The Presentation Covers the General Technical Features of Tunnel T 80 across Pir Panjal Mountain Range, for Kashmir Rail Link. This presentation was made at Civil Engineering Society, IIT Kanpur on 30th September 2013.

1. WELCOME YOU TO
PIRPANJAL RAILWAY TUNNEL
SITE
THE LONGEST TRANSPORTATION
TUNNEL IN INDIA

2. 2
• Location Overview
• Salient Features of The Tunnel
• Construction Approach
• Pre-construction Planning
• Usage Of NATM in T-80
• Construction Activities
• Quality Assurance
• Environment Issues
• Social Impact
PRESENTATION COVERS

3. LOCATION OVERVIEW

4. 4
ALIGNMENT PLAN
JAMMU-UDHAMPUR-SRINAGAR-BARAMULLA RAIL
LINK
QAZIGUN
D
SADUR
A
ANANTNAG
BIJBEHARA
PUNZGA
M
AWANTIPORA
KAKPORA
PAMPOR
E
SRINAGA
R
BUDGA
M
RAJWANSHE
R
PATTAN
HAMRE
SOPORE
BARAMULLA
BANIHA
LARPINCHALA
BHATTA
LOALE
KOHLISANGALDAN
BARALA
BASAND
A--DHAR
REASI
KATRA
CHAKARWAH
UDHAMPUR
SALAL
RAMNAGAR
ROAD
MANWA
L
SANGAR
BAJALT
A
JAMM
U
SURUKOT
PIR PANJAL RAIL TUNNEL
Length 11100 mts.
South portal photo
SOUTH PORTAL

5. 5

6. 6
SALIENT FEATURES OF T-80
• Total length – 11 Km
• Adit – 774 m (58 m2 exc. Area)
• Shaft : 55 m depth , 12 m dia
• Maximum overburden - 1.10 Km
• Tunnelling method :NATM (New Austrian
Tunneling Method)
• Completed Cost – 1150 Crores
• Approx. 440 m below existing Jawahar Road
Tunnel(2.75km)
• Underground excavation : 10 lac cubic meter
• Cross section Area : Excavation : 67 to 78 m2 ,
Finished Tunnel : 48 m2
• Investigation Bore Holes depth upto 640 m

7. 7
SALIENT FEATURES OF T-80
(Contd.)
• 3 m wide road in tunnel for maintenance,
emergency rescue & relief.
• High mid point & sloping in both directions for
drainage.
• Provision of system for ventilation, fire fighting &
safety monitoring.
• Adit & shaft for parallel working, to be used for
ventilation, maintenance & emergency relief
during service.
• Extensive instrumentation for monitoring during
tunneling
• Consultants : M/s Geoconsult-RITES JV

8. 8
MANY FIRSTS
• The Longest Transport Tunnel In The Country
(11Km)
• Highest ‘Over- burden’ of 1100M
• Deepest ‘Drill holes’ for Geotechnical
Investigations 640M
• First Large Scale Use of ‘New Austrian Tunneling
Method (NATM)’ in India
• First Use of ‘Road header’ for ‘Tunnel Excavation’
in Railway Tunneling

9. CONSTRUCTION
APPROACH

10. 10
APPROACH TO CONSTRUCTION
NO ADIT

11. 11
Vertcal Shaft
55m deep,
12m dia
Cross Passage 55 m
Adit 788 m
APPROACH TO CONSTRUCTION
WITH SHAFT AND ADIT

12. 12
Tunnel
Cross
Section:
STRUCTURAL GAUGE

13. 13
TUNNELS
SECTIONS
USED ON
KONKAN
TRACK

14. 14
TYPICAL
RAILWAY
TUNNEL
SECTION
USED ON
JAMMU-
UDHAMPUR
RAIL LINK
SHOTCRETE(25mm+WIRE MESH +50mm)
OR 50mm SFRS
300 TH. C.C. LINING
ISHB 150 @ 500 C/C
50mm TH. R.C.C. LAGGING
Min. EXCAVATION LINE
75Ø @ 2000 C/C
MS PLATE 12mm THICK
ISHB150-2NOS.
INVERT STRUT ISHB150 @ 500mm
ISHB200 @ 750 C/C
1676
R2600
43701312
150
150
Max.
150(max)
50M20
1 in 40
RAIL LEVEL
FINISH LINE
PAY LINE 150 TH. FROM Min. EXCAVATION
25 mm Ø 3 to 5m ROCK BOLTS
AS PER SITE REQUIREMENT
ISHB 150 @ 750 c/c
PRESSURE RELIEF HOLES 5m DEEP @
3m c/c LONGITUDINALLY AS PER SITE
REQUIREMENT
150
PAY LINE
MIN. EXCAV. LINE
BASE PLATE
12mm THICK
R3000
ISHB150@500c/c
SHOTCRETE25mm+
WIREMESH+50mmOR50mmSFRS
50TH.R.C.C.LAGGING
150
PRESSURERELIEFHOLES5m
DEEP@3mc/cLONGITUDINALLY
ARASPERSITEREQUIREMENT
BACKFILLINGM-10
50
FINISHLINE
300TH.CONC.LININGM-20
150
100
900
BLOWER
8Ø @ 150 C/C
50 675 150
100
65
675
25mmØ3mto5m
ROCKBOLTAS
PERSITE
REQUIREMENT
SEC.ATA-A
75

15. 15
LOADING DIAGRAM FOR TUNNEL
TOP PRESSURE-15000KG/M
AND SIDE PRESSURE-5000KG/M

16. 16
BENDING MOMENTS DIAGRAM FOR
D-SHAPE TUNNEL
TOP PRESSURE-15000KG/M AND SIDE PRESSURE-5000KG/M
MAX BENDING MOMENT = 137KN-M

17. 17
BENDING MOMENT DIAGRAM FOR ELLIPITCAL TUNNEL
TOP PRESSURE 15000KG/M AND SIDE PRESSURE 5000KG/M
MAX. BENDING MOMENT = 35.80KN-M

18. COMPARISION BETWEEN D-SHAPED AND ELLIPTICAL TUNNEL
DESCRIPTION MAX.
AXIAL
FORCE
MAX.
BENDING
MOMENT
MAX.
SHEAR
FORCE
MAX.
DISPLACEMENT
WITH TOP PRESSURE 15000 KG/M & SIDE PRESSURE
5000 KG/M
D-SHAPED
TUNNEL
412.5KN 137KN-M 15129 KG 0.083 M
ELLIPTICAL
TUNNEL
567 KN 35.80KN-M 9025 KG 0.024 M
WITH TOP PRESSURE 15000 KG/M
D-SHAPED
TUNNEL
412.5KN 48.10 KN-M 8565 KG 0.03 M
ELLIPTICAL
TUNNEL
639 KN 35.65 KN-M 9635 KG 0.028 M

19. 19
CONSTRUCTION METHOD
SELECTION
• DRILL AND BLAST
• ROAD HEADER
• TUNNEL BORING MACHINE (TBM)

20. 20
DRILL AND BLAST
• CONVENTIONAL, ART
WHICH COMES WITH
EXPERIENCE
• GOOD IN HARD ROCKY
STRATA
• WITH EXPERIENCE, CAN
DELIVER GOOD PROGRESS
• NON CONTINUOUS- CYCLE
INVOLVES VARIOUS
ACTIVITIES IN SEQUENCE
• MAY SPRING SUDDEN
SURPRISES

21. 21
ROAD HEADER
• CONTINUOUS ADVANCE-
LESS SURPRISES
• MORE CONTROLLED
EXCAVATION- LESS
OVERBREAK/CAVITY
FORMATION
• SUITABLE FOR MEDIUM
HARD ROCK
• CAN BE WITHDRAWN
MID WAY TO GIVE WAY
FOR OTHER METHODS

22. 22
TUNNEL BORING MACHINE
• CONTINUOUS ADVANCE
• CIRCULAR SECTION
• NOT SUITABLE UNDER
SQUEEZING
CONDITIONS
• CANNOT BE
WITHDRAWN MIDWAY
TO GIVE WAY TO
OTHER METHODS

23. 23
WHY NO TBM
• Likelihood of Mixed Geology
• Heavily Faulted Areas and/or Wide
Fault Zones
• High Squeezing Anticipated in middle
with High Overburden (1100 mts.)
• Heavy Water Flow in Lime Stone Zone
with High overburden
• TBM may be Trapped by Ground
Movement Behind the Face

24. PRE-CONSTRUCTION
PLANNING

25. 25
PRE-CONSTRUCTION
PLANNING
• Engagement of Consultant
– QCB System Of tendering
• Survey and Investigation
• Head start by Taking up ADIT and shaft
works in advance
• Tender Planning
– Key dates
– Multi Method Approach
• Road Header/ D&B

27. 27
USAGE OF NATM IN T-80
• Suitable for poor and Varying Geology of
Himalayan Region
• X-Section designed to develop Maximum Self
Supporting Capacity
• Face Mapping, Probe Hole & Instrumentation
data input for Initial Support Design – RESS
– Primary Support System
• Resilient enough to Accept the deformations and readjustment of
stresses and Strong enough to take the loads
• Deformation Monitoring to assess the stress
redistribution, and stabilization before final
lining

28. 28
INSTRUMENTATION
To provide early information about tunnel behaviour in order to optimize
excavation & support activities during construction and to recognize the requisite
remedial measures.
Instrumentation data is basic input of the NATM, the observational approach.
Instrumentation in Pir Panjal Tunnel:
Optical 3 D monitoring: With bi-reflex targets to monitor deformation in
tunnel on daily basis
Extensometers: To measure stresses in surrounding rock mass
Radial Pressure Cells: To measure pressure of rockmass on shotcrete
lining
Shotcrete Strain meter: To monitor stresses in shotcrete lining
Piezometer: To monitor hydrostatic pressure during tunneling

29. 29
CONSTRUCTION ACTIVITES
• Open excavation & portal development
• Tunnel mining & primary lining
• Water-proof membrane installation +
drainage system.
• Secondary lining.
• Ventilation, system and safety
installations
• Track laying

30. 30
QUALITY ASSURANCE
• Laid down responsibilities,
procedures and checklists for
various activities through:
–CPM, CQM, SH&EM
–PPM, PSM
–Organogram
–QAP
–ITP

31. 31
QUALITY ASSURANCE (contd…)
• Availability of relevant documentation and defining
the manner of execution of various activities
• Maintaining compliance through appropriate
monitoring
• Ensuring adequate support facilities for successful
& scheduled execution of work.
• Availability of competent/trained personnel to carry
out various activities
• Compliance of statutory/regulatory requirements
related to safety, environment etc.

32. 32
Quality Assurance (contd…)
Check Lists and Forms for Process Control During
Execution of Works:
• Required Excavation and Support Sheet (RESS)
• ATSS/ Shift Report/Blasting clearance report/ R/Bolt
Installation report
• Shotcrete testing by Penetrometer test, Core
crushing test, thickness verification etc.
• Geological mapping (Geological face mapping sheet)
• Lining Air Permeability Test
• All Material Testing at Site Lab

33. 33
ENVIRONMENT ISSUES
• Identified Muck Dumping areas
• Recycling of Excavated Rocks
– aggregate for concrete constn.
• Effluent Settling Tank
– Fit for agriculture discharge
• Ventilation during Construction Stage
– Gas Analyser for air quality monitoring
• Controlled Blasting below Inhabited
areas
• Lined Waterproof Tunnel
– No long term impact on water table/ Aquifers

34. 34
SOCIAL IMPACT
• All weather link, Alternate to Jawahar
Tunnel
• Even at Construction stage, given a
boost to
– local construction-industry
– Employment
– Transportation business
• A boost to Local economy of Banihal

35. 35
Time Line

36. 36
PIR PANJAL TUNNEL-
EXCAVATION PROGRESS
Year Excavation
(mts.)
Remarks
2006 722 Two Faces
2007 1876 Start From 4 Faces
2008 2475
2009 2533
2010 1739 Two Faces after Jan’10
2011 947 High overburden,
Squeezing, Shale
2012 63

40. 40
Miles to go……
“A thing should be made
as simple as possible,
but not simpler”.
Einstein

41. 41
THANKS !

42. 42
ENGAGEMENT OF CONSULTANT
• Investigations for Tunneling Methodology
Assessment
• Initial Design
– Usage of NATM
– Usage of Water proof Membrane for Semi Dry
Tunnel
– Development of 4-Arc Tunnel X-Section
– Additional Access through ADIT and Shaft
– Portal Location Review
• Real Time Monitoring / Instrumentation
and Design Support

43. 43
INVESTIGATIONS & PLANNING
2003 Geological L-Section Profile Submitted by M/s
RITES based on GSI data.-
Used to decide the Bore hole Location.
2003-04 Bore holes by RITES/ MECL-
To Confirm Geological Mapping inference
2004 Consultants engaged in Feb. 2004
Geological Surface Mapping along the entire alignment by -
For Detailed Geological Section
2004 Data input for Tendering and a Decision Support System for
ADIT and Shaft decision
– Adit & Shaft Work Awarded in June 2004
2004 Detailed Topographical Survey for Portal
Location
2005 Main Tunnel Construction Work Awarded in
August 2005

44. 44

45. 45

46. 46

47. BASIC PRINCIPLES OF NATM
• Rock Mass is the major load bearing
member
• Primary Support shall
 maintain the integrity & strength of Rock Mass
 light, have good and area contact (shotcrete)
 strengthen Rock Mass (bolt, grouting)
 provide protection to workers (steel rib, mesh)
 installed quickly
• Provide always an effective ring closure, if
necessary by an invert if rock is not
suitable

48. BASIC PRINCIPLES OF NATM (Contd.)
• Rounded shape of Cross-Section
• Continuous control of system behaviour
by monitoring
• Inner lining shall be installed only after
balance of stresses („zero“ deformation)

49. 49

50. 503D Monitoring Targets

51. 51

52. 52

53. 53
EXTENSOMETER

54. 54
FACE MAPPING

55. 55
PROBING SHEET

56. 56

57. 57

58. 58

59. 59
Deformation
Monitoring in Primary
Lining Before start of
Secondary Lining

60. 60

61. 61

62. 62Charging of Face

63. 63Ventilation Duct

64. 64Mucking

65. 65Wire mesh & Lattice Girder Erection

66. 66
Face sealing
Face sealing by Shotcrete

67. 67Drilling for Forepoling

68. 68
Rock Bolting

69. 69
TUNNEL MINING
Activity
Cycle Time (hr.) 2 mt.
RC IV
Cycle time (hr.) 1.25
mt. RC V
Drilling & Excavation 1.7 0.9
Charging , Blasting
& Defuming
2.7 1.5
Mucking 1.1 0.8
Wire Mesh & Lattice
Girder
2.4 2.3
Shotcrete 0.9 0.8
Rock Bolting 1.8 1.0
Preparation of new
face
0.3 0.3
Maintenance 1.6 1.1
Forepoling 1.6 1.7
Total 14.1 10.4

70. 70

71. 71
Kicker Beam Casting

72. 72
Geotextile Fixing

73. 73
PVC Membrane Fixing

74. 74Membrane Stitching

75. 75
Reinforcement for Overt Lining

76. 76
Reinforcement Cage for Inner Lining

77. 77Concrete Lining Gantry

78. 78
View of Finished Lining Concrete

79. 79
Profile Checking with Total Station

80. 80Core Cutting

81. 81Testing of Joints (Membrane)

82. 82
Sedimentation Tank

83. 83
Effluent Quality
Test Report

84. 84