20100514 pipe arch presentation to iem may 2010
DESCRIPTION
TRANSCRIPT
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
MMC-Gamuda Joint Venture
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
MMC-Gamuda Joint Venture
General Project Information – Berapit Tunnel
MMC-Gamuda Joint Venture
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
MMC-Gamuda Joint Venture
• 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
General Project Information – Berapit Tunnel
MMC-Gamuda Joint Venture
PA
DA
NG
RE
NG
AS
EN
D P
OR
TA
L
- E
ND
CH
11
00
60
TA
IPIN
G E
ND
PO
RT
AL
- S
TA
RT
CH
10
71
70
EXISTING NORTHSOUTH HIGHWAY TO
BE MAINTAINED
EXISTINGRAILWAY TRACK
EXISTING FEDERAL ROUTE 1 / NORTH SOUTH HIGHWAY
TO BE MAINTAINED
22
0m
Gradient 0.39%
Federal Route 1 temporarily diverted for tunnel construction
Pipe Arch Tunnel Crossing
North-South Expressway (approx. 4m overburden only)
General Project Information – Berapit Tunnel
Drill & BlastSection
Pipe ArchSection
Cut & Cover Section
MMC-Gamuda Joint Venture
Typical Berapit Tunnel Cross Section:
General Project Information – Berapit Tunnel
MMC-Gamuda Joint Venture8
General Project Information – Berapit Tunnel
MMC-Gamuda Joint Venture
CROSS PASSAGES EVERY 350m
General Project Information – Berapit Tunnel
MMC-Gamuda Joint Venture
Pipe Arch Tunnel – Chronology of Construction
MMC-Gamuda Joint Venture
Northbound
Southbound
Northbound railway tunnel
Southbound railway tunnel
Pipe Arch Tunnel – Chronology of Construction
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
Pipe Arch Tunnel – Chronology of Construction
MMC-Gamuda Joint Venture
Construction Of Triple Cell
MMC-Gamuda Joint Venture
LONG-SECTION OF DRAINAGE CULVERT
IL 76.025
39
96
IL 75.812
RL 83.421 RL 82.808
3000m
m EXISTING GROUND LEVEL
NORTH SOUTH EXPRESSWAY
PROPOSED DRAINAGE CULVERT(LENGTH = 45.50m)
IL 76.130 IL 75.676
Jacking Length = 45.5m
4000
3000
IL IL
PLUS HIGHWAYSHOULDER LEVELEDGE OF
PROPOSED TRIPLE 3000mm Ø
1500 1500
RCP DRAINAGE CULVERT
PROPOSED TRIPLE 3.0m RCP DRAINAGE CULVERT
13800
10200
LONGITUDINAL SECTION
CROSS SECTION
Construction of Triple Cell 3m Ф Drainage Culvert
MMC-Gamuda Joint Venture
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
Construction of Triple Cell 3m Ф Drainage Culvert
MMC-Gamuda Joint Venture
Jacking works ongoing
Construction of Triple Cell 3m Ф Drainage Culvert
Construction of Triple 3m Ф Cell with Soft Ground Cutterhead Microtunneling Machine
MMC-Gamuda Joint Venture
Breaktrough of the first drive
Construction of Triple Cell 3m Ф Drainage Culvert
Construction of Triple 3m Ф Cell with Soft Ground Cutterhead Microtunneling Machine
MMC-Gamuda Joint Venture
Lifting of microtunneling machine after breakthough of first drive
Construction of Triple Cell 3m Ф Drainage Culvert
Construction of Triple 3m Ф Cell with Soft Ground Cutterhead Microtunneling Machine
MMC-Gamuda Joint Venture
Close up of RASA microtunneling machine
Construction of Triple Cell 3m Ф Drainage Culvert
Construction of Triple 3m Ф Cell with Soft Ground Cutterhead Microtunneling Machine
MMC-Gamuda Joint Venture
Completed construction of triple cell drainage culverts
Construction of Triple Cell 3m Ф Drainage Culvert
Construction of Triple 3m Ф Cell with Soft Ground Cutterhead Microtunneling Machine
MMC-Gamuda Joint Venture
Demolition of Existing 3m x 3m Twin Box Drainage Culvert
MMC-Gamuda Joint Venture
Demolition of Existing 3m x 3m Twin Box Drainage Culvert
PLAN VIEW
CROSS SECTION VIEW
MMC-Gamuda Joint Venture
Existing twin box culvert at KM 232.7 PLUS North-South Expressway before demolition
Demolition of Existing 3m x 3m Twin Box Drainage Culvert
Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction
MMC-Gamuda Joint Venture
Demolition by coring & hacking to rid of reinforcement within existing twin box culvert for pipe arch tunnel construction
Demolition of Existing 3m x 3m Twin Box Drainage Culvert
Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction
MMC-Gamuda Joint Venture
Demolition by coring & hacking to rid of reinforcement within existing twin box culvert for pipe arch tunnel construction
Demolition of Existing 3m x 3m Twin Box Drainage Culvert
Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction
MMC-Gamuda Joint Venture
Sealing of existing twin box culvert for pipe arch tunnel construction
Demolition of Existing 3m x 3m Twin Box Drainage Culvert
2. Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
MMC-Gamuda Joint Venture
Pipe Arch Tunnel– Concept
MMC-Gamuda Joint Venture
Pipe Arch Tunnel – Concept
Mined excavation
MMC-Gamuda Joint Venture
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
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
LONGITUDINAL SECTION
CROSS SECTION
MMC-Gamuda Joint Venture
Limits of PLUS North-South Expressway (NSE)
Cut &Cover
Section
JackingPit Top of Soil Support Pipes
Southbound NSE
Residual Soil
Northbound NSE
ReceivingPit
Fill
Weathered Rock
Scale in Meters
0 5 10
RockBottomof Structure
Fill
Cut &CoverSection
0
5
10
15
20
Direction ofMicrotunneling
Pipe Arch Tunnel Construction
Jacking Length up to Toe of Highway Embankment= 90 m
MMC-Gamuda Joint Venture
Limits of PLUS North-South Expressway (NSE)
Cut &Cover
Section
JackingPit Top of Soil Support Pipes
Southbound NSENorthbound NSE
ReceivingPit
Fill
Weathered Rock
Scale in Meters
0 5 10
RockBottom
of Structure
Fill
Cut &CoverSection
0
5
10
15
20
Direction of MicrotunnelingResidual Soil
Pipe Arch Tunnel Construction (Right Bore)
Jacking Length up to Toe of Highway Embankment= 92 m
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Cardox System – Non-explosive blasting
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Cardox Blasting
Cardox Drilling & Connection
Cardox Gas Filling
Pipe Arch Tunnel Construction
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Mini Pipe Arch
MMC-Gamuda Joint Venture
AVN500
Pipe Arch Tunnel Construction
Pipe Arch Tunnel Construction
Microtunneling machine with retraction mechanism in case of rock face encountered
MMC-Gamuda Joint Venture
780m
m O
D
Jacking
Direction
Pre-welded Line-up Band
10mm Pipe Wall Thickness
Pipe Arch Tunnel Construction
Pipe Arch Tunnel Construction
Pipe joint detail
MMC-Gamuda Joint Venture
Construction & staged excavation of bored pile jacking pit
Pipe Arch Tunnel Construction
Pipe Arch Tunnel Construction
MMC-Gamuda Joint Venture
Coring of reinforcement of shotcreted bored pile wall to prepare soft eye for microtunneling machine advance
Pipe Arch Tunnel Construction
Pipe Arch Tunnel Construction
MMC-Gamuda Joint Venture
Construction of thrust wall for jacking of microtunneling machine
Pipe Arch Tunnel Construction
Pipe Arch Tunnel Construction
MMC-Gamuda Joint Venture
Microtunneling machine preparing to jack
Pipe Arch Tunnel Construction
Pipe Arch Tunnel Construction
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Pipe Arch Tunnel Construction
MMC-Gamuda Joint Venture
Jacking of microtunneling machine ongoing
Pipe Arch Tunnel Construction
Pipe Arch Tunnel Construction
MMC-Gamuda Joint Venture
Welding Of Pipe
Pipe Arch Tunnel Construction
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Pipe Arch Tunnel Construction
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Pipe Arch Tunnel Construction
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Pipe Arch Tunnel Construction
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Catastrophe
Catastrophe
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Catastrophe
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Catastrophe
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Catastrophe
MMC-Gamuda Joint Venture
Catastrophe
Pipe Arch Tunnel Construction
Set up to pull back pipe
MMC-Gamuda Joint Venture
Catastrophe
Locking device
Pipe Arch Tunnel Construction
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Catastrophe
First pipe retreated
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Catastrophe
Damaged section
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Catastrophe
Damaged section exposed
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Catastrophe
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Catastrophe
Existing drive pressurized
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Catastrophe
Damaged pipe on surface
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Catastrophe
Damaged pipe on surface
MMC-Gamuda Joint Venture
Pipe Arch Tunnel Construction
Catastrophe
Rebar excavated under Plus Highway
MMC-Gamuda Joint Venture
THANK YOU
MMC-Gamuda Joint Venture
Q & A Session