20100514 pipe arch presentation to iem   may 2010
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20100514 pipe arch presentation to iem   may 2010 20100514 pipe arch presentation to iem may 2010 Presentation Transcript

  • Presentation to Institution of Engineers, Malaysia
    Electrified Double Track Project Ipoh to Padang Besar
    PIPE ARCH TUNNEL
    by
    Mr. Don R. Hall
    Head of Tunneling Division,
    Gamuda Engineering Sdn Bhd
    May 2010
  • Outline of Presentation:
    General Project Information – Berapit Tunnel
    Pipe Arch Tunnel – Geological Profile & Concept
    Pipe Arch Tunnel – Chronology of Construction
    Construction of Triple Cell 3m Ф Drainage Culvert
    Demolition of Existing 3m x 3m Twin Box Drainage Culvert
    Pipe Arch Tunnel Construction
    Catastrophe
    Summary and Q&A
  • General Project Information
    – Berapit Tunnel
  • General Project Information – Berapit Tunnel
  • General Project Information – Berapit Tunnel
    North-South Expressway (NSE)
    YTL
    CEMENT
    PLANT
    To Taiping
    To Ipoh
    Pipe Arch Tunnel Crossing NSE
    Existing Railway Track
    • Tunnel Length = Approximately 2900m
    • Twin Tunnels, Single track each
    • Track Structure : Slab Track
  • General Project Information – Berapit Tunnel
    Drill & Blast
    Section
    Pipe Arch
    Section
    Cut & Cover Section
    Gradient 0.39%
    Pipe Arch Tunnel Crossing
    North-South Expressway (approx. 4m overburden only)
    Federal Route 1 temporarily diverted for tunnel construction
  • General Project Information – Berapit Tunnel
    Typical Berapit Tunnel Cross Section:
  • 8
    General Project Information – Berapit Tunnel
  • General Project Information – Berapit Tunnel
    CROSS PASSAGES EVERY 350m
  • Pipe Arch Tunnel –
    Chronology of Construction
  • Pipe Arch Tunnel – Chronology of Construction
    1. Triple 3mФcell drainage culvert at KM 232.6 of PLUS North-South Highway to replace existing 3m x3m twin box culvert
    Northbound
    Southbound railway tunnel
    Southbound
    Northbound railway tunnel
    2. Existing 3m x 3m twin box drainage culvert to be demolished & replaced
    3. Twin pipe arch tunnel crossing underneath PLUS North-South Highway KM 232.7
    Plan Layout of Twin Pipe Arch Tunnel
  • 12
    Pipe Arch Tunnel – Chronology of Construction
    1. Triple 3mФcell drainage culvert at KM 232.6 of PLUS North-South Highway to replace existing 3m x3m twin box culvert
    Southbound
    Northbound
    2. Existing 3m x 3m twin box drainage culvert to be demolished & replaced
    3. Twin pipe arch tunnel crossing underneath PLUS North-South Highway KM 232.7
    3-D View of Twin Pipe Arch Tunnel
  • Construction Of Triple Cell
  • Construction of Triple Cell 3m Ф Drainage Culvert
    Jacking Length = 45.5m
    LONGITUDINAL SECTION
    CROSS SECTION
  • Construction of Triple Cell 3m Ф Drainage Culvert
    First drive of jacking works of 3m Ф concrete pipes ongoing. Second & third drives awaiting for jacking with prepared entrance rings
    Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine
  • Construction of Triple Cell 3m Ф Drainage Culvert
    Jacking works ongoing
    Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine
  • Construction of Triple Cell 3m Ф Drainage Culvert
    Breaktrough of the first drive
    Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine
  • Construction of Triple Cell 3m Ф Drainage Culvert
    Lifting of microtunneling machine after breakthough of first drive
    Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine
  • Construction of Triple Cell 3m Ф Drainage Culvert
    Close up of RASA microtunneling machine
    Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine
  • Construction of Triple Cell 3m Ф Drainage Culvert
    Completed construction of triple cell drainage culverts
    Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine
  • Demolition of Existing 3m x 3m Twin Box Drainage Culvert
  • Demolition of Existing 3m x 3m Twin Box Drainage Culvert
    PLAN VIEW
    CROSS SECTION VIEW
  • Demolition of Existing 3m x 3m Twin Box Drainage Culvert
    Existing twin box culvert at KM 232.7 PLUS North-South Expressway before demolition
    Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction
  • Demolition of Existing 3m x 3m Twin Box Drainage Culvert
    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 Culvert for Pipe Arch Tunnel Construction
  • Demolition of Existing 3m x 3m Twin Box Drainage Culvert
    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 Culvert for Pipe Arch Tunnel Construction
  • Demolition of Existing 3m x 3m Twin Box Drainage Culvert
    Sealing of existing twin box culvert for pipe arch tunnel construction
    2. Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction
  • Pipe Arch Tunnel Construction
  • Pipe Arch Tunnel
    – Concept
  • Pipe Arch Tunnel – Concept
    Mined excavation
  • Pipe Arch Tunnel – Concept
    Site picture of project by Metropolitan Atlanta Rapid Transit Authority in USA
    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 Construction
    LONGITUDINAL SECTION
    CROSS SECTION
  • Pipe Arch Tunnel Construction
    Limits of PLUS North-South Expressway (NSE)
    Receiving
    Pit
    Jacking
    Pit
    Top of Soil Support Pipes
    Southbound NSE
    Northbound NSE
    Fill
    Fill
    0
    Cut &
    Cover
    Section
    Cut &Cover
    Section
    Residual Soil
    Direction of
    Microtunneling
    5
    Weathered Rock
    10
    Bottom
    of Structure
    Rock
    15
    20
    Scale in Meters
    0 5 10
    Jacking Length up to Toe of Highway Embankment= 90 m
  • Pipe Arch Tunnel Construction (Right Bore)
    Limits of PLUS North-South Expressway (NSE)
    Receiving
    Pit
    Jacking
    Pit
    Top of Soil Support Pipes
    Southbound NSE
    Northbound NSE
    Fill
    Fill
    0
    Cut &
    Cover
    Section
    Cut &Cover
    Section
    Direction of Microtunneling
    Residual Soil
    Weathered Rock
    5
    10
    Rock
    Bottom
    of Structure
    15
    20
    Scale in Meters
    0 5 10
    Jacking Length up to Toe of Highway Embankment= 92 m
  • Pipe Arch Tunnel Construction
    Cardox System – Non-explosive blasting
  • Pipe Arch Tunnel Construction
    Cardox Gas Filling
    Cardox Drilling & Connection
    Cardox Blasting
    Pipe Arch Tunnel Construction
  • Pipe Arch Tunnel Construction
    Mini Pipe Arch
  • Pipe Arch Tunnel Construction
    AVN500
    Microtunneling machine with retraction mechanism in case of rock face encountered
    Pipe Arch Tunnel Construction
  • Pipe Arch Tunnel Construction
    10mm Pipe Wall Thickness
    Jacking
    Direction
    780mm OD
    Pre-welded Line-up Band
    Pipe joint detail
    Pipe Arch Tunnel Construction
  • Pipe Arch Tunnel Construction
    Construction & staged excavation of bored pile jacking pit
    Pipe Arch Tunnel Construction
  • Pipe Arch Tunnel Construction
    Coring of reinforcement of shotcreted bored pile wall to prepare soft eye for microtunneling machine advance
    Pipe Arch Tunnel Construction
  • Pipe Arch Tunnel Construction
    Construction of thrust wall for jacking of microtunneling machine
    Pipe Arch Tunnel Construction
  • Pipe Arch Tunnel Construction
    Microtunneling machine preparing to jack
    Pipe Arch Tunnel Construction
  • Pipe Arch Tunnel Construction
    Pipe Arch Tunnel Construction
  • Pipe Arch Tunnel Construction
    Jacking of microtunneling machine ongoing
    Pipe Arch Tunnel Construction
  • Pipe Arch Tunnel Construction
    Welding Of Pipe
  • Pipe Arch Tunnel Construction
    Pipe Arch Tunnel Construction
  • Pipe Arch Tunnel Construction
    Pipe Arch Tunnel Construction
  • Pipe Arch Tunnel Construction
    Pipe Arch Tunnel Construction
  • Catastrophe
    Catastrophe
    Pipe Arch Tunnel Construction
  • Catastrophe
    Pipe Arch Tunnel Construction
  • Catastrophe
    Pipe Arch Tunnel Construction
  • Catastrophe
    Pipe Arch Tunnel Construction
  • Catastrophe
    Set up to pull back pipe
    Pipe Arch Tunnel Construction
  • Catastrophe
    Locking device
    Pipe Arch Tunnel Construction
  • Catastrophe
    First pipe retreated
    Pipe Arch Tunnel Construction
  • Catastrophe
    Damaged section
    Pipe Arch Tunnel Construction
  • Catastrophe
    Damaged section exposed
    Pipe Arch Tunnel Construction
  • Catastrophe
    Pipe Arch Tunnel Construction
  • Catastrophe
    Existing drive pressurized
    Pipe Arch Tunnel Construction
  • Catastrophe
    Damaged pipe on surface
    Pipe Arch Tunnel Construction
  • Catastrophe
    Damaged pipe on surface
    Pipe Arch Tunnel Construction
  • Catastrophe
    Rebar excavated under Plus Highway
    Pipe Arch Tunnel Construction
  • THANK YOU
  • Q & A Session