number 7 extension presentation to pmi nj chapter · -site j ventilation building & ... number...
TRANSCRIPT
Project Overview
Contract 1 – Running Tunnels
Methods of Excavation and Construction
Concrete Work
AGENDA
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414141ststst St.St.St.
424242ndndnd St.St.St.
Site K
Site P
34th Street Station Cavern Length: 1,212’34th Street Station
Cavern Length: 1,212’
Tunnel1.5 mile extension from Times
Square Station
Tunnel1.5 mile extension from Times
Square Station
Tail Track ModificationLength: 275’
Tail Track ModificationLength: 275’
Site J
Site A
Site L
8THA
ve.
9THA
ve.
Dye
r Ave
.
10TH
Ave
.
26th St.
36th St.35th St.
11TH
Ave
.
34th St.
41st St.
Legend:Project SiteStationStation Entrance
Number Subway Line
Extension
Project Scope
Key Plan
7
Project FactsLength: 1.5 mile extension34th Street Station: 1,212 ftProject cost: $2.366BCompletion Date: June 2014
City Representative: Hudson Yards Development Corp.
Funding: Hudson Yards Infrastructure Corp.
Design Consultant: PB Team
Consultant Construction Management (CCM):
HLH7Hill International, Inc.LiRo Engineers, Incl.HDR| Daniel Frankfurt
34th
St.
Sta
tion
Site A
Site L
Site K
Site P
Site J
Construction Contracts
- Running Tunnels (Contract 1)
- Site L Ventilation Building
- Site J Ventilation Building & Station Entrance
- Site K Ventilation Building
- Systems & Finishes
- Secondary Station Entrance(Site P)
11th Avenue – 31st to 39th Streets
34th St. 38th St.
Site P Site K
Jacob JavitsConvention Center
34th
Stre
et
41st Street – 11th to 9th Avenues
10th
Ave
nue
Dye
r Ave
.
9thA
venu
e
Site L
41st Street
10th Ave.9th Ave
Site M
11th
AVE
NU
E
10th
AVE
NU
E
DYE
R A
VEN
UE
9thA
VEN
UE
8thA
VEN
UE
41st STREET
SITE ‘L’
RECEIVING PIT
TBM Locations (April 19, 2010)
Tunnel Boring Machines (TBMs)
Manufactured in Germany by Herrenknecht.
Two TBM’s arrived job site January/ February 2009.
Lowering of first TBM Cutterhead February 2009.
Assembled in starter tunnels April 2009.
Commenced boring May 2009.
Complete boring June 2010.
Disassembly and removal from site August 2010.
Ground Freezing11th Avenue between 26th and 28th Streets
26th St. 30th St. 34th St.
Amtrak Tunnel
No. 7 Tunnel 34th Street StationSite A Adit
Amtrak Tunnel
40’
Approx. Rock Line
Top of Ground
11th Avenue Viaduct
Precast Tunnel LinersManufacturer Technopref Industries
Royersford, PATotal estimated liners: 9,388 LFDimensions:
Number of planned precast rings: ~1,900Ring width: 5 ftInside diameter: 22.5 ftOne ring: 5 segment + 1 “key” pieceSegment thickness 1 ftWeight: ~ 4-5 tons/piece
~ 2 tons/ “key” pieceConcrete: ~ 12 yds3/ring, or 22,800 yd3 total
Precast Tunnel Liners – Cont’dStrength
Design mix:
Actual:
8,000 psi (28 days)
8,000 psi (7 days)10,000-12,000 (28 days)
Formwork: Black steel rebarsPolypropylene fibersStripped after 8 hours; 2,500 psi
Gaskets: EDPM – applied 12 hours after initial casting
Hydrophylic – applied with epoxy-like glue within 7 days of tunnel installation
Unique ring and segment identification codeProduction rate: 5 rings/shaft @ 2 shifts/day = 10 rings/dayCareful procedures for each ring segment:
HandlingStorageTransportPlacement
HANDLING OF SEGMENT IN PLANT
SEGMENTAL LINING RINGS
Segmental Tunnel Lining Rings
PRECAST SEGMENT CONTROL NUMBERS
41
Construction Management Association of America (CMAA)
• Metro NY/NJ Chapter - Honorable Mention Project of the Year
2012
• National - 2012 Project Achievement Award
Colorado School of Mines• Tunnel Achievement Award for Project Excellence
( Best National & International Tunneling Project - 2012)
Engineering News Record New York• Award of Merit (Transportation)
Recognition Awards to Date
41
• Cost Management
• Schedule Management
• Quality Management
• Safety Management
PROJECT MANAGEMENT AND CONTROLS
42
Cost Management (Cont’d)
Establish Budget
• $2.1 Billion Subway Program established by MOU
• Breakdown Budget into major categories• Design• Construction• Construction Management • Contingencies
• Further broken down to measurable sub categories.
• Detail bottom up estimation for each budgeted line item
• Categories to remain valid for life of project
44
Cost Management (Cont’d)Breakdown of Budget
• Construction cost - per contract
• Design cost –- Preliminary Engineering (PE)- Final Design (FD)- Design Support During Construction (DSDC)
• Construction Management (CM) Cost
– In-house CM cost (MTA’s Project team)
– CM Consultant cost (CCM)
– Transit Authority Costo Transit Authority Labor (TA Labor)o Engineering Force Account cost (EFA)
45
46
Number 7 Line Project Budget
• Subway Related Cost : $2,100 Million• Non-Subway Related Cost: $266 Million
Cost Management (Cont’d)Monitor Expenditures
•To date Administered $1.5 billion total disbursement
•Timely and prompt payment for every invoice
•Peak monthly payment - $50 millions to Contractors
•Negotiated Changes of total $10.5 million, includes several
millions in credits
•Tunnel contract ($1.1 billion) was completed below budget
•Developed Baseline Budget and Baseline Cash Flow for
each line item separately.
•Track Actual against Plan each month and review trend
47
Cost Management (Cont’d)
Cost Control
• Perform Trend Analysis• Based on the trend, revise budget allocation, i.e. Re-
baseline• Forecast “Estimate-At-Completion” (EAC)• Look for Opportunities
48
Cost Performance To-Date
• Project Budget ………………. $2,366 million
• Construction Contracts…….. $1,972 million
• Construction Completed …... $1,535 million (78%)
• Remaining Construction …... $437 million (22%)
• Contingency Budget ……….. $100 million• Contingency Spent …………. $10.5 million
(0.53% of Construction Cost)
• Number of Contracts Completed...………..........3 out of 6
• Contingency spent on Completed Contracts ….0.22%
• Estimate-At-Completion (EAC)………………….$2,366 million
Cost Management (Cont’d)
51
Schedule Management (Cont’d)
Vision
• Revenue Service by June 2014
• Dignitary Train by December 2013
• Achieve Project Completion by June 2016
54
Schedule Management (Cont’d)
• Overall Integrated Project Schedule (IPS)
• Include all aspects of work
• Detailed schedule for each construction contract
• Each Detailed schedules has more than 1000 activities
• Largest schedule has more than 7000 activities
• Update the schedule on monthly basis, review/analyze
• Identify Critical path and near critical paths
• Identify delays and potential delays, discuss mitigation
measures and implement
• Identify Opportunities and Implement55
Some unique steps taken for this project
• Implementing Guaranteed Maximum Price (GMP) Contract
for Design Support During Construction services.
• Added Bonus sharing feature for accelerated completion.
• Transferred Scope among Contracts, to expedite the work
• Ensured follow-on Systems and Finishes Contractor had
on-time or early access.
• Minimized changes
• Dispute Resolution Board (DRB) for Tunnel Contract.
• Developed “What-if” contracting and construction scenarios
63
Impact Due To Hurricane Sandy
Short Term• Impact on material supply chain• Time lost in review of Submittals due to 2 Broadway
closing
Long Term• Industry wide shortage of construction materials
• Potential damages to materials on hand
• Diversion of TA resources
• Availability of resources for Testing & Commissioning
64
Quality Control
Phase QC Performed By
Design Engineer of Record
Construction Each Respective Contractor
66
Quality Assurance
Phase QA Performed By
Design MTACCe.g., Semi-annual Performance EvaluationsMTACC and Consultant Construction Manager (CCM)e.g., Spot Check Programs (applicable design standards, Co-ordination of drawings, etc.)
Construction MTACC and Consultant Construction Management (CCM)e.g., Semi-annual Performance EvaluationsConsultant Construction Managere.g., Quarterly Quality Audits and Spot Check
Programs (i.e., Material Certifications, Witness Tests, Tunnel Leaks, etc.) 67