02 tsl from tender until rfc by pablo arecco

1

Challenge the future

Third Set of Locks: From Conceptual

Design until RFC Design Pablo Arecco

PIANC YP-Com Chairman / MWH Global

2

Challenge the future

From 2007, the story keeps going…

• Prequalification period: 4 months.

• Tender Design: 14 months from 2008.

Design

& Build

US$ 3,221,631,384.00

Best technical proposal

3

Challenge the future

Design of the Third Set of Locks

MWH - Chicago

IV-Infra - Rotterdam Netherlands

Panama

MWH - Buenos Aires

Tetratech - Bellevue

Sembenelli - Milano, Italy

CICP Design Integration Office and Design Centers

Design phases: Preliminary, Intermediate, Final, Release for Construction,

Optimization & As Built (Engineering services during construction).

4

Challenge the future

Design of the Third Set of Locks

• Hydraulic

• Geotechnical

• Seismic

• Lock Heads & Rolling Gates / Culvert Valves

• Mechanical / Electrical / I & C

• Buildings (by Others)

• Site Development & Infrastructure

Engineering Discipline Interfaces

5

Challenge the future

Components of each new Lock Complex Three Lock Chambers and four Lock Heads in each site

Upper Chamber

Middle Chamber

Lower Chamber

Lock Head 4

6

Challenge the future

7

Challenge the future

8

Challenge the future

9

Challenge the future

10

Challenge the future

11

Challenge the future

12

Challenge the future

13

Challenge the future

14

Challenge the future

15

Challenge the future

16

Challenge the future

17

Challenge the future

Numerical & Physical models

18

Challenge the future

Numerical & Physical models

19

Challenge the future

Atlantic & Pacific Locks

• Use of existing 1939 excavations for New Locks

• Geology (Sandstone vs. Basalt)

• Excavation, slope protection & rock restitution

• Availability of concrete aggregate at Atlantic

• Seismic criteria / Fault zones

• Lock floor slabs

• Borinquen dams / Approach channels

Major differences

20

Challenge the future

Lock Head

Lock Walls with central connection

Typical Lock Walls

Lock chamber components For each type a structural model was identified for the design

23 monoliths per side per chamber

7 types of structural Lock Walls

Several loads combinations

Crossunder

Chamber Conduit

21

Challenge the future

Lock Chamber monolith walls Pacific & Atlantic Lock Wall monoliths are different

August 2012

Final concrete volumes: Lock walls ≈ 2.100.000 m3

Lock heads ≈ 1.200.000 m3

Lock Wall Typical

Monolith

up to 350

22

Challenge the future

Finite Elements Models with Abaqus®

23

Challenge the future

Rock Foundation

(Gatún Rock)

Rolling gates (Steel)

Backfill (Gatún Rockfill)

Lock Walls (Concrete)

Lock Walls (Concrete) Lock Head

Large Recess (Concrete)

Lock Head Small

Recess (Concrete)

Lock Head Slab

(Concrete)

Finite Elements Models with Abaqus®

24

Challenge the future

Finite Elements Models with Abaqus®

25

Challenge the future

• No service disruption

• Reparable damage

• Structure essentially elastic

Level I

475 years

• No collapse

• Reparable damage

• Limited non linear behavior

Level II

950 years

Lock structures - Seismic criteria Earthquake level & performance criteria

ATL 0,33g

PAC 0,52g

ATL 0,42g

PAC 0,72g

26

Challenge the future

Final design quantities reduction

maintaining same Design Req.:

• Concrete and excavation of over

10% compared to tender

• Reduction in reinforcement of 40%

(around 17 Eiffel Towers)

Concrete reinforcement Weight 190,000 tonnes or 26 Eiffel Towers

27

Challenge the future

28

Challenge the future

Design Facts & Figures Total for Atlantic and Pacific

• The MWH-led team peaked at over Equivalent 300 Full Time Staff

working in 6 design offices on 3 continents.

• 9,500 Design Drawings (Atlantic & Pacific Total)

• 13,000 Concrete Lift Shop Drawings Reviewed

• 26,000 Reinforcement Shop Drawings Reviewed

• 50 Quality Audits (33 Internal, 17 External – GUPC, ACP)

• Design 95% Complete, 88.5% Design Packages Submitted

29

Challenge the future

THIS IS THE

EFFORT OF A

HUGE TEAM!