20100514 pipe arch presentation to iem may 2010

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20100514 pipe arch presentation to iem may 2010

  1. 1. Presentation to Institution of Engineers, Malaysia<br />Electrified Double Track Project Ipoh to Padang Besar<br />PIPE ARCH TUNNEL<br />by<br />Mr. Don R. Hall<br />Head of Tunneling Division, <br />Gamuda Engineering Sdn Bhd<br />May 2010<br />
  2. 2. Outline of Presentation:<br />General Project Information – Berapit Tunnel<br />Pipe Arch Tunnel – Geological Profile & Concept<br />Pipe Arch Tunnel – Chronology of Construction<br />Construction of Triple Cell 3m Ф Drainage Culvert<br />Demolition of Existing 3m x 3m Twin Box Drainage Culvert<br />Pipe Arch Tunnel Construction<br />Catastrophe<br />Summary and Q&A<br />
  3. 3. General Project Information <br />– Berapit Tunnel<br />
  4. 4. General Project Information – Berapit Tunnel<br />
  5. 5. General Project Information – Berapit Tunnel<br />North-South Expressway (NSE)<br />YTL<br />CEMENT<br />PLANT<br />To Taiping<br />To Ipoh<br />Pipe Arch Tunnel Crossing NSE<br />Existing Railway Track<br /><ul><li> Tunnel Length = Approximately 2900m
  6. 6. Twin Tunnels, Single track each
  7. 7. Track Structure : Slab Track</li></li></ul><li>General Project Information – Berapit Tunnel<br />Drill & Blast<br />Section<br />Pipe Arch<br />Section<br />Cut & Cover Section<br />Gradient 0.39%<br />Pipe Arch Tunnel Crossing <br />North-South Expressway (approx. 4m overburden only)<br />Federal Route 1 temporarily diverted for tunnel construction<br />
  8. 8. General Project Information – Berapit Tunnel<br />Typical Berapit Tunnel Cross Section:<br />
  9. 9. 8<br />General Project Information – Berapit Tunnel<br />
  10. 10. General Project Information – Berapit Tunnel<br />CROSS PASSAGES EVERY 350m<br />
  11. 11. Pipe Arch Tunnel – <br />Chronology of Construction<br />
  12. 12. Pipe Arch Tunnel – Chronology of Construction<br />1. Triple 3mФcell drainage culvert at KM 232.6 of PLUS North-South Highway to replace existing 3m x3m twin box culvert<br />Northbound<br />Southbound railway tunnel<br />Southbound<br />Northbound railway tunnel<br />2. Existing 3m x 3m twin box drainage culvert to be demolished & replaced<br />3. Twin pipe arch tunnel crossing underneath PLUS North-South Highway KM 232.7<br />Plan Layout of Twin Pipe Arch Tunnel<br />
  13. 13. 12<br />Pipe Arch Tunnel – Chronology of Construction<br />1. Triple 3mФcell drainage culvert at KM 232.6 of PLUS North-South Highway to replace existing 3m x3m twin box culvert<br />Southbound<br />Northbound<br />2. Existing 3m x 3m twin box drainage culvert to be demolished & replaced<br />3. Twin pipe arch tunnel crossing underneath PLUS North-South Highway KM 232.7<br />3-D View of Twin Pipe Arch Tunnel<br />
  14. 14. Construction Of Triple Cell<br />
  15. 15. Construction of Triple Cell 3m Ф Drainage Culvert<br />Jacking Length = 45.5m<br />LONGITUDINAL SECTION<br />CROSS SECTION<br />
  16. 16. Construction of Triple Cell 3m Ф Drainage Culvert<br />First drive of jacking works of 3m Ф concrete pipes ongoing. Second & third drives awaiting for jacking with prepared entrance rings<br />Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine<br />
  17. 17. Construction of Triple Cell 3m Ф Drainage Culvert<br />Jacking works ongoing<br />Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine<br />
  18. 18. Construction of Triple Cell 3m Ф Drainage Culvert<br />Breaktrough of the first drive<br />Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine<br />
  19. 19. Construction of Triple Cell 3m Ф Drainage Culvert<br />Lifting of microtunneling machine after breakthough of first drive<br />Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine<br />
  20. 20. Construction of Triple Cell 3m Ф Drainage Culvert<br />Close up of RASA microtunneling machine<br />Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine<br />
  21. 21. Construction of Triple Cell 3m Ф Drainage Culvert<br />Completed construction of triple cell drainage culverts<br />Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine<br />
  22. 22. Demolition of Existing 3m x 3m Twin Box Drainage Culvert<br />
  23. 23. Demolition of Existing 3m x 3m Twin Box Drainage Culvert<br />PLAN VIEW<br />CROSS SECTION VIEW<br />
  24. 24. Demolition of Existing 3m x 3m Twin Box Drainage Culvert<br />Existing twin box culvert at KM 232.7 PLUS North-South Expressway before demolition<br />Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction<br />
  25. 25. Demolition of Existing 3m x 3m Twin Box Drainage Culvert<br />Demolition by coring & hacking to rid of reinforcement within existing twin box culvert for pipe arch tunnel construction<br />Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction<br />
  26. 26. Demolition of Existing 3m x 3m Twin Box Drainage Culvert<br />Demolition by coring & hacking to rid of reinforcement within existing twin box culvert for pipe arch tunnel construction<br />Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction<br />
  27. 27. Demolition of Existing 3m x 3m Twin Box Drainage Culvert<br />Sealing of existing twin box culvert for pipe arch tunnel construction<br />2. Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction<br />
  28. 28. Pipe Arch Tunnel Construction<br />
  29. 29. Pipe Arch Tunnel<br />– Concept<br />
  30. 30. Pipe Arch Tunnel – Concept<br />Mined excavation<br />
  31. 31. Pipe Arch Tunnel – Concept<br />Site picture of project by Metropolitan Atlanta Rapid Transit Authority in USA<br />Construction Sequence<br /> 1. Execution of sheet piles<br /> 2. Execution of the pipe arch microtunneling<br /> 3. Mined excavation of tunnel with steel ribs with bullflex, reinforced shotcrete & fibre glass elements<br /> 4. Casting of permanent concrete lining<br />
  32. 32. Pipe Arch Tunnel Construction<br />LONGITUDINAL SECTION<br />CROSS SECTION<br />
  33. 33. Pipe Arch Tunnel Construction<br />Limits of PLUS North-South Expressway (NSE)<br />Receiving<br />Pit<br />Jacking<br />Pit<br />Top of Soil Support Pipes<br />Southbound NSE<br />Northbound NSE<br />Fill<br />Fill<br />0<br />Cut &<br />Cover<br />Section<br />Cut &Cover<br />Section<br />Residual Soil<br />Direction of<br />Microtunneling<br />5<br />Weathered Rock<br />10<br />Bottom<br />of Structure<br />Rock<br />15<br />20<br />Scale in Meters<br />0 5 10<br />Jacking Length up to Toe of Highway Embankment= 90 m<br />
  34. 34. Pipe Arch Tunnel Construction (Right Bore)<br />Limits of PLUS North-South Expressway (NSE)<br />Receiving<br />Pit<br />Jacking<br />Pit<br />Top of Soil Support Pipes<br />Southbound NSE<br />Northbound NSE<br />Fill<br />Fill<br />0<br />Cut &<br />Cover<br />Section<br />Cut &Cover<br />Section<br />Direction of Microtunneling<br />Residual Soil<br />Weathered Rock<br />5<br />10<br />Rock<br />Bottom<br />of Structure<br />15<br />20<br />Scale in Meters<br />0 5 10<br />Jacking Length up to Toe of Highway Embankment= 92 m<br />
  35. 35. Pipe Arch Tunnel Construction<br />Cardox System – Non-explosive blasting<br />
  36. 36. Pipe Arch Tunnel Construction<br />Cardox Gas Filling<br />Cardox Drilling & Connection<br />Cardox Blasting<br />Pipe Arch Tunnel Construction<br />
  37. 37. Pipe Arch Tunnel Construction<br />Mini Pipe Arch<br />
  38. 38. Pipe Arch Tunnel Construction<br />AVN500<br />Microtunneling machine with retraction mechanism in case of rock face encountered<br />Pipe Arch Tunnel Construction<br />
  39. 39. Pipe Arch Tunnel Construction<br />10mm Pipe Wall Thickness<br />Jacking<br />Direction<br />780mm OD<br />Pre-welded Line-up Band<br />Pipe joint detail<br />Pipe Arch Tunnel Construction<br />
  40. 40. Pipe Arch Tunnel Construction<br />Construction & staged excavation of bored pile jacking pit <br />Pipe Arch Tunnel Construction<br />
  41. 41. Pipe Arch Tunnel Construction<br />Coring of reinforcement of shotcreted bored pile wall to prepare soft eye for microtunneling machine advance<br />Pipe Arch Tunnel Construction<br />
  42. 42. Pipe Arch Tunnel Construction<br />Construction of thrust wall for jacking of microtunneling machine<br />Pipe Arch Tunnel Construction<br />
  43. 43. Pipe Arch Tunnel Construction<br />Microtunneling machine preparing to jack<br />Pipe Arch Tunnel Construction<br />
  44. 44. Pipe Arch Tunnel Construction<br />Pipe Arch Tunnel Construction<br />
  45. 45. Pipe Arch Tunnel Construction<br />Jacking of microtunneling machine ongoing<br />Pipe Arch Tunnel Construction<br />
  46. 46. Pipe Arch Tunnel Construction<br />Welding Of Pipe <br />
  47. 47. Pipe Arch Tunnel Construction<br />Pipe Arch Tunnel Construction<br />
  48. 48. Pipe Arch Tunnel Construction<br />Pipe Arch Tunnel Construction<br />
  49. 49. Pipe Arch Tunnel Construction<br />Pipe Arch Tunnel Construction<br />
  50. 50. Catastrophe<br />Catastrophe<br />Pipe Arch Tunnel Construction<br />
  51. 51. Catastrophe<br />Pipe Arch Tunnel Construction<br />
  52. 52. Catastrophe<br />Pipe Arch Tunnel Construction<br />
  53. 53. Catastrophe<br />Pipe Arch Tunnel Construction<br />
  54. 54. Catastrophe <br />Set up to pull back pipe<br />Pipe Arch Tunnel Construction<br />
  55. 55. Catastrophe<br />Locking device<br />Pipe Arch Tunnel Construction<br />
  56. 56. Catastrophe<br />First pipe retreated<br />Pipe Arch Tunnel Construction<br />
  57. 57. Catastrophe<br />Damaged section<br />Pipe Arch Tunnel Construction<br />
  58. 58. Catastrophe<br />Damaged section exposed <br />Pipe Arch Tunnel Construction<br />
  59. 59. Catastrophe<br />Pipe Arch Tunnel Construction<br />
  60. 60. Catastrophe<br />Existing drive pressurized<br />Pipe Arch Tunnel Construction<br />
  61. 61. Catastrophe<br />Damaged pipe on surface<br />Pipe Arch Tunnel Construction<br />
  62. 62. Catastrophe<br />Damaged pipe on surface<br />Pipe Arch Tunnel Construction<br />
  63. 63. Catastrophe<br />Rebar excavated under Plus Highway<br />Pipe Arch Tunnel Construction<br />
  64. 64. THANK YOU<br />
  65. 65. Q & A Session<br />

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