richard graham - salini impreglio - nrw jv
TRANSCRIPT
CONTRACTOR’S UPDATE
• About SI-NRW JV
• Key Challenges
• Design
• Key Equipment
• Execution
• Summary
• Total length of mechanized excavated tunnels: 14.2km
• Total length of Cut and Cover Dives: 0.8km
• Total number of stations: 3
• Total number of Cross Passages: 12
• Total number of Emergency Egress Shafts: 3
• Trackwork
• Power & System
• 10 years Maintenance
FORRESTFIELD AIRPORT LINK
About the SI-NRW JVForrestfield Airport Link is the new challenge that the Joint Venture between Salini-Impregilo S.p.A. and NRW are proud to design, construct and maintain for Perth Transport Authority (PTA).
• Joint Venture Leader
• 80% share
• Global contractor of large complex projects
• Joint Venture Partner
• 20% share
• Strong local civils and mining contractor
SI-NRW JV
● Largest Italian Contractor, ranked #27 in ENR’s Top 250 International
Contractors
● Turn over Euro 4.74bn /year, backlog Euro 28.8bn
● More than 35,000 employees worldwide from over 100 nationalities
● 110 years on the international construction market
● 34 TBMs all around the World
● In 2015 Awarded the ‘Project of the Year’ by the International
Tunnelling Association for the Lake Mead Tunnel, Las Vegas, USA
Salini-Impregilo is present all around the globe
257 Dams and
Hydropower plants
producing more than
37,500MW
51,660km of roads &
motorways 1,450km of tunnels
350km of
bridges & viaducts
6,830 km of railways
METROMOVERMIAMI
LINE 3, CARACAS METRO
RECONSTRUCTION OF LINE 1, SAINT PETERSBURG
LINE 3 & EXTENSIONS, ATHENS METRO
LINE 1, NAPLES METRO
GENOVA METRO
METRO DO PORTO
PARIS:- REGIONAL METRO LINE 3, LOT 35B - NEW METRO LINE, LOTS M21/M22
LINE 2, LOT 3, METRO LILLE
METRO AND RAILWAY SISTEMMILAN
EXTENSION OF METROSINGAPORE
EXTENSION OF METRONEW YORK SUBWAY
UNDERGROUND RAILWAY LOOPMELBOURNE
ROMA METRO
THESSALONIKI METRO
●400km of metros!
NRW - Local construction knowledge
Civil Infrastructure Mining
2015 ‘Project of the Year’ - Lake Mead Tunnel, Las Vegas, USA
World record for TBM able tooperate with pressures up to
18 bars!
Lake Mead Mix-mode TBM from Herreknecht:
• 2,500m excavated with pressure up to 16.3bars in Slurry Mode
• 1,900m excavated in Open Mode
Key Project ChallengesWhile the great benefits of the FAL Project will be to provide the residents and visitors to Perth the opportunity to use an efficient Public Transport Link to & from the International Airport, there are nevertheless a number of significant challenges:
• Complicated geology, fully below water table
• Passing under the fully operational Perth Airport
• Passing under the Swan River
• Very tight contract duration: only 52 months
• Very tight budget!
Bayswater Dive
Airport West Station
Swan River
PAPL Airport land
ForrestfieldDive
PAPL Airport Land
Airport StationForrestfield
Station
Complicated Geology:
• Tunnels alignment fully below water table
• Various strata from sandy alluvial to clay rock (2-4Mpa)
• Maximum depth of tunnels 38.0m Maximum pressure considered 4.0bars
• Geological Risk Mitigation – alignment lowered by 5.0m into Osborne Formation
TBM Direction
TBM Direction
Passing under of fully operational Perth Airport:
• Twin Tunnels below Runways
• No access for intervention from Top!
• Settlements lower than 10mm!
Program Summary
Contract Award
Mobilisation
Commencement of Works
TBM 1 Procurement
Design of Forrestfield Dive
Forrestifield Dive
TBM Support Facilities (incl
intial Segment Manufacture)
Tunnelling - Tunnel 1 & 2
Forrestfield Station
Bayswater Deviation
Bayswater Dive
Cross Passages
Track Slab
Cable Tray and Cable Haul
Tunnel Fitout
Commissioning
Abernethy Egress Shaft
Consolidated Airport Station
Airport West Station
49 50 51 52 5343 44 45 46 47 4837 38 39 40 41 4231 32 33 34 35 3625 26 27 28 29 3019 20 21 22 23 2413 14 15 16 17 187 8 9 10 11 12
SO N D J F M
1 2 3 4 5 6
A M JA M J J A SO NSO N D J F M J AD J F MA M J
2016 2017 2018 2019 2020
M J J A S A M J J A SO N D J F M J A
Project Delivery: 17th September 2020
Design
The Designers’ team for FAL Project contains various Design Companies working in Australia and Europe
Key Design Challenges:
• Tight Program – D&C
• Variable Ground Conditions / High Water Table
• Passing under Perth Airport Runways
• Environmental Sensitive Project
• Multidisciplinary Design
• Design life of 120 years
• ‘Excellent’ ISCA Sustainability Rating
• Rail Safety Accreditation
• Design of TBM Tunnels
• Design of Dives
• Design of Cross Passages
• Design of Stations
• Design of Emergency Egress Shafts
• Full Multidisciplinary Design
• Track works
• Systems
• Stations and Tunnels Fit-Out
Design Scope:
Tunnel Design
• Total number of more than 9000 rings
• Hybrid Solution: 40kg/m3 of reo + 40kg/m3 fibers
• High Fire resistance
• Configuration 5+1
• Durability of 120 years
• Double Convex system for Lining Segments
• Double Gasket System
• Bolting and Secondary Grouting
• Coating of Segmental Lining
• 50 MpA Concrete
Tunnels are connected with CP approx. 330m apart. Treatments for the CP:
• 7 CP with full jet-grouting treatment
• 1 with jet-grouting treatment (only crown)
• 3 CP with ground freezing;
• 1 CP with half face freezing (only crown)
• Total 12 CP
Cross Passages Design
Cross Passage Design
Cross Passage Data Base Specification
Jet Grouting Treatment (Full) 7
Jet Grouting Treatment (Crown) 1
Freezing Treatment (Full) 3
Freezing Treatment (Crown) 1
Cross Passage Design• Pre-treatment from surface
with Jet-grouting columns
• Bi-fluid treatment
• Cross Passage equipped with temporary steel support
Instrumentation and Monitoring Design> 8000 instruments to be installed along the alignment
• 2 Variable Density TBMs
• Less than 10 such machines in world
• 7.10m diameter
• Unique technology of double mode operation:
Slurry excavation
EPB excavation
• Nominal Thrust 50,600 kN
• Nominal Torque 51,100 kNm
• Main Drive Power 1440 kW
Key Equipment
EPB vs. Mix-shield TBMs
Variable Density TBM
Difference between traditional Slurry TBM and Variable Density TBM:
• No opening in submerged wall - Special supply lines
MSVs:
• Capacity 60t –two rings transportation
• Capacity 30t –personnel and equipment
Multi Service Vehicles
• Total maximum capacity: 500m3/h
• 12 Booster Slurry Pumps in Tunnel (600kW each)
• Min Environmental Impact – max Recycling
Slurry Treatment Plant
• Off-site Shed for Plant rented
• Carousel System
• 9 sets of moulds
• 24 Rings /144 segments / day
• Casting rate: 8 mins per
segment
• Steam Curing for 6h – 420
degree C
• 22MpA after 6 hrs
Precast Segment Lining Plant
ExecutionStations:
• Top-Down Sequence
• D-Walls and Barrettes
Cross Passages:
• Jet-Grouting
• Freezing
ExecutionCurrent Progress:
• Site Mobilization commenced
• Approvals Applications submitted
• All main equipment ordered and under manufacture
• Progress of Design: more than 20% ready by October 2016
• Jet Grouting Trials due to start next week
• Ready for Start of Diaphragm Walls in Forrestfield Dive Structure –November 2016
• First TBM due on Site in May 2017 – start of boring July 2017
Summary
The FAL Project:
• Very tight Programme
• Technically Challenging
• Assembled Team with great Competencies & Experiences
• Design Progressing to Schedule
• Constant collaboration with PTA and PAPL (Perth Airport Authority)
• Formal working Group to encourage Aborigine Business participation
• Numerous Critical Stakeholders
• Strict environmental controls for all the Works
Thank You !!
Together
We build value!