerk divided a 12m-long GRP-coated steel pipe into two 6m-long pieces. One 6m-long piece of pipe was welded onto the 24m-long pipe section already in the ground and the weld was re-insulated and covered as described above. This procedure was also repeated for the second pipeline. The chosen pipe-jacking method allowed traffic on the B197 between Waltersdorf and Bohnsdorf to be maintained without restrictions. Based on the soils report, jacking the steel pipes with an unprotected outer PE coating was classified as too risky. Since 1997, BKP Berolina has coated more than 100,000 metres of steel pies with this special and “impact-resistant” GRP coating.
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SEWER
Life under the third lane Contractors are about two-thirds through a sewer-installation job in Connecticut, US
T
he Federal Highway Administration (FHWA), in conjunction with the Connecticut Department of Transportation, is widening the Interstate 84 and improving associated infrastructure in Waterbury. The US$298 million I-84 Waterbury Project involves adding a third lane and fullwidth shoulders in each direction, and safety improvements to a 4.3km (2.7 mile) segment of the highway from Washington Street, east to Pierpont Road in the City of Waterbury. The slated completion date is June 2020, with incentives to complete about 10 months earlier. The project also includes the construction or replacement of eight highway bridges, one pedestrian crossing over the Mad River, seven culverts (five within the Beaver Pond Brook, one within East
Mountain Brook, and one within the Mad River), and 20 retaining walls. In addition, trenchless methods will help replace or relocate sanitary sewer, potable water and other public utilities.
Gaining access
The Waterbury scheme includes a $1.1 million contract to install 370 linear feet (LF) (112.8 metres) of sewer, consisting of 24in (609.6mm)-diameter ductile iron pipe inside 48in steel casing. I-84 Constructors JV and M&P Pipe Jacking Corp began building the sewer
on May 11 this year, 25 feet beneath the highway works, through dense brown coarse gravel. Large stone has to be either chipped or split with hydraulic wedges to advance the casing. “The jacking pit is located within the existing 2:1 slope of I-84 westbound, adjacent to the Mad River,” Christopher Zukowski, project engineer, Connecticut Department of Transportation, tells Trenchless World. “Access was created by cutting a narrow bench into the slope, resulting in limited work space. The jacking pit is located within a groundwater
Above left: applying load to the jack and pushing pipe Left: the 200t jacks seen when fully retracted Above centre: applying load to the jacks and pushing pipe Above right: retrieving the cart with rock and obstruction-removal equipment
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Best practice: microtunnelling Far left: excavator installing spacer block to increase the stroke on the jacks and allow enough push to install the next pipe Near left: crew loading hydraulic splitter into cart for obstruction removal Inset below: cable spool for hydraulic winch
“In this case the soil in the area is contaminated and therefore any water encountered during the jacking operation, or within the jacking pit, is considered contaminated and must be treated prior to being discharged. The system consists of a 4,000gal (15,142L) collection tank and pump on the westbound side of I-84. Groundwater is then pumped to the eastbound side of I-84, treated and discharged to the Mad River.” To date, crews have installed 250LF of the total 370LF. “The contractor has allotted 72 days for this work with 28 days of float. Based on current production rates, he will meet his schedule.”
Equipment in use
AOEC [Area of Environmental Concern], which necessitated design and construction of a groundwater-reatment facility.
Jacking of the 48in steel casing is accomplished with four 200t hydraulic jacks. “A jacking shield with a cutting edge and four 50t jacks to aid in steering is installed ahead of the first casing,” Zukowski explains. “Line and grade are ultimately controlled with a laser set on a permanent fixture in the jacking pit. Once the shield is through the wall of the jacking pit, the first casing is joined to the shield with an external ring.” Subsequent casings are joined together
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by “Permalock”, an interlocking pipe system. As the pipe is jacked, the soil from inside the pipe is removed manually and placed in a scale pan. The scale pan is pulled out and in with a hydraulic winch. Obstructions are removed with the use of pneumatic tools, hydraulic splitting wedges or hydraulic cutting saws. Voids resulting from jacking are filled with grout. The grout is mixed on site and applied under pressure through a 1.5in injection plug attached to the shield. Grouting is continuous until the desired pressure is achieved. The annular space inside the casing and outside the sanitary pipe is filled through a 2in-diameter schedule-80 steel pipe. Sand is blown in using up to 750cfm (21.2m³/minute) of air. The steel pipe is retrieved while the quantity of sand is monitored to ensure complete fill and compaction. “[On this project, trenchless methods] eliminated deep trenching and difficult earth-retaining systems. Trenchless projects are used where it is not feasible to open-cut the excavation due to extreme depth required or due to the inability to maintain ongoing traffic during construction,” says Zukowski.
5-DAY BASIC DRILLING FLUIDS WORKSHOP • Designing the Right Drilling Fluid
Cebo Holland produces and delivers high quality industrial minerals and additives, from stock and according to customer specifications. Every year in November Cebo Holland organizes, together with Baroid and Herrenknecht, a 5-day basic drilling fluids workshop = Mudschool.
• Laboratory Tools and Exercises • Instruction by Industry Experts
Last year people came from 15 different countries to follow the HDD or Micro Tunnelling course. Hands-on laboratory exercises, practical demonstrations and interactive lectures are the main topics of these workshops.
In cooperation with
Next Mudschool will be held on the 2 - 6 November 2015
Industrial Minerals, Powerful Logistics
mudschool@cebo.com - www.cebo.com 1534544_CBH_adv_178x124.indd 1 Microtunnelling_Trench1509.indd 15
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Special report: No-Dig International
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SHOW PREVIEW
Construction under the crossroads The Turkish city of Istanbul sits on the seams of two continents – Europe and Asia. It is home to this year’s ISTT International No-Dig Conference and Exhibition, from September 28 to 30 at the WOW Convention Center
T
his year, No-Dig Istanbul will be held in the same venue as the 2nd Water Loss Forum. Aside from industry manufacturers, contractors and decision makers, experts and managers from the water administration units of the nation’s municipalities will attend. There is also a full programme of social activities, either in the exhibition area or hosted by offsite organisations. Turkey’s rich cultural and traditional heritage will be showcased. New government regulations are helping to increase awareness of trenchless technology, which will spur development in the sector.
Considering these issues, both local and international relations should be mutually enhanced. Around 80 exhibitors
Trenchless applications in and around the capital Location Beylerbeyi (Istanbul) Buyukcekmece (Istanbul)
Galata – Cendere (Istanbul)
Details (waste-water transmission tunnels)
Kucuksu Microtunnelling Project: Ø2,200mm diameter, 4,441m long. To be completed in January 2016. Buyukcekmece Microtunnelling Project: Ø2,000mm diameter, 7,367m long. Forecast to be finished in November 2016. Baltalimani Microtunnelling Project: Ø3,600mm diameter, 9,525m long. To be finalised by March 2018.
Gurpinar – Silivri (Istanbul)
Canta Microtunnelling Project: Ø2,000mm diameter, 5,927m long. October 2015 deadline.
Kazlicesme (Istanbul)
Cirpici Microtunnelling Project: Ø3,000mm diameter, 1,969m long. Finalisation date: July 2019.
Tuzla (Istanbul)
Akfirat Microtunnelling Project: Ø2,200mm diameter, 8,125m long. Works to end in October 2016.
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Istanbul
Botas crossing: 36in (914.4mm) steel pipe, 847m long. This natural-gas pipeline was recently completed.
Istanbul
ISKI CIPP rehabilitation project: Ø100mm to Ø400mm wastewater pipelines, 40km long, recently completed.
and 1,000 visitors are expected to be at the show. The conference will be assembled by a technical committee comprising representatives of the Turkish Society for Infrastructure and Trenchless Technologies (TSITT) and of the International Society for Trenchless Technology (ISTT), with speakers, projects and technologies from around the world. The official language of the conference will be English, but there may also be some sessions conducted in Turkish only. In addition to these presentations, delegates can attend the 3rd Microtunnelling Short Course on September 30. Yasin Torun, chairman of AKATED-TSITT, will provide the welcoming speech and give a paper on the social and economic benefits of trenchless construction. Other themes for papers include: microtunnelling principles and techniques; cutting tools; shaft construction; pipe selection; and ground improvement and settlement control. Attendees will hear from companies
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Special report: No-Dig International
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Top inset: skyline of Istanbul Main picture: Turkish HDD operation under way Bottom left inset: a microtunnel boring machine used by a Turkish contractor
including CSM, Herrenknecht, SMET and AKATED-TSITT.
Regional overview
Experts note that sewer and gas projects are most likely to use trenchless in the country. Turkey is involved in many major projects because of its location at a significant geographic area. For instance, in March, contractors broke ground on the US$11.7 billion Trans-Anatolian Natural Gas Pipeline (TANAP). The 56in (1,422.4mm) pipeline will span 1,841km, from Azerbaijan through Georgia and Turkey to Greece and Italy. 1,334km of this pipeline will be installed inside Turkey. This project is of strategic importance for both Azerbaijan and Turkey. It will allow the first Azerbaijani gas exports to Europe, beyond Turkey. It will also strengthen the role of Turkey as a regional energy hub. Construction of the pipeline is slated for completion in 2018.
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Above: groundpenetrating radar in use by a engineer
Yasin Torun, chairman of AKATED-TSITT
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Special report: No-Dig International
Turkish underground construction is seeing a range of activity. These TBMs are working on the Istanbul metro
TSITT turns five The Turkish Society for Infrastructure and Trenchless Technology (TSITT) has performed well in the last five years by professionalising its activities, Ufuk Tumer, board member of TSITT, says. TSITT has been working with the same professional congress organisation since 2011 to organise several successful trenchless events in Turkey. Since 2012, TSITT began publishing its quarterly trenchless magazine to reach municipalities, utilities, contractors, consultants, manufacturers, suppliers, and universities in the country. Since 2014, TSITT has held trenchless training and certification programmes for utility staff. Every year, TSITT representatives visit several trenchless events around the world in order to follow the latest developments in the international trenchless industry. TSITT members have the opportunity to take roles in several trenchless working groups to improve their knowledge.
Q&A
Talking Turkey Ufuk Tumer, board member of TSITT and member of the International No-Dig Istanbul organising committee, provides an insight into the sector
Q
What is the history of trenchless in Turkey?
In the early 1990s, trenchless applications started in Turkey. The first type of these projects involved microtunnelling within the diameters from Ø1m to Ø2m. Afterwards, horizontal directional drilling (HDD) in mini-size capacity became popular, as well as cured-in-place pipe (CIPP) for waste-water applications in sizes from Ø100mm to Ø400mm. However, microtunnelling projects have been always in first place.
Q
What are the challenges that hindered growth?
“The number of trenchless projects is increasing year by year in Turkey”
The most significant challenge was that utilities were not familiar with the advantages of trenchless methods. It took several years to train many utility people to see the benefits. On the other hand, as most of the trenchless equipment and materials are imported to Turkey, utility personnel thought trenchless methods cost much more than open-trench ones. Due to the penetration of several international companies in the Turkish market, and the increasing capacity of local manufacturers, the prices have become more reasonable.
Q
Can you describe the country’s geology?
There are several types of geology (soft soil, silt, clay, rock, hardrock, etc.) in Turkey. The contractors take precautions to handle the geology and it does not cause serious problems for trenchless projects.
Q
What are your expectations for the next five years?
The number of trenchless projects is increasing year by year in Turkey. It is expected that microtunnelling applications for the construction of water and waste-water transmission tunnels will keep first place in the market with several schemes planned for 2015 and for the next few years in Istanbul. In the upcoming two years, there will be huge HDD applications on the Trans-Anatolian Natural Gas Pipeline Project. A new CIPP rehabilitation project, 70km long, will be starting this year in the capital. Currently, CIPP is only applied for waste-water pipelines; potable-water lines are also expected to be included in CIPP applications in the future. In order to reduce huge water losses, Turkish cities will soon release tenders on leak detection and rehab applications; an ongoing scheme for the next half-decade.
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Special report: ICUEE
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SHOW PREVIEW
Take tomorrow for a test drive The International Construction and Utility Equipment Exposition (ICUEE) is back at the Kentucky Exposition Center in Louisville, Kentucky, from September 29 to October 1
M
uch has changed in the world of utilities since the 1960s. ICUEE can trace its history back about 50 years. The field-demonstration concept was developed in 1964 to help solve an equipment evaluation and communications problem. Illinois Bell invited 12 trencher manufacturers to demonstrate equipment in the same field, on the same day in the summer of 1966. The show was recreated on a more formal basis and continued to grow in 1969 and 1972. Manufacturers of many kinds of equipment from across the country were invited to turn the farmland near Elburn, Illinois, into a productive three-day utility equipment show. The event moved to DuPage County Fairgrounds for 1975 and 1977, and eventually grew to such a level that Illinois Bell could no longer manage it. It was in Kansas City in 1979 and Louisville, Kentucky, starting in 1987. Association of Equipment Manufacturers (AEM) provided industry direction, and in the late 1980s became the show’s owner and producer. ICUEE has developed and grown with the industry to meet industry needs for utilities and contractors seeking new equipment, technologies and best practices for utility construction, maintenance and rehabilitation projects. The show is known for its hands-on
working equipment demonstrations, especially in the show’s outdoor lots for digging. Overall, the show will feature more than 25 acres (101,171m2) of exhibits to explore and compare through equipment test drives and interactive product demonstrations (the theme is Take Tomorrow for a Test Drive). This year’s ICUEE is expected to be one
Robbins will be introducing its SBU-RC smalldiameter small boring unit at ICUEE
of the biggest ever with more than 850 exhibitors. The show typically attracts visitors in the 17,000-plus range. In addition to the newest products and innovations, ICUEE features a variety of industryfocused education programming inspired by the industry’s hottest topics and led by industry professionals and opportunities to network with industry peers and take the pulse of the industry; what is happening and expected to happen. ICUEE is the largest event for the utility industry, owned and produced by the AEM. The show brings together industry professionals to gain comprehensive insights into the latest technologies, innovations and trends affecting their industry. “Utility professionals are some of the unsung heroes in our local communities, especially during disaster relief, ensuring delivery of electricity, gas, clean water and other vital services,” the organiser says. ICUEE 2015 will recognise the importance of utility professionals and military personnel with a benefit auction and other events at Heroes Day on October 1. New things to do and see at the show this year include free bourbon tasting and the Demo Derby game, a feature of the ICUEE 2015 mobile app. ICUEE is held every two years and the 2017 show will be held in Louisville.
No Dig
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Special report: ICUEE
From the exhibition floor Trenchless companies at this year’s ICUEE include: Akkerman; American Augers/Trencor; Automated Trench
Shoring; Barbco; Bit Brokers International; Blue Diamond; CETCO; Ditch Witch; HammerHead; HDD Broker; Hunting Trenchless; Mi-Swaco; McLaughlin Group; North American Pipe Corp; Pioneer One; Radiodetection Corporation; Subsite Electronics; The Robbins Company; TT Technologies; The Toro Company; Tulsa Rig Iron; Utility1source; Vac-Tron Equipment; Vacuworx; and Vermeer. Below: some of these exhibitors tell Trenchless World what visitors can expect from them at the event. One of the blowers in the Condux range
American Augers rig in use
American Augers
Kelly Foos, marketing manager The company has been exhibiting at ICUEE for several years, at least 15 in the same booth space outside. For the 2015 show, American Augers will be displaying several new products including mud systems and drills. 2015 new products include: • M-500P mud system – 500 US gal/min; • M-200D mud system – 200 US gal/min with Derrick Shakers; • all-new 2015 DD-110 – restyled and redesigned with new features; and • a new advancement in auger-boring machines, unveiling at the show. The opportunities in Maxi-rigs are great with the move to improve infrastructure around the globe. Even though the shalegas industry has slowed in the US, there are still opportunities to run pipelines to move the gas. Europe has been a stuggle with the weakening of the euro vs. the strength of the US dollar. Sales and opportunities in Europe are tough for American manufacturers right now. There are several auger-boring machines working in Mexico to connect an American gas pipeline from southwest Texas through to central Mexico. This project is called Las Ramones and American Augers has been proud to have equipment involved.
Condux
Jenna Manske, marketing co-ordinator Condux has exhibited at ICUEE for many years. In addition to the new demonstration van packed full of installation tools,
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Condux will debut the newest addition to its underground puller line – the 7500# Underground Cable Puller, as well as the new Gulfstream 150 Micro Fiber Blower. With a growing movement to place utilities underground due to aesthetic concerns and to lessen the likelihood of storm damage, there’s plenty of opportunity in the market. However, the expense and growing underground congestion make the transition challenging. Condux products have been used with virtually every major utility, municipal electric company and Internet service provider during the past year. The company expects the thirst for faster Internet and replacement of power infrastructure in an ageing system to continue to drive demand for installation tools. Hunting Trenchless drilling components
Hunting Trenchless
Klane Kirby, general manager Hunting Trenchless has exhibited its HDD mud motors, drill pipe and HDD tooling accessories at ICUEE before. The fibre market is booming and opportunities on small drill accessories is good. There are also challenges: with oilfield business being down, the large drillpipe market has slowed, but HDD mud motors are offsetting that somewhat. Hunting Trenchless has some new products that are slated for 2016.
McLaughlin
Keely Coppess, senior public relations supervisor, Two Rivers Marketing McLaughlin will be exhibiting its ON-Target steering head for auger bores at this year’s show. As the need for gas, water and sewer line installations grows, more contractors are turning to time-test augerboring methods. The steering head gives contractors the ability to make horizontal and lateral – left to right – directional changes to accurately and cost-efficiently complete difficult on-grade bores in just one pass. The ON-Target auger-boring system can bore 16in to 60in (40.64cm to 152.40cm) in diameter, and is compatible with most brands of auger-boring machines. The cutting path – grade and lateral movement – of the steering head is controlled by hydraulic-actuated panels that open and close to keep the head on the intended path. A control station features a hydraulic power pack to control the movement of the steering head. A built-in vertical-alignment sensor provides continuous monitoring of grade, while twin line projection halogen lights enclosed in the steering head check and maintain line throughout the bore for improved accuracy.
The Robbins Company
Liz Stone, marketing manager This year Robbins is bringing its booth indoors. The company will be promoting its line of small boring units (SBUs) at ICUEE, as well as introducing its latest addition to the SBU product line, a smaller-diameter remote-controlled SBU, called the SBU-RC. The SBU-RC will be on display in graph-
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Special report: ICUEE ics. This machine is a new type of boring machine capable of excavating smalldiameter hard-rock tunnels at long distances while maintaining line and grade. The machine is currently manufactured in the 36in-diameter range, but can be designed as small as 30in in diameter. Features that differentiate this machine from other SBU products are a smart guidance system controlled from the operator’s station on the surface, and a vacuum system for muck removal. The machine is considered a cost-effective alternative to microtunnelling machines, which require slurry and cleaning plants onsite. The SBUs have been doing very well, especially in the North American market. Robbins has a well-known name in the industry and high customer loyalty, both trends that it expects to continue. Robbins hopes to expand worldwide with its new SBU-RC, leasing the machine used on a recent project in Oregon as well as expanding the fleet of SBU-RC as demand increases. A major project took place recently in Bend, Oregon, US. On this project, an SBU-RC completed its first project: a critical hard-rock crossing below railroad
tracks, breaking through two weeks ahead of schedule on May 15, 2015. The machine holed through on line and grade after achieving up to 50ft (15m) of advance per day in abrasive basalt rock up to 7,000psi (48MPa) UCS. Robbins plans to continue introducing the industry to the SBU-RC, and is expecting industry acceptance of this new product.
The Toro Company
Andrew Gillman, Performance Marketing The Toro Company was an exhibitor at the 2013 ICUEE show, where it launched its horizontal directional drill (HDD) line for the first time. For the 2015 show, in addition to the Toro Dingo compact utility loader line, the company will again be exhibiting its full line of trenching and trenchless products. The Toro Dingo TX 1000 is the newest addition to the Dingo family of compact utility loaders, and will be on display at ICUEE. Toro also offers a range of HDD rigs including the DD20245 and DD4045. Toro has a generally positive outlook for the trenchless market, and is looking forward to gauging international interest at the 2015 show. The company recently partnered with a well-known equipment dealer in Mexico. Cominsa has eight locations strategically located throughout Mexico, providing outstanding local sales and service to all markets in the country.
Vermeer
A Toro Dingo TX 1000 loader
Jon Kuyers, senior global product manager, Underground Vermeer notes that the overall market for trenchless products continue to be posi-
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One of Vermeer’s new line of S3 drills
tive. The demand for faster download speeds continues to drive the demand for the installation of fibre-optic lines providing positive momentum. Demand for infrastructure improvement and replacement (gas, electric, water and sewer) continues to provide stable growth and opportunities for utility-installation contractors. The company continues to see positive and stable growth in the trenchless market due to the market conditions above. Vermeer expects the oil and gas pipeline business to pick up in mid-2016 along with transmission/distribution development continuing to fuel the coal-to-gas powerplant conversion. Vermeer is launching a new line-up of S3 drills with improved capabilities in speed, simplicity and sound, as well as InSite Productivity Tools, which are geared toward contractors to help them collect more information and help them become more productive from the planning stages of the project to its completion.
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