NORTH SHORE CONNECTORNORTH SHORE CONNECTOR
TUNNELS AND STATION SHELLTUNNELS AND STATION SHELLTUNNELS AND STATION SHELLTUNNELS AND STATION SHELLLIGHT RAIL PROJECTLIGHT RAIL PROJECT
PAUL ZICK, PE
NORTH SHORE CONSTRUCTORS JV
North Shore Connector Alignment
•• 7300 lf 7300 lf Extension to existing 25 mile systemExtension to existing 25 mile system
•• 18 Contracts18 Contracts
• $435 Million$435 Million
Funding – $ 435 Million
80%
17%17%3%
Project Location006006007007
Future- to Airport North ShoreNorth Shore
003003
006006007007
Airport North Shore North Shore Connector Connector Light Rail Light Rail E iE iExpansionExpansion
004 New Gateway Station004 New Gateway Station
Existing
EXISTING GATEWAY EXISTING GATEWAY STATIONSTATION
Existing Light Rail System
Project Team• Owner
–– Port Authority of Allegheny CountyPort Authority of Allegheny County
• Construction ManagerTriGoldTriGold–– TriGoldTriGold
• Jacobs Civil
• HDR
• Kwame
Project Team• Design Engineer
–– DMJMDMJM
• ContractorNorth Shore Constructors JVNorth Shore Constructors JV–– North Shore Constructors JVNorth Shore Constructors JV
• Obayashi Corp.
• Trumbull Corp.
What we are building
• Two Contracts
• Combined Contract Value - $156 500 000Combined Contract Value $156,500,000
• Time ––– NTPNTP Oct 2, 2006Oct 2, 2006
–– 003 Tunnels 003 Tunnels 1243 days1243 days Feb 26, 2010Feb 26, 2010
–– 006 Station / C&C006 Station / C&C 870 days870 days Feb 18, 2009Feb 18, 2009
Four Major Structure Types
• Boat Section – 340 lf–– SOE SOE -- Steel Soldier Piles and Wood LaggingSteel Soldier Piles and Wood LaggingSOSO Stee So d e es a d ood agg gStee So d e es a d ood agg g
• Cut and Cover – 1200 lfSOESOE C t D S il Mi i W ll (CDSM)C t D S il Mi i W ll (CDSM)–– SOE SOE -- Cement Deep Soil Mixing Wall (CDSM)Cement Deep Soil Mixing Wall (CDSM)
–– SOE SOE –– Cement Bentonite Wall (CB)Cement Bentonite Wall (CB)
• Top Down Construction - Station–– SOE SOE -- Slurry WallSlurry Wallyy
• Bored Tunnel – 2240 lfSOESOE P t C t S t l Li iP t C t S t l Li i–– SOE SOE -- Precast Concrete Segmental LiningPrecast Concrete Segmental Lining
Boat Section – Soldier pile and lagging• Excavation – 0 to 35 feet
• Soldier Piles and Wood Lagging
• Above or at the water table
• Deep Wells
Walls and Waterproofing
EXISTING SOILSEXISTING SOILS
Boat Section - SOE - Soldier Piles & Lagging
Soldier Piles andSoldier Piles andSoldier Piles and Soldier Piles and LaggingLagging
Cut & Cover – SOE CDSM Walls
BACKFILLCDSM Walls
60’ +/60’ +/-
Cut off ground water
ROCK
Cut & Cover / Launch Pit – CDSM Walls
Cut & Cover / Launch Pit - CDSM WALLSI l il i d ithIn place soils mixed with Bentonite Slurry going down
Cement Slurry mixed going up
Insert Steel Soldier Piles
CDSM –SOE – Drill Rock Socket
CDSM WALLS – Temporary Bridge
Excavation / Mud Slab / WP/ Base Slab
ROCK
Structural Concrete
Waterproofing
ROCK
Structural Concrete – Cut and Cover
Backfill
BACKFILL
ROCK
Bridge to hold the Bridge
Support two Bents
Cut & Cover – InstrumentationInstruments
Stain gauges
Weather
Tilt MetersTilt Meters
MotorizedMotorized Total Station
Underpinning – SR-65
Drilled PierDrilled PierDrilled PierDrilled Pier
Drilled PierDrilled Pier
Underpinning – SR-65
ROCK
Underpinning – SR-65
Drilled PierDrilled Pier
Underpinning – SR-65
ROCK
Underpinning – SR-65
ROCK
North Side Station Shell
North Shore Station - Slurry Walls
SEA PARKING GARAGE
Concourse
North Shore Station - Slurry Walls
North Shore Station – Slurry WallsDESANDING
P iP iP i
DESANDING
Excavate Slot Primary Panel
Primary Panel
Primary Panel
SecondarySecondary Panel
North Side Station – Slurry walls
Concrete P iP iP iConcrete Primary Panel
Primary Panel
Primary Panel
Secondary Secondary
Rebar
Tremie pipeSecondary
PanelSecondary
Panel
Rebar
Slurry Walls - Rebar Cage
North Side Station – Top Down
ROCK
North Side Station – Pour Roof Slab
Roof SlabRoof Slab
ROCK
Excavate to Concourse
BackfillRoof Slab
CONCOURSE
Roof Slab
ROCK
Excavate to Concourse
BackfillRoof Slab
Soldier Piles installed by building Soldier Piles installed by building contractorcontractor
CONCOURSE
Roof Slabcontractorcontractor
ROCK
Excavate to first row of struts
BackfillRoof Slab
CONCOURSE
Roof Slab
ROCK
Station Roof Slab Excavation
60 ft
40 ft40 ft
Excavate to Invert – Pour Base Slab
BackfillRoof Slab
CONCOURSE
Roof Slab
SLAB ANCHORS
ROCK
Station Ground Anchors
Ground Anchors
Construct Platform & Deck
BackfillRoof Slab
CONCOURSE
Roof Slab
ROCK
TBM Launch Pit - SOE
CDSM WALL
TBM Launch Pit - SOE – Tie Backs
Launch Pit - SOE – Tie Backs
TIE BACKS
TIE BACKS
TBM
ROCK
Ground Improvement - Jet Grouting
Launch Pit - Jet Grout
Jet Grout column construction
Drill Down
Grout bottom up
Launch Pit – Entrance Packing
Soft Eye
TBM – Move to Launch Pit
TBM – Move to Launch Pit
150 feet fully assembled150 feet fully assembled
Launch Pit – TBM Launch
JET
GROUTJET
GROUT
21
GROUT
3 21 3
Launch Pit – Structure Work
JET
GROUT
Stanwix St. Receiving Pit Location
GATEWAY II
HORNE BUILDING
RECEIVING PIT
Ground Improvement - Jet Grout
75% COVERAGE
Receiving Pit
100%
100% Coverage
6’ Around Tunnel6 Around Tunnel
Ground Improvement - Jet Grout – 75%HORNE BLGHORNE BLG.
MinimizeMinimize Angular Distortion due t dto ground loss
Jet Grouting Stanwix Street
Stanwix Street Receiving Pit – CB Wall
Bored Tunnels
Tunnel Tunnel Boring Boring M hiM hiMachine Machine Launch PitLaunch Pit
TBM Tunnels – 2200 lfNORTH SHORENORTH SHORE
Receiving Pit
SOUTH SHORESOUTH SHORE
Bored Tunnel SectionPRECASTPRECAST SEGMENTLININGLINING
Segment Lining 20’ inside diameter
CAST IN PLACEPLACE INVERT
TBM TunnelsSl P B l TBM (SPBTBM)• Slurry Pressure Balance TBM (SPBTBM)
–– Mixed Shield (Soft Ground and Rock)Mixed Shield (Soft Ground and Rock)
–– Working Pressure 3 barWorking Pressure 3 bar
Mining Cycle – Mine 4’ & Grout
Mine 4’Mine 4’
GROUT MAINTAINEDGROUT MAINTAINED BEHIND SHIELD
Mining Cycle – Install 4’ Segment Ring
Build 4’ RingBuild 4 Ring
Mining Cycle – Ring Complete - Mine
Mine 4’Mine 4’
GROUT MAINTAINEDGROUT MAINTAINED BEHIND SHIELD
Segment Grouting
Segments Grout Nozzle
Grout
TBM – SLURRY – MIX SHIELD
22’-9”
SPTBM Mixed Shield
Slurry TBM – 22’- 9” dia (6.92 m)24 17 i h t i• 24 -17 inch twin disk cutters
• 20 - Scrapers20 Scrapers
• Bucket lips
• 3 - Wear• 3 - Wear detection devices
• 0-2.7 rpm
• Left or Right
Cutting Tools – After first tunnelDi k C tt• Disk Cutters
• Scrappers• Bucket Lips
Rock Crusher
TBM Assembly – Man Locks – 3 Bar (45 psi)
Material Lock
Cutter Head Drive
• Motors - 8 – 101 hp
• Total - 808 hp18
2Total 808 hp
• Variable Frequency Drive (VFD)
7
Drive (VFD)
• 480 v AC 4
3
5
6
• 0-2.7 rpm (l or r)
• Main bearing 8 5 ft
45
• Main bearing – 8.5 ft
TBM – Rear of Middle Shield5 Cylinders 4 Steering Groups
6 Cylinders
7 Cylinders
TBM – Rear of Middle Shield• Propel Cylinders - 24
• Piston Diameter - 260 mm
• Rod Diameter - 220 mm
• Max Stroke - 1750 mmMax Stroke 1750 mm
• Advance force - 38227 kN (4,296 tn)
TBM Operation
Excavation Chamber
Working Chamber
Hydrostatic and Soil
Slurry In
and Soil Pressure
Slurry OutSlurry Out
TBM – Operation Plan
455 hp PUMP
SLURRY IN
2 EA 455 h PUMPSSLURRY OUT2 EA - 455 hp PUMPS
Slurry Separation Plant
Plant Capacity Plant Capacity 1000 m1000 m33/hr/hr1000 m1000 m /hr/hr
Segment ErectorH d li l iH d li l i•• Hydraulic telescopic arm type Hydraulic telescopic arm type
•• 6 ranges of movement6 ranges of movement
•• TelescopeTelescope
R t tiR t ti•• RotationRotation
•• TravelTravel
•• Independent Independent Roll & YawRoll & Yaw–– Roll & YawRoll & Yaw
•• Controlled by joy stickControlled by joy stick
Segment Erector
• Thrust rams retracted 4’- 6”
Segment Installation
BOLTBOLT
Segment ErectorSegment ErectorSegment ErectorSegment Erector
Key Segment Installation
TBM Shield
Key Segment Installation
MOVE OUT
KEY SEGMENT MOVE FORWARD
TBM Mining – Start North SideNORTH SHORESOUTH SHORE
Equitable
NORTH SHORESOUTH SHORE
Equitable Resources
Building
Soft Ground
Fluvioglacial Material• Gravel 40% - 57%
• Sand 50% - 38%
• Fines 10% - 5%
• Cobbles - up to 2’Cobbles up to 2
TBM Mining - River CrossingNORTH SHORESOUTH SHORE
Equitable
NORTH SHORESOUTH SHORE
Equitable Resources
Building
Mixed Face
TBM – North River Wall
Alluvium
Claystone
Fluvioglacial
Siltstone
TBM North River Wall - Grouting
Alluvium
Claystone
Fluvioglacial
Siltstone
River CrossingNORTH SHORESOUTH SHORE
Equitable
NORTH SHORESOUTH SHORE
Equitable Resources
Building
Rock
River Crossing
25 feet ALLEGHENY RIVER
RIVER SILTS (ALLUVIAL)22 feet
Top of Rock FLUVIOGLACIAL
( )22 feet
SILTY SHALE (5,400 SILTY SHALE (5,400 –– 11,800 psi)11,800 psi)
CLAYSTONE (200CLAYSTONE (200 4 400 psi)4 400 psi)COALCOAL
10 feet
CLAYSTONE (200CLAYSTONE (200-- 4,400 psi)4,400 psi)
SILTSTONE (3 400SILTSTONE (3 400--11 000 psi)11 000 psi)SILTSTONE (3,400SILTSTONE (3,400--11,000 psi)11,000 psi)
River CrossingNORTH SHORESOUTH SHORE
Equitable
NORTH SHORESOUTH SHORE
Equitable Resources
Building
Well Horne Blg.
Soft GroundJet Grout
Mixed Face
TBM Guidance System – VMT
Total StationTotal Station Operator’s DisplayOperator’s Display
80 mm
TargetTarget
Precast Segments – Universal RingSix pieces + Key4’ – Long
20’ ID
4 Long
Bolted
Two tapers 2-3/8 & 1-5/8
Segment Rebar Cages
Seg Plant – cycle 4 rings X 2/ day
Segment Finishing Line•• Rotate Segments Rotate Segments ––
curve upcurve up
•• Repair SurfacesRepair Surfaces
•• Add GasketAdd Gasket
•• Add Joint PackingAdd Joint Packing
•• Stack in reverse order Stack in reverse order of installationof installation
Secondary Steam Curing
• 5 day Secondary Cure
• 8000 psi8000 psi
Multi Purpose Vehicle (MVP)
Multi Purpose Vehicle (MVP)
Heading Segment Unloading
Heading Segment Unloading
Segment Erection
Tunnel Infrastructure
50,000 CFM Ventilation50,000 CFM VentilationTemporary Temporary LightingLighting
2 - 4” water
8” Discharge
Walkwayy
First Tunnel to Receiving Pit - July 10, 2008
Soft eye Soft eye ––Fiberglass pilesFiberglass piles
First Tunnel to Receiving Pit - July 10, 2008
Containment Wall
TBM U-Turn
TBM U-Turn- Rotate 180 deg
TBM U-Turn- Rotate 180 deg
TBM U-Turn- Rotate 180 deg
TBM U-Turn- Rotate 180 deg
Invert Clean Up
Invert Placement
Thank YouThank You
Questions?Questions?