NORTH SHORE CONNECTORNORTH SHORE CONNECTOR

TUNNELS AND STATION SHELLTUNNELS AND STATION SHELLTUNNELS AND STATION SHELLTUNNELS AND STATION SHELLLIGHT RAIL PROJECTLIGHT RAIL PROJECT

PAUL ZICK, PE

NORTH SHORE CONSTRUCTORS JV

North Shore Connector Alignment

•• 7300 lf 7300 lf Extension to existing 25 mile systemExtension to existing 25 mile system

•• 18 Contracts18 Contracts

• $435 Million$435 Million

Funding – $ 435 Million

80%

17%17%3%

Project Location006006007007

Future- to Airport North ShoreNorth Shore

003003

006006007007

Airport North Shore North Shore Connector Connector Light Rail Light Rail E iE iExpansionExpansion

004 New Gateway Station004 New Gateway Station

Existing

EXISTING GATEWAY EXISTING GATEWAY STATIONSTATION

Existing Light Rail System

Project Team• Owner

–– Port Authority of Allegheny CountyPort Authority of Allegheny County

• Construction ManagerTriGoldTriGold–– TriGoldTriGold

• Jacobs Civil

• HDR

• Kwame

Project Team• Design Engineer

–– DMJMDMJM

• ContractorNorth Shore Constructors JVNorth Shore Constructors JV–– North Shore Constructors JVNorth Shore Constructors JV

• Obayashi Corp.

• Trumbull Corp.

What we are building

• Two Contracts

• Combined Contract Value - $156 500 000Combined Contract Value $156,500,000

• Time ––– NTPNTP Oct 2, 2006Oct 2, 2006

–– 003 Tunnels 003 Tunnels 1243 days1243 days Feb 26, 2010Feb 26, 2010

–– 006 Station / C&C006 Station / C&C 870 days870 days Feb 18, 2009Feb 18, 2009

Four Major Structure Types

• Boat Section – 340 lf–– SOE SOE -- Steel Soldier Piles and Wood LaggingSteel Soldier Piles and Wood LaggingSOSO Stee So d e es a d ood agg gStee So d e es a d ood agg g

• Cut and Cover – 1200 lfSOESOE C t D S il Mi i W ll (CDSM)C t D S il Mi i W ll (CDSM)–– SOE SOE -- Cement Deep Soil Mixing Wall (CDSM)Cement Deep Soil Mixing Wall (CDSM)

–– SOE SOE –– Cement Bentonite Wall (CB)Cement Bentonite Wall (CB)

• Top Down Construction - Station–– SOE SOE -- Slurry WallSlurry Wallyy

• Bored Tunnel – 2240 lfSOESOE P t C t S t l Li iP t C t S t l Li i–– SOE SOE -- Precast Concrete Segmental LiningPrecast Concrete Segmental Lining

Boat Section – Soldier pile and lagging• Excavation – 0 to 35 feet

• Soldier Piles and Wood Lagging

• Above or at the water table

• Deep Wells

Walls and Waterproofing

EXISTING SOILSEXISTING SOILS

Boat Section - SOE - Soldier Piles & Lagging

Soldier Piles andSoldier Piles andSoldier Piles and Soldier Piles and LaggingLagging

Cut & Cover – SOE CDSM Walls

BACKFILLCDSM Walls

60’ +/60’ +/-

Cut off ground water

ROCK

Cut & Cover / Launch Pit – CDSM Walls

Cut & Cover / Launch Pit - CDSM WALLSI l il i d ithIn place soils mixed with Bentonite Slurry going down

Cement Slurry mixed going up

Insert Steel Soldier Piles

CDSM –SOE – Drill Rock Socket

CDSM WALLS – Temporary Bridge

Excavation / Mud Slab / WP/ Base Slab

ROCK

Structural Concrete

Waterproofing

ROCK

Structural Concrete – Cut and Cover

Backfill

BACKFILL

ROCK

Bridge to hold the Bridge

Support two Bents

Cut & Cover – InstrumentationInstruments

Stain gauges

Weather

Tilt MetersTilt Meters

MotorizedMotorized Total Station

Underpinning – SR-65

Drilled PierDrilled PierDrilled PierDrilled Pier

Drilled PierDrilled Pier

Underpinning – SR-65

ROCK

Underpinning – SR-65

Drilled PierDrilled Pier

Underpinning – SR-65

ROCK

Underpinning – SR-65

ROCK

North Side Station Shell

North Shore Station - Slurry Walls

SEA PARKING GARAGE

Concourse

North Shore Station - Slurry Walls

North Shore Station – Slurry WallsDESANDING

P iP iP i

DESANDING

Excavate Slot Primary Panel

Primary Panel

Primary Panel

SecondarySecondary Panel

North Side Station – Slurry walls

Concrete P iP iP iConcrete Primary Panel

Primary Panel

Primary Panel

Secondary Secondary

Rebar

Tremie pipeSecondary

PanelSecondary

Panel

Rebar

Slurry Walls - Rebar Cage

North Side Station – Top Down

ROCK

North Side Station – Pour Roof Slab

Roof SlabRoof Slab

ROCK

Excavate to Concourse

BackfillRoof Slab

CONCOURSE

Roof Slab

ROCK

Excavate to Concourse

BackfillRoof Slab

Soldier Piles installed by building Soldier Piles installed by building contractorcontractor

CONCOURSE

Roof Slabcontractorcontractor

ROCK

Excavate to first row of struts

BackfillRoof Slab

CONCOURSE

Roof Slab

ROCK

Station Roof Slab Excavation

60 ft

40 ft40 ft

Excavate to Invert – Pour Base Slab

BackfillRoof Slab

CONCOURSE

Roof Slab

SLAB ANCHORS

ROCK

Station Ground Anchors

Ground Anchors

Construct Platform & Deck

BackfillRoof Slab

CONCOURSE

Roof Slab

ROCK

TBM Launch Pit - SOE

CDSM WALL

TBM Launch Pit - SOE – Tie Backs

Launch Pit - SOE – Tie Backs

TIE BACKS

TIE BACKS

TBM

ROCK

Ground Improvement - Jet Grouting

Launch Pit - Jet Grout

Jet Grout column construction

Drill Down

Grout bottom up

Launch Pit – Entrance Packing

Soft Eye

TBM – Move to Launch Pit

TBM – Move to Launch Pit

150 feet fully assembled150 feet fully assembled

Launch Pit – TBM Launch

JET

GROUTJET

GROUT

21

GROUT

3 21 3

Launch Pit – Structure Work

JET

GROUT

Stanwix St. Receiving Pit Location

GATEWAY II

HORNE BUILDING

RECEIVING PIT

Ground Improvement - Jet Grout

75% COVERAGE

Receiving Pit

100%

100% Coverage

6’ Around Tunnel6 Around Tunnel

Ground Improvement - Jet Grout – 75%HORNE BLGHORNE BLG.

MinimizeMinimize Angular Distortion due t dto ground loss

Jet Grouting Stanwix Street

Stanwix Street Receiving Pit – CB Wall

Bored Tunnels

Tunnel Tunnel Boring Boring M hiM hiMachine Machine Launch PitLaunch Pit

TBM Tunnels – 2200 lfNORTH SHORENORTH SHORE

Receiving Pit

SOUTH SHORESOUTH SHORE

Bored Tunnel SectionPRECASTPRECAST SEGMENTLININGLINING

Segment Lining 20’ inside diameter

CAST IN PLACEPLACE INVERT

TBM TunnelsSl P B l TBM (SPBTBM)• Slurry Pressure Balance TBM (SPBTBM)

–– Mixed Shield (Soft Ground and Rock)Mixed Shield (Soft Ground and Rock)

–– Working Pressure 3 barWorking Pressure 3 bar

Mining Cycle – Mine 4’ & Grout

Mine 4’Mine 4’

GROUT MAINTAINEDGROUT MAINTAINED BEHIND SHIELD

Mining Cycle – Install 4’ Segment Ring

Build 4’ RingBuild 4 Ring

Mining Cycle – Ring Complete - Mine

Mine 4’Mine 4’

GROUT MAINTAINEDGROUT MAINTAINED BEHIND SHIELD

Segment Grouting

Segments Grout Nozzle

Grout

TBM – SLURRY – MIX SHIELD

22’-9”

SPTBM Mixed Shield

Slurry TBM – 22’- 9” dia (6.92 m)24 17 i h t i• 24 -17 inch twin disk cutters

• 20 - Scrapers20 Scrapers

• Bucket lips

• 3 - Wear• 3 - Wear detection devices

• 0-2.7 rpm

• Left or Right

Cutting Tools – After first tunnelDi k C tt• Disk Cutters

• Scrappers• Bucket Lips

Rock Crusher

TBM Assembly – Man Locks – 3 Bar (45 psi)

Material Lock

Cutter Head Drive

• Motors - 8 – 101 hp

• Total - 808 hp18

2Total 808 hp

• Variable Frequency Drive (VFD)

7

Drive (VFD)

• 480 v AC 4

3

5

6

• 0-2.7 rpm (l or r)

• Main bearing 8 5 ft

45

• Main bearing – 8.5 ft

TBM – Rear of Middle Shield5 Cylinders 4 Steering Groups

6 Cylinders

7 Cylinders

TBM – Rear of Middle Shield• Propel Cylinders - 24

• Piston Diameter - 260 mm

• Rod Diameter - 220 mm

• Max Stroke - 1750 mmMax Stroke 1750 mm

• Advance force - 38227 kN (4,296 tn)

TBM Operation

Excavation Chamber

Working Chamber

Hydrostatic and Soil

Slurry In

and Soil Pressure

Slurry OutSlurry Out

TBM – Operation Plan

455 hp PUMP

SLURRY IN

2 EA 455 h PUMPSSLURRY OUT2 EA - 455 hp PUMPS

Slurry Separation Plant

Plant Capacity Plant Capacity 1000 m1000 m33/hr/hr1000 m1000 m /hr/hr

Segment ErectorH d li l iH d li l i•• Hydraulic telescopic arm type Hydraulic telescopic arm type

•• 6 ranges of movement6 ranges of movement

•• TelescopeTelescope

R t tiR t ti•• RotationRotation

•• TravelTravel

•• Independent Independent Roll & YawRoll & Yaw–– Roll & YawRoll & Yaw

•• Controlled by joy stickControlled by joy stick

Segment Erector

• Thrust rams retracted 4’- 6”

Segment Installation

BOLTBOLT

Segment ErectorSegment ErectorSegment ErectorSegment Erector

Key Segment Installation

TBM Shield

Key Segment Installation

MOVE OUT

KEY SEGMENT MOVE FORWARD

TBM Mining – Start North SideNORTH SHORESOUTH SHORE

Equitable

NORTH SHORESOUTH SHORE

Equitable Resources

Building

Soft Ground

Fluvioglacial Material• Gravel 40% - 57%

• Sand 50% - 38%

• Fines 10% - 5%

• Cobbles - up to 2’Cobbles up to 2

TBM Mining - River CrossingNORTH SHORESOUTH SHORE

Equitable

NORTH SHORESOUTH SHORE

Equitable Resources

Building

Mixed Face

TBM – North River Wall

Alluvium

Claystone

Fluvioglacial

Siltstone

TBM North River Wall - Grouting

Alluvium

Claystone

Fluvioglacial

Siltstone

River CrossingNORTH SHORESOUTH SHORE

Equitable

NORTH SHORESOUTH SHORE

Equitable Resources

Building

Rock

River Crossing

25 feet ALLEGHENY RIVER

RIVER SILTS (ALLUVIAL)22 feet

Top of Rock FLUVIOGLACIAL

( )22 feet

SILTY SHALE (5,400 SILTY SHALE (5,400 –– 11,800 psi)11,800 psi)

CLAYSTONE (200CLAYSTONE (200 4 400 psi)4 400 psi)COALCOAL

10 feet

CLAYSTONE (200CLAYSTONE (200-- 4,400 psi)4,400 psi)

SILTSTONE (3 400SILTSTONE (3 400--11 000 psi)11 000 psi)SILTSTONE (3,400SILTSTONE (3,400--11,000 psi)11,000 psi)

River CrossingNORTH SHORESOUTH SHORE

Equitable

NORTH SHORESOUTH SHORE

Equitable Resources

Building

Well Horne Blg.

Soft GroundJet Grout

Mixed Face

TBM Guidance System – VMT

Total StationTotal Station Operator’s DisplayOperator’s Display

80 mm

TargetTarget

Precast Segments – Universal RingSix pieces + Key4’ – Long

20’ ID

4 Long

Bolted

Two tapers 2-3/8 & 1-5/8

Segment Rebar Cages

Seg Plant – cycle 4 rings X 2/ day

Segment Finishing Line•• Rotate Segments Rotate Segments ––

curve upcurve up

•• Repair SurfacesRepair Surfaces

•• Add GasketAdd Gasket

•• Add Joint PackingAdd Joint Packing

•• Stack in reverse order Stack in reverse order of installationof installation

Secondary Steam Curing

• 5 day Secondary Cure

• 8000 psi8000 psi

Multi Purpose Vehicle (MVP)

Multi Purpose Vehicle (MVP)

Heading Segment Unloading

Heading Segment Unloading

Segment Erection

Tunnel Infrastructure

50,000 CFM Ventilation50,000 CFM VentilationTemporary Temporary LightingLighting

2 - 4” water

8” Discharge

Walkwayy

First Tunnel to Receiving Pit - July 10, 2008

Soft eye Soft eye ––Fiberglass pilesFiberglass piles

First Tunnel to Receiving Pit - July 10, 2008

Containment Wall

TBM U-Turn

TBM U-Turn- Rotate 180 deg

TBM U-Turn- Rotate 180 deg

TBM U-Turn- Rotate 180 deg

TBM U-Turn- Rotate 180 deg

Invert Clean Up

Invert Placement

Thank YouThank You

Questions?Questions?