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T03 river crossing-misterly
This document discusses a large construction project to install a new water pipeline using horizontal directional drilling. The project involves drilling a 6,572 foot long, 36-inch diameter pipeline 100 feet below the St. Johns River in Jacksonville, Florida on an aggressive schedule. The owner, JEA, chose to use a design-build approach to take advantage of the contractor's early involvement and ensure schedule and cost certainty. Key challenges included navigating two curves in the drill path below the river and coordinating pipe assembly along a busy roadway.
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T03 river crossing-misterly
- 2. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackground DesignDesignDesignDesign Outline 2 Outline  Backgroundg Design Build Approach  Project Development Project Development  Design C t ti Construction
- 3. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackground DesignDesignDesignDesign  JEA 3 7th largest utility in US  2nd largest in Florida  North & South Grids  TWMP- $80M  Shift water to South Grid  6 Pipe Segments K i i Ri C i Key portion is River Crossing  Directional Drill
- 4. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackground DesignDesignDesignDesign  RiverCrossing 4 g  Downtown Jax  Directional Drill  36” diameter  6,572’ long  100’ below River 100 below River  Highly complex  Aggressive schedule  Chose Design-Build Project Location – Jax, Florida
- 5. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackground DesignDesignDesignDesign 5 River Drill RigDrillRig Pipe Delivery River A Pipe Delivery & Staging Pipe Assembly HDD PipelineDrill Pilot Hole B Drill Pilot Hole & Begin Pipe String Assembly Pipe String Assembled Ream/Swab Hole C Ream/Swab Hole & Finish Pipe String Assembly Drill Rig Pipe String Pulled HDD Pullback D HDD Pullback HDD PipelineInstalled Subaqueous Pipeline E Installed Subaqueous Pipeline
- 6. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackground DesignDesignDesignDesign 6 Drill Rig DrillPipe Casing D ill H d Entry Pit & Mud Pit Drill Head (See Blow-up)
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- 8. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign Outline 8 Outline  Backgroundg Design Build Approach  Project Development Project Development  Design C t ti Construction
- 9. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign 9  ProjectChallengesj g  Schedule – Jags, FL/GA  Design – alignment, diameter, length, drill path, FDOT, ROW, multiple curvesu p e cu ves  Construction – pilot hole, pipe assembly, pullback, d lroad closures  Permitting – ACOE, FDEP, FDOT, City of Jax EverBank Stadium FDOT, City of Jax
- 10. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign  DesignBuild Advantage 10  Single point of accountability  Proper risk allocation  Early involvement of builder Early involvement of builder  Early involvement of specialized contractor  Schedule  Certainty of cost  Reduced claims  Unused allowances return to ownerUnused allowances return to owner
- 11. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign  JEA’sDecision Making Process 11  Project Drivers  Regulatory  Capacity Needs ProjectDrivers  Capacity Needs  JEA’s objectives  Proper risk allocation P DELIVERYDELIVERY  Predictability of Cost  Project Complexity  Specialized engineering DELIVERY METHOD DELIVERY METHOD p g g  Specialized construction  Challenging conditions  Multi agency permitting Multi-agency permitting  Environmental compliance  Traffic impacts
- 12. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign 12 Risk AllocationMatrix Design-Bid- Build (DBB) Progressive Design Build (DB) Design and Construction Design Build Cost JEA Design-Builder Design Defects JEA Design-Builder Errors and/or Omissions JEA Design-Builder Constructability JEA Design-Builder Schedule/Completion JEA Design-Builder Construction Warranties JEA Design-BuilderConstruction Warranties JEA Design Builder Hazardous Materials JEA JEA Unidentified Utilities JEA Design-Builder Changing Soil Conditions JEA Design-Builder Asset Management System Performance JEA Design-Builder Life Cycle Costs JEA JEA Operations and Maintenance JEA JEAp Legal Third Party Litigation JEA JEA
- 13. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign  SelectionProcess 13  Progressive Design Build  2 step selection process  Qualifications based Qualifications based  Qualifications Packages  3 teams shortlisted  InterviewsInterviews  Key personnel & approach
- 14. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign  JEA’sProcurement Documents 14  Detail  Get what you want  Pipe size  Capacity  Service life  Schedule  Submittal requirementsS q  Not so specific that you take on risk  Geology  Drilling method  Shared savings  Shift design/construction risk to DB Team
- 15. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign Outline 15 Outline  Backgroundg Design Build Approach  Project Development Project Development  Design C t ti Construction
- 16. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign  BaseRoute 16  2 HDDs  Open cut on Island  Environmental Impacts Environmental Impacts  Permitting challenges  Marine support  Frac out  Noise impact Base Route
- 17. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign  BaseRoute 17  2 HDDs  Open cut on Island  Environmental Impacts Environmental Impacts  Permitting challenges  Marine support  Frac out  Noise impact Base Route
- 18. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign  AlternativeRoute 18  Single HDD  Reduced Environmental Impacts  Reduced cost by $5M Reduced cost by $5M  Shorter schedule  Reduced permitting  Approach  Evaluated multiple staging areas  Chose to use Arlington Expressway Alt route & pipe staging  Chose to use Arlington Expressway  Straight, but significant traffic impacts  Marine support  Frac out  Noise impact
- 19. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesign Outline 19 Outline  Backgroundg Design Build Approach  Project Development Project Development  Design C t ti Construction
- 20. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesign  Design 20 Survey, geotech, SUE  Route  CurvesCurves  Staging  Pipe Assembly  Calculations Calculations  Pull loads  Stresses  Operating pressures Operating pressures  Frac out calcs  Pipe M t i l Typical HDD Design  Material  Thickness  Coatings
- 21. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesign  DesignSummary 21  6,572’ long  36” diameter, ¾ thick  60’ below River 60 below River  Epoxy coating  Powercrete coating  3,600’ max bend radius  Entry/Exit angles 8 & 10 deg  Two vertical curves Note bend radiusTwo vertical curves  Three horizontal curves  Cathodic protection systems (both sides)
- 22. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesign  PipeAssembly Planning 22  Very challenging  6,572’ along AEW  Close coordination Close coordination  Designers  Contractor  FDOT FDOT  Customized solution  Detailed schedule Limited area for pipe string
- 23. ConstructionConstructionConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesign  PipeAssembly Planning 23  3 Assembly Areas  #1 – (2) 766 ft segments  #2 – (2) 1,000 ft segments  #3 – (2) 1,520 ft segments
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- 25. ConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign Outline 25 Outline  Backgroundg Design Build Approach  Project Development Project Development  Design C t ti Construction
- 26. ConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign  PipeProcurement/Delivery 26  Spec issued at 60% Design Step  Pipe arrived as design completed  40’ lengths  168 sticks  330 lbs/ft  2.2 M lbs2.2 M lbs Pipe deliveryPipe delivery Pipe manufacturing
- 27. ConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign  PipeAssembly 27  Welding  July – 12 hr/day; 6 dpw  All welds inspected  X-ray  Ultrasonic  Linings/coatings repaired & tested  200 psi hydrostaic test Pipe delivery Pipe weld
- 28. ConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign  TemporaryCasing 28  60” steel  150’ each side  1” thick  Prevents Frac-out  Stabilizes pilot hole  Maintains drill angleMaintains drill angle  Grundoram  3 Trenchless Technologies  HDDHDD  Pipe ramming  Jack and Bore
- 29. ConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign  PilotHole 29  Intersect method  12.5” drill bit  East Rig – Atlas 440  West Rig – Hercules 1200  Reaming & Swabbing  27” reaming pass 27 reaming pass  36” reaming pass  50” reaming pass S b Swab pass
- 30. ConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign  FinalPipe String Assembly 30  Coordinate with Matthews Bridge Closure  Start Friday 7pm  2.5 days to complete  Move pipes from assembly areas  Create 1 pipe string  6,572’ long6,572 long
- 31. ConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign  FinalPipe String Assembly 31  Elevate pipe to align with entry pit  100 ton cranes  Install coupling and pipe head  Install buoyancy line
- 32. ConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign  Pullback 32 1.2M lb Rig - pulling  300 ton hydraulic thruster  If pipe gets stuck
- 33. ConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign  Pullback 33 Broke drill rods 2x  Impacts to traffic  Owner and DB Team worked together  Developed recovery plan  Recover drill rod  Re-ream hole to 50”  Use thruster together with rig  Communicate with media  Successful pullback N l i No claims
- 34. ConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign  Pullback 34 Broke drill rods 2x  Impacts to traffic  Owner and DB Team worked together  Developed recovery plan  Recover drill rod  Re-ream hole to 50”  Use thruster together with rig  Communicate with media  Successful pullback N l i No claims
- 35. ConstructionConstruction ProjectProject DevelopmentDevelopment ProjectProject DevelopmentDevelopment DBDB ApproachApproach DBDB ApproachApproach BackgroundBackgroundBackgroundBackground DesignDesignDesignDesign Summary 35 Summary  ComplexProjectC p j  Design Build  Team worked together Team worked together
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