November 14 - 15, 2006

44 Pages·2008·3.96 MB·English

Reader Service Number 1
C O N T E N T S
CONTENTS
August 2006
Cover Story
The Letter of the Law —
Experts Discuss Legal Issues in Tunneling 16
TBM sat down with four prominent construction attorneys,
each representing different parties involved in tunnel contracts.
They talked about how their roles in projects have changed and
some of the biggest challenges facing them and their clients.
Features
Shotcrete Showcase 23
Shotcrete has become a standard tool in tunnel construction.
Included are a few of the biggest names in the marketplace and
what they have to offer.
Waterproofing Boston’s Big Dig 26
16
In the Central Artery of Boston’s Big Dig, a short-term means of
controlling groundwater flow was needed. In this case, the only
feasible solution was chemical grouting.
Big Walnut’s Silver Lining 28
Since starting construction more than two years ago, the BWARI
project in Columbus, Ohio, has involved several variables. However,
installing the liners has been a relatively smooth process.
Going Underground at Indianapolis Airport 30
Akey component in renovating Indianapolis International Airport is
the construction of a new utility connector that will link an existing
energy plant to the new passenger terminal. By James W. Rush
Tunneling in Australia 32
Tunneling and underground construction projects continue to boom in
Australia and New Zealand. By Jeff Sharp and Steve Rosin
Columns
32
Editor’s Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Mega Problems for Mega Projects . . . . . . . . .by James W. Rush
Dr. Mole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Risky Business . . . . . . . . . . . . . . . . . . . . . . . . . .by Gary Brierley
Microtunneling Project Update . . . . . . . . . . . . . . . . . . . . .40
A recap of recently completed, current and future microtunneling
projects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .by Nick Zubko
Departments
Business Briefs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
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1579 to TBM: Tunnel Business Magazine, P.O. Box 190, Peninsula, OH 44264.USA
August 2006 Tunnel Business Magazine 3
’
E D’I TO R S M E S S AG E
EDITOR S MESSAGE
Bernard P. Krzys Mega Problems for Mega Project
Publisher
Unless you’ve been living in a tunnel, you have heard the
Richard J. Krzys
tragic news coming out of Boston regarding the death of
Associate Publisher &
Conference Director Milena Del Valle, who was killed July 10 when 12 tons of con-
crete ceiling panels inside the I-93 connector to the Ted
Robert D. Krzys
Williams Tunnel fell onto the car she was traveling in. As of
Associate Publisher
press time, the I-90 connector tunnel is closed indefinitely.
James W. Rush
This is the latest in a long line of problems plaguing
Editor
the Central Artery/Tunnel project— aka the Big Dig—the
Nick Zubko
largest highway project in U.S. history. Shortly after its
Associate Editor
opening in September 2004, a failed slurry wall resulted in
Sharon M. Bueno flooding, a 10-mile traffic backup and temporary closure of
Katherine Fulton
I-93. Subsequently, some 500 more leaks were found, leading
Keith Gribbins
Brad Kramer to public concern over the quality of construction.
Jason Morgan Of course, the project came under public scrutiny well before its opening as
Contributing Staff Editors cost overruns were widely reported. The initial price tag for the project was
W.M. Conley $2.6 billion and it was supposed to be completed in seven years; instead, it took
Creative Director nearly 15 years and repeated cost overruns until it had ballooned to $14.6
billion, according to an AP report.
Edward A. Haney
Senior Graphic Designer In July 2003, I visited the jobsite as one of the last major pieces of
construction was under way. At the time, portions of the tunnel, including the Ted
Chris Slogar
Williams Tunnel, were opened and Boston residents were beginning to see the
Elizabeth C. Stull
Graphic Designers project’s potential value. Then came the leaks. And falling debris. Now, the
tunnel is being treated as a crime scene and fingers of blame are being pointed
Kelly Dadich
Marketing Manager in every direction. The July 10 accident has already led to the resignation of
Massachusetts Turnpike Authority chairman Matthew Amorello.
Dan Sisko
So what does this mean for the tunneling industry? That remains to be seen, but
Regional Sales Representative
it is almost certainly bad news. To play an effective role in society, tunnels have to
Alexis R. Tarbet
be viewed by public officials and the public at large as 1) safe, and 2) a good value.
Circulation Coordinator
Unfortunately in the case of the Big Dig, it is being viewed as unsafe as well as a
financial boondoggle. Internet searches reveal headlines such as: “The Big
Editorial Council
Problem,” “Big Dig or Big Scam,” or “The Big Dig: The Sky is Falling in Boston.”
Chairman How will public officials in Seattle react as they move forward in the
Gary Brierley, P.E.
Brierley Associates, William H. Edgerton planning of the Alaskan Way Viaduct replacement? Will New York leaders
Jacobs Associates
Denver San Francisco choose to follow a similar construction program of buried highway in Brooklyn
Randy Essex, P.E. Joe Gildner for the Gowanus Expressway reconstruction project? Certainly not without
Hatch Mott MacDonald
Rockville, Md. Sound Transit the backing of all parties involved— and it’s hard to imagine an enthusiastic
Seattle
Roberto Gonzalez Izquierdo reception in the light of Big Dig’s failures to date.
Boro Lukajic
Moldequipo The sad part is thinking about the “what ifs.” The cost and schedule overruns
Consulting Engineer
Internacional
Mississauga, Ont. are understandable– the initial cost may well have been lowered to ensure that
Tepotzotlan, Mexico
Dru Desai the project got off the ground in the first place. And it is construction, after all,
Dr. Levent Ozdemir, P.E.
Colorado School of DMJM+HARRIS some delays and overruns are to be expected. But what if the project had been
Baltimore
Mines completed without leaks, failures or finger-pointing, without cost recovery
Golden, Colo. Ted Budd
Bob Pond Kenny Construction committees, and, most important, without fatalities?
Frontier-Kemper Wheeling, Ill. What we would have seen is an underground project that simplified the lives
Evansville, Ind. David Caiden of motorists, restored the beauty of one of America’s most picturesque cities,
George Yoggy Arup reunited parts of the city divided by the construction of the elevated structure,
New York, N.Y.
GCS LLC
and created new economic opportunities and parkland. It could have been a
Allentown, Pa.
project that showcased the benefit of going underground for the next 100 years,
or more. Instead, we have an opportunity wasted.
Regards,
EDITORIAL & ADVERTISING OFFICES
1770 Main St., P.O. Box 190
Peninsula, OH 44264 USA
Ph: [phone] • Fax: [phone]
James W. Rush
Internet home page: http://www.tunnelingonline.com
e-mail: [email protected] Editor
4 Tunnel Business Magazine August 2006
Reader Service Number 2
Business Briefs
Panel to Advise Massachusetts Governor on Big Dig Review
According to an article in the Boston Globe, Massachusetts He said he has narrowed the search for an engineering firm
Gov. Mitt Romney said recently that he is on the verge of to three companies. The work will be paid for out of a $20 million
hiring a diagnostic engineering firm and naming a special appropriation that the legislature approved recently when it
panel of experts to carry out a review of Boston’s Big Dig, handed Romney oversight of the Big Dig after the accident.
including its roads, bridges, tunnels and mechanical systems. He subsequently forced out turnpike chairman Matthew
The $15 billion project has been in the spotlight since the Amorello, who was set to leave Aug. 15.
July 10 collapse in which a car was crushed by falling cement, Federal accident investigators said recently that they are
killing its passenger, Milena Del Valle. Inspections of the 7.8- focusing on the design of the drop ceiling in the Interstate
mile tunnel system have since shown that connectors holding 90 connector tunnel, compared with the ceiling in the
up many portions of the tunnel’s ceiling could be faulty. nearby Ted Williams Tunnel, and are looking at whether
Romney is also completing interviews with engineers and the epoxy used to anchor ceiling bolts, the method used to
other construction specialists to serve on what he expects apply the adhesive, or construction oversight may also have
to be a three- to five-member panel to advise him and the contributed to the accident.
engineering firm. He expects the review to be completed National Transportation Safety Board officials confirmed
by the end of the year. that a total of 20 ceiling bolts abruptly failed that night, send-
“This is going to narrowly focus on issues of safety,” ing heavy concrete ceiling panels crashing to the highway.
Romney said. “There will be no attempt by the firm or the “We continue to make progress in this investigation and
panel to assess responsibilities for any shortcomings ... this is seek to learn as much as possible from this tragic accident ...
not a fault-finding effort. They and I have one clear incentive to prevent similar accidents in the future,” board chairman
... make sure these tunnels are safe.” Mark V. Rosenker said in a statement.
NAT 2006: Extreme Success Terex Reedrill Showcases Hydraulic
The Underground Construction Association of SME (UCA of Track Drill in South Africa
SME) presented the 2006 North American Tunneling (NAT)
Terex Reedrill, a leader in drilling equipment for the quarry,
Conference, June 10-15, in Chicago. Total conference attendance
construction and mining industries, has announced that it will
reached 570 and 86 premier industry companies exhibited.
display its SCH5000 hydraulic track drill during the Electra
The conference theme of “Extreme Tunneling: Improving
Mining Show in Johannesburg, South Africa, Sept. 11-15.
Progress, Cost, Performance, and Safety,” was reflected in the
Equipped with a powerful 310-hp diesel engine, the
16 technical session and more than 80 presentations.
SCH5000 delivers 2,500 to 3,100 bpm and features the
Sessions included: Project Management and Predicting and
reliable HPR5128 rock drill. This drill is field serviceable,
Controlling Cost and Schedule; Going Underground: Protecting
with almost half the total parts of competitors’ models, for
Critical Infrastructure; Innovations in Tunneling; Specialized
easy maintenance. The SCH5000 also features a heavy-duty,
Urban Construction; Identifying, Quantifying and Managing
long-life mainframe weldment mounted on the excavator
Risk in Underground Construction; Transit Oriented
undercarriage for advanced stability in rough terrain.
Development: Making the Case for Going Underground; Soft
The machine’s powerful and efficient dust collector ensures a
Ground Tunnels; Ground Modification for Underground
cleaner work area, while its easily maintained hydraulic system
Construction; Alternative Delivery Methods for Underground
and reliable linear rod
Works; Going Public: Selling the Underground Solution; Tunnel
changer provide for reliable
Lining Design; Machine Mining: Soft Ground to Hard Rock and
operation. For optimal oper-
Everything in Between; Stakeholder Interests in Design and
ator visibility and comfort
Construction; Show Me the Money: Creative Financing for
on the job, the SCH5000
Underground Projects; Challenging Tunnel Designs; and
offers a unique, two-man
Conventional Underground Construction. Additionally, lun-
“Swing Cab,” adding to
cheon speakers Hugh Kelly and Charles Daugherty presented
productivity.
“SSC Retrospective.”
“The SCH5000’s proven
Other conference highlights included the three pre-confer-
performance features and
ence workshops; DRB Continuing Education “Brush-Up,”
distinctive cab design make
Better Contracting Practices for Underground Construction,
it one that’s in high demand
and Second Edition of GBR Guidelines Documents. A field trip
in rough terrain, and of
to the Department of Energy’s Fermilabs completed the
particular note to this
conference. Hardbound proceedings with a complimentary CD
South African market,”
were published and are available for purchase through SME.
said Ron Passmore, Terex
The 2008 NAT is scheduled for June 7-11 at the Hyatt
Reedrill district manager
Embarcadero, San Francisco. For more information on SME
for Australasia and South
The SCH5000 will be featured at the
meetings visit SME at www.smenet.org, or contact them at
Africa. Electra Mining Show in Johannesburg,
[email protected] [phone].
South Africa, Sept. 11-15
6 Tunnel Business Magazine August 2006
Alaskan Way Viaduct Facing experts evaluating the plans, state Nickels’ administration downplays
Big Dig Comparisons House Speaker Frank Chopp, a Seattle such criticism, saying they have
Democrat, and two other influential accounted for inflation and difficul-
As Seattle Mayor Greg Nickels and
state lawmakers made their views clear. ties in attracting enough money
his allies push for a major new tunnel to
“The Legislature funded a rebuild, not from Congress or other sources.
replace the Alaskan Way Viaduct, some
a tunnel,” they wrote. “Almost all of the Instead, city leaders seem certain
critics are pointing to Boston’s Big Dig
[tunnel’s] proposed funding sources are their vision for a once-in-a-genera-
as support for an alternative, according
future possibilities, some years ahead. We tion waterfront overhaul will carry
to a recent article in the Seattle-Post
believe they are too risky to count on.” the plan to victory.
Intelligencer.
Seattle’s viaduct shares common ele-
ments with the Big Dig: Both involve
coastal cities, hungry to reclaim the views
and property values that were scarred by
their Cold War-era elevated highways. The
comparison breaks down in the details.
The Big Dig created a series of tunnels
to replace Boston’s old Central Artery.
At $14.6 billion, it is the most expensive
highway project in U.S. history. And it
has been plagued by cost overruns,
delays and faulty construction that culmi-
nated in one motorist’s death under a
collapsed tunnel ceiling in July.
Nickels’ plan for Seattle is more mod-
est, consisting of a single tunnel topped by
a sweeping new urban park and commer-
cial zone. State Transportation Secretary
Doug MacDonald, who formerly served as
director of the Massachusetts Water
Resource Authority, said the Big Dig
comparison is not entirely apt. But you
can expect to see Boston’s troubles refer-
enced whenever officials publicly battle
over a major project, he said.
“The Big Dig now has become almost
a mythical thing in the American public
works landscape, for good and for ill,”
MacDonald said. “I don’t think simply
labeling something as the next Big Dig
teaches you very much.”
The present viaduct is definitely a lia-
bility. Built in the 1950s, it was damaged
in 2001 by a 6.8-magnitude earthquake.
Engineers warn that another tremblor
from the faults crisscrossing this area
could collapse its towering decks.
Two replacement options have emerged
as serious contenders: Nickels’ tunnel,
and a competing proposal to build a new
elevated highway. Depending on the size
of each, an elevated highway could cost
between $2 billion and $3.1 billion; a tun-
nel could cost from $3 billion to $4.5 billion,
according to state officials.
There is about $2.4 billion committed
for the viaduct project, but some key
legislators have warned Nickels that his
tunnel plan is a nonstarter. In a letter to
Reader Service Number 3
August 2006 Tunnel Business Magazine 7
Business Briefs
World’s Largest Hard Rock
TBM Launched in Ontario, Canada
A ceremony was held on Aug. 8 to celebrate the official
startup of the largest hard rock TBM in existence for the
Niagara Tunnel Project. Christened “Big Becky,” the 47.5
ft (14.4-m) diameter Robbins TBM is now fully assembled
in Queenston, Ontario, Canada.
The completion of the machine comes several weeks ahead
of an aggressive 12-month schedule. The TBM was assembled
onsite rather than at the Robbins factory in Solon, Ohio.
The swift build was hailed by contractor Strabag AG, Austria,
as “unprecedented for a TBM of this size.”
Rather than pre-assembling the machine at its manufac-
turing facility; a team of Robbins specialists worked full-time
to assemble the TBM onsite. The machine is now ready to
begin its 6.5-mile (10.4-km) long bore connecting the Sir
Adam Beck Generating Complex to an intake shaft above
Niagara Falls.
The project, launched by owner Ontario Power
Generation (OPG), will increase the maximum capacity of
the generating complex by 150 MW. The increased power
generation is much needed since the current system is close
to exceeding its capacity during peak summer months.
The TBM launch ceremony was attended by top executives
from Ontario Power Generation, Strabag AG, and The
Robbins Company. The Premier of Ontario, Dalton
McGuinty, gave a speech and started the machine. The cere- The 47.5-ft Robbins hard rock TBM named “Big Becky” recently began
mony concluded with the turning of the cutterhead. a 6.5-mile trek to connect the Sir Adam Beck Generating complex to
an intake shaft above Niagara Falls.
Milwaukee Sewer Project Honored range, Milwaukee needed to develop a solution for aging and
as Public Works Project of the Year undersized sewer and stormwater infrastructure, with the
resulting sewer overflows and basement backups during wet
The Milwaukee Northwest Side Relief Sewer was recently
weather. In 1998, the Milwaukee Metropolitan Sewerage
named a Public Works Project of the Year by the American
District formulated a farsighted proposal to accommodate
Public Works Association (APWA). The Milwaukee
growth, protect water quality and safeguard public health
Metropolitan Sewerage District, managing agency, along with
within its 420-sq mile service area. The Northwest Side
primary contractor Shea-Kenny Joint Venture and primary
Relief Sewer was the top priority capital improvement
consultant Black & Veatch Corp. will be presented with the
project in the District’s 2010 Facilities Plan.
award during APWA’s International Public Works Congress
It took more than $121 million, longer than a year to dig, a
and Exposition held in September in
machine powerful enough to cut a
Kansas City, Mo.
22-ft diameter hole through bedrock
Awards are presented annually to
and thousands of truckloads of
promote management and adminis-
concrete to complete the massive
tration excellence of public works
project. More than seven years of
projects by recognizing alliances
planning, design and construction
between managing agencies, contrac-
went into the 7.1-mile sewer tunnel,
tors, consultants and their coopera-
which serves seven northwestern
tive achievements. This year APWA
Milwaukee County communities.
selected 19 projects in five cate-
The project demonstrates impor-
gories: Disaster or Emergency
tant strategies to confront capital-
Construction/Repair, Environment,
intensive sewer overflow challenges,
Historical Restoration/ Preservation,
where available funding often falls
Structures and Transportation.
short and pressure to meet regula-
Awarded in the Environment More than seven years of planning, design and construction
went into the 7.1-mile sewer tunnel. tory compliance is intense.
category, more than $100 million
8 Tunnel Business Magazine August 2006
Minneapolis Tunnel Project a solution that best
Wins ACEC Grand Award serves the needs of
the traveling pub-
The American Council of Engineering Companies (ACEC)
lic, while meeting
recently recognized the Minneapolis-St. Paul Metropolitan
airport operational
Airports Commission (MAC) and the design and project
and safety stan-
management team of HNTB Corp. with a Grand Award at
dards; creating an
the 2006 Engineering Excellence Awards ceremony. The
innovative mined
award was given for the design team’s work on the design
signature station
and construction of twin light rail transit (LRT) tunnels and
for the Lindbergh
the underground Lindbergh Terminal LRT station at the
Terminal; minimiz-
Minneapolis-St. Paul International Airport (MSP).
ing airside and
The team for MAC (led by HNTB and comprised of CNA
landside disruption
Consulting Engineers; Hatch Mott MacDonald; and
during construc-
Hammel, Green and Abrahamson) designed twin 1.8-mile- The twin 1.8-mile-long, 21-ft diameter LRT tunnels
tion; maintaining
long, 21-ft diameter LRT tunnels, which are the largest are the largest TBM-bored tunnels in Minnesota.
near zero ground
TBM-bored tunnels in Minnesota. The team also designed
subsidence under airfield pavements and structures; and
the underground LRT station at the airport’s Lindbergh
minimizing disruption to concurrent projects within the
Terminal, which measures 63 ft wide by 40 ft tall and 530 ft
airport’s $3 billion expansion program.
long — making it the state’s largest underground public
HNTB was one of only seven Grand Award winners out
structure. The project was delivered within budget and one
of 163 entries. Accepting the award at the gala held in
month ahead of schedule.
Washington, D.C., on May 2 was Greg Alberg, HNTB
The project was heralded for meeting all of the set goals
project champion and Minneapolis office leader; Rich
outlined from the beginning of the project, including devel-
Johnson, HNTB project manager; and Pat Mosites, MAC
oping a cost-effective design and maintaining project bud-
airside project manager.
get; working collaboratively with all stakeholders to develop
Reader Service Number 15 Reader Service Number 4
August 2006 Tunnel Business Magazine 9
Business Briefs
Arup Promotes Koutsoftas, been involved in the design, construc-
Nicholls and Lagger tion and instrumentation of many
significant building engineering and
Arup, a global firm of planners, designers, engineers and
infrastructure projects around the
business consultants providing a diverse range of professional
world and has a particular interest
services to clients around the world, recently announced three
in the assessment of soil/structure
promotions in its Tunnels, Geotechnics and Underground
interaction issues. Nicholls is busy
Structures group.
on geotechnical design projects in
Demetrious Koutsoftas P.E., G.E., was promoted to principal
Washington, D.C., New York, and is
in Arup’s San Francisco office with more than 33 years of expe-
leading the geotechnical design work
rience as a geotechnical engineer. Koutsoftas provides geot-
Nicholls for the $15 billion New Songdo City in
echnical expertise on projects involving transportation, deep
South Korea.
foundations, coastal reclamations, deep excavations, tunneling,
Hannes Lagger, CEng, was promoted to associate. Lagger
high-rise buildings, groundwater and dewatering, shoring
is a tunnel engineer with more than eight years of experience
design, slope stabilization, earth and
in the tunneling industry, specializing in soft ground shallow
rockfill dams, tailings dams, waterfront
tunnels and large underground openings in weak and hard
developments and industrial facilities.
rock. He has extensive U.S. and overseas experience in devel-
Koutsoftas, who joined Arup in 2003,
oping detailed designs and supporting contract documents for
leads the San Francisco Geotechnical
initial and final tunnel support, for ground conditions ranging
Group. Under his direction, the group
from hard rock to heavily faulted rock and soft soils.
has completed a number of high-profile
Lagger worked on the tender design for the North South
projects including the New Crystal
Bypass Tunnel in Brisbane, Australia, was bid manager for
Springs Bypass Tunnel for the SF
the successful bid of the multi-billion
Public Utilities Commission, the
dollar contract for the CrossRail Project
Caltrans Downtown Extension, and the
Lot 2 in London, and is part of the core
award-winning Hamilton Wetlands
Koutsoftas cavern design group for the mined
project for the U.S. Army Corps of
stations on the Second Avenue Subway
Engineers — recognized by the San Francisco section
project in New York. Hannes is a char-
of ASCE with the engineering excellence award for the
tered engineer and serves as an active
“outstanding small project of the year” in 2005.
member of the UCA of SME-NATM
Rachel Nicholls, P.E., was promoted to associate principal
committee. He chaired a session at the
in Arup’s New York office with nearly 20 years experience
2006 North American Tunneling (NAT)
in geotechnical engineering, working within the building
Conference in Chicago, as well as one at
engineering, infrastructure and energy sectors. Nicholls has Lagger
the GoldenRocks Conference in Denver.
DFI Educational Trust
Deep Foundations Institute (DFI) recently announced Educational Trust Board of Trustees: Larry Rayburn, Byrl
the creation of the DFI Educational Trust. The Trust Williams, David Coleman, Bill Loftus and Dick Short. In
is an independent charitable foundation of the Deep addition, The DFI president, Tracy Brettmann, and treasur-
Foundations Institute. The goals of the Trust include er, Jim Morrison, are named trustees of the DFI Educational
providing scholarships for students seeking degrees in Trust by virtue of their positions on the DFI Board.
civil engineering and construction engineering curricula The DFI Educational Trust met on Jan. 28 to set the
related to the deep foundation industry. The Trust will agenda for the year and elected the following individuals to
support programs that instill interest in the heavy serve one-year terms as officers of the Trust: Dick Short,
construction and civil engineering sciences in high school chairman; David Coleman, vice chairman; Larry Rayburn,
and college level students that will lead to careers in the secretary; and Jim Morrison, treasurer. The DFI
deep foundation industry. Educational Trust will rely solely on charitable donations
Current academic related programs begun by the Deep and fundraising events and is categorized as a 501 (c) (3)
Foundations Institute are to be immediately managed and by the Internal Revenue Code. The Trust Board has
supported by the DFI Trust in order to foster the goals of established a funding raising goal of $500,000 by 2010.
their educational focus. They are the Annual Paper Two upcoming fundraising events include a golf outing
Competitions for Students and Young Professors, the scheduled for Oct. 23 in Pleasanton, Calif., and a gala black
Foundation Engineering Poster Program and the Paul tie dinner in New York City, date and location to be
Debruyn Scholarship Fund. announced. If you are interested in making a charitable
The DFI Trust will operate as a separate entity of DFI donation to the DFI Educational Trust, wish to obtain more
and will be governed by its Board of Trustees, who where information or would like to sponsor or participate in one of
affirmed in January at the annual DFI planning meeting. the upcoming events; please contact DFI headquarters at
DFI announced the following individuals to the DFI [phone] or [email protected].
10 Tunnel Business Magazine August 2006