20100514 pipe arch presentation to iem may 2010

MMC-Gamuda Joint Venture

Electrified Double Track Project Ipoh to Padang Besar

PIPE ARCH TUNNELby

Mr. Don R. Hall

Head of Tunneling Division, Gamuda Engineering Sdn Bhd

May 2010

Presentation to Institution of Engineers, Malaysia

Outline of Presentation:

1) General Project Information – Berapit Tunnel

2) Pipe Arch Tunnel – Geological Profile & Concept

3) Pipe Arch Tunnel – Chronology of Construction

4) Construction of Triple Cell 3m Ф Drainage Culvert

5) Demolition of Existing 3m x 3m Twin Box Drainage Culvert

6) Pipe Arch Tunnel Construction

7) Catastrophe

8) Summary and Q&A

General Project Information – Berapit Tunnel

CHARACTERISTICS Twin bore tunnels

LENGTH OF TUNNEL 2900m

GRADIENT IN TUNNEL 0.39%

OVERBURDEN Ave. 110m, Max. 220m

EXCAVATION SECTION AREA 50-60 m2

CROSS PASSAGE 9 nos.

GEOLOGY Granites of different weathering & fracturing degrees

TRAIN SPEED POTENTIALDesign speed for passenger train : 180 km/hOperating speed for passenger train : 140 km/hOperating speed for freight train : 90 km/h

CONSTRUCTION METHODS Mainly 80% drill & blast, 20% as cut & cover tunnel

• Tunnel Length = Approximately 2900m• Twin Tunnels, Single track each• Track Structure : Slab Track

North-South Expressway (NSE)

Existing Railway Track

To IpohTo Taiping

YTLCEMENTPLANT

Pipe Arch Tunnel Crossing NSE

EXISTING NORTHSOUTH HIGHWAY TO

BE MAINTAINED

EXISTINGRAILWAY TRACK

EXISTING FEDERAL ROUTE 1 / NORTH SOUTH HIGHWAY

TO BE MAINTAINED

Gradient 0.39%

Federal Route 1 temporarily diverted for tunnel construction

Pipe Arch Tunnel Crossing

North-South Expressway (approx. 4m overburden only)

Drill & BlastSection

Pipe ArchSection

Cut & Cover Section

Typical Berapit Tunnel Cross Section:

MMC-Gamuda Joint Venture8

CROSS PASSAGES EVERY 350m

Pipe Arch Tunnel – Chronology of Construction

Northbound

Southbound

Northbound railway tunnel

Southbound railway tunnel

3. Twin pipe arch tunnel crossing underneath PLUS North-South Highway

KM 232.7

1. Triple 3m Ф cell drainage culvert at KM 232.6 of PLUS North-South

Highway to replace existing 3m x3m twin box culvert

2. Existing 3m x 3m twin box drainage

culvert to be demolished & replaced

Plan Layout of Twin Pipe Arch Tunnel

MMC-Gamuda Joint Venture12

3-D View of Twin Pipe Arch Tunnel

Northbound

Southbound

2. Existing 3m x 3m twin box drainage

culvert to be demolished & replaced

1. Triple 3m Ф cell drainage culvert at KM 232.6 of PLUS North-South

Highway to replace existing 3m x3m twin box culvert

3. Twin pipe arch tunnel crossing underneath PLUS North-South Highway

KM 232.7

Construction Of Triple Cell

LONG-SECTION OF DRAINAGE CULVERT

IL 76.025

IL 75.812

RL 83.421 RL 82.808

m EXISTING GROUND LEVEL

NORTH SOUTH EXPRESSWAY

PROPOSED DRAINAGE CULVERT(LENGTH = 45.50m)

IL 76.130 IL 75.676

Jacking Length = 45.5m

PLUS HIGHWAYSHOULDER LEVELEDGE OF

PROPOSED TRIPLE 3000mm Ø

1500 1500

RCP DRAINAGE CULVERT

PROPOSED TRIPLE 3.0m RCP DRAINAGE CULVERT

LONGITUDINAL SECTION

CROSS SECTION

Construction of Triple Cell 3m Ф Drainage Culvert

Construction of Triple 3m Ф Cell with Soft Ground Cutterhead Microtunneling Machine

First drive of jacking works of 3m Ф concrete pipes ongoing. Second & third drives awaiting for jacking with prepared entrance rings

Jacking works ongoing

Breaktrough of the first drive

Lifting of microtunneling machine after breakthough of first drive

Close up of RASA microtunneling machine

Completed construction of triple cell drainage culverts

Demolition of Existing 3m x 3m Twin Box Drainage Culvert

PLAN VIEW

CROSS SECTION VIEW

Existing twin box culvert at KM 232.7 PLUS North-South Expressway before demolition

Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction

Demolition by coring & hacking to rid of reinforcement within existing twin box culvert for pipe arch tunnel construction

Sealing of existing twin box culvert for pipe arch tunnel construction

2. Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction

Pipe Arch Tunnel Construction

Pipe Arch Tunnel– Concept

Pipe Arch Tunnel – Concept

Mined excavation

Construction Sequence 1. Execution of sheet piles 2. Execution of the pipe arch microtunneling 3. Mined excavation of tunnel with steel ribs with bullflex, reinforced shotcrete & fibre glass elements 4. Casting of permanent concrete lining

Pipe Arch Tunnel – Concept

Site picture of project by Metropolitan Atlanta Rapid Transit Authority in USA

LONGITUDINAL SECTION

CROSS SECTION

Limits of PLUS North-South Expressway (NSE)

Cut &Cover

Section

JackingPit Top of Soil Support Pipes

Southbound NSE

Residual Soil

Northbound NSE

ReceivingPit

Weathered Rock

Scale in Meters

0 5 10

RockBottomof Structure

Cut &CoverSection

Direction ofMicrotunneling

Jacking Length up to Toe of Highway Embankment= 90 m

Limits of PLUS North-South Expressway (NSE)

Cut &Cover

Section

JackingPit Top of Soil Support Pipes

Southbound NSENorthbound NSE

ReceivingPit

Weathered Rock

Scale in Meters

0 5 10

RockBottom

of Structure

Cut &CoverSection

Direction of MicrotunnelingResidual Soil

Pipe Arch Tunnel Construction (Right Bore)

Jacking Length up to Toe of Highway Embankment= 92 m

Cardox System – Non-explosive blasting

Cardox Blasting

Cardox Drilling & Connection

Cardox Gas Filling

Mini Pipe Arch

AVN500

Microtunneling machine with retraction mechanism in case of rock face encountered

Jacking

Direction

Pre-welded Line-up Band

10mm Pipe Wall Thickness

Pipe joint detail

Construction & staged excavation of bored pile jacking pit

Coring of reinforcement of shotcreted bored pile wall to prepare soft eye for microtunneling machine advance

Construction of thrust wall for jacking of microtunneling machine

Microtunneling machine preparing to jack

Jacking of microtunneling machine ongoing

Welding Of Pipe

Catastrophe

Set up to pull back pipe

Catastrophe

Locking device

Catastrophe

First pipe retreated

Catastrophe

Damaged section

Catastrophe

Damaged section exposed

Catastrophe

Existing drive pressurized

Catastrophe

Damaged pipe on surface

Catastrophe

Damaged pipe on surface

Catastrophe

Rebar excavated under Plus Highway

THANK YOU

Q & A Session

20100514 pipe arch presentation to iem may 2010

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