Richard Graham - Salini Impreglio - NRW JV

CONTRACTORS UPDATE

About SI-NRW JV

Key Challenges

Design

Key Equipment

Execution

Summary

Total length of mechanized excavated tunnels: 14.2km

Total length of Cut and Cover Dives: 0.8km

Total number of stations: 3

Total number of Cross Passages: 12

Total number of Emergency Egress Shafts: 3

Trackwork

Power & System

10 years Maintenance

FORRESTFIELD AIRPORT LINK

About the SI-NRW JVForrestfield Airport Link is the new challenge that the Joint Venture between Salini-Impregilo S.p.A. and NRW are proud to design, construct and maintain for Perth Transport Authority (PTA).

Joint Venture Leader

80% share

Global contractor of large complex projects

Joint Venture Partner

20% share

Strong local civils and mining contractor

SI-NRW JV

Largest Italian Contractor, ranked #27 in ENRs Top 250 International

Contractors

Turn over Euro 4.74bn /year, backlog Euro 28.8bn

More than 35,000 employees worldwide from over 100 nationalities

110 years on the international construction market

34 TBMs all around the World

In 2015 Awarded the Project of the Year by the International

Tunnelling Association for the Lake Mead Tunnel, Las Vegas, USA

Salini-Impregilo is present all around the globe

257 Dams and

Hydropower plants

producing more than

37,500MW

51,660km of roads &

motorways 1,450km of tunnels

350km of

bridges & viaducts

6,830 km of railways

METROMOVERMIAMI

LINE 3, CARACAS METRO

RECONSTRUCTION OF LINE 1, SAINT PETERSBURG

LINE 3 & EXTENSIONS, ATHENS METRO

LINE 1, NAPLES METRO

GENOVA METRO

METRO DO PORTO

PARIS:- REGIONAL METRO LINE 3, LOT 35B - NEW METRO LINE, LOTS M21/M22

LINE 2, LOT 3, METRO LILLE

METRO AND RAILWAY SISTEMMILAN

EXTENSION OF METROSINGAPORE

EXTENSION OF METRONEW YORK SUBWAY

UNDERGROUND RAILWAY LOOPMELBOURNE

ROMA METRO

THESSALONIKI METRO

400km of metros!

NRW - Local construction knowledge

Civil Infrastructure Mining

2015 Project of the Year - Lake Mead Tunnel, Las Vegas, USA

World record for TBM able tooperate with pressures up to

18 bars!

Lake Mead Mix-mode TBM from Herreknecht:

2,500m excavated with pressure up to 16.3bars in Slurry Mode

1,900m excavated in Open Mode

Key Project ChallengesWhile the great benefits of the FAL Project will be to provide the residents and visitors to Perth the opportunity to use an efficient Public Transport Link to & from the International Airport, there are nevertheless a number of significant challenges:

Complicated geology, fully below water table

Passing under the fully operational Perth Airport

Passing under the Swan River

Very tight contract duration: only 52 months

Very tight budget!

Bayswater Dive

Airport West Station

Swan River

PAPL Airport land

ForrestfieldDive

PAPL Airport Land

Airport StationForrestfield

Station

Complicated Geology:

Tunnels alignment fully below water table

Various strata from sandy alluvial to clay rock (2-4Mpa)

Maximum depth of tunnels 38.0m Maximum pressure considered 4.0bars

Geological Risk Mitigation alignment lowered by 5.0m into Osborne Formation

TBM Direction

TBM Direction

Passing under of fully operational Perth Airport:

Twin Tunnels below Runways

No access for intervention from Top!

Settlements lower than 10mm!

Program Summary

Contract Award

Mobilisation

Commencement of Works

TBM 1 Procurement

Design of Forrestfield Dive

Forrestifield Dive

TBM Support Facilities (incl

intial Segment Manufacture)

Tunnelling - Tunnel 1 & 2

Forrestfield Station

Bayswater Deviation

Bayswater Dive

Cross Passages

Track Slab

Cable Tray and Cable Haul

Tunnel Fitout

Commissioning

Abernethy Egress Shaft

Consolidated Airport Station

Airport West Station

49 50 51 52 5343 44 45 46 47 4837 38 39 40 41 4231 32 33 34 35 3625 26 27 28 29 3019 20 21 22 23 2413 14 15 16 17 187 8 9 10 11 12

SO N D J F M

1 2 3 4 5 6

A M JA M J J A SO NSO N D J F M J AD J F MA M J

2016 2017 2018 2019 2020

M J J A S A M J J A SO N D J F M J A

Project Delivery: 17th September 2020

Design

The Designers team for FAL Project contains various Design Companies working in Australia and Europe

Key Design Challenges:

Tight Program D&C

Variable Ground Conditions / High Water Table

Passing under Perth Airport Runways

Environmental Sensitive Project

Multidisciplinary Design

Design life of 120 years

Excellent ISCA Sustainability Rating

Rail Safety Accreditation

Design of TBM Tunnels

Design of Dives

Design of Cross Passages

Design of Stations

Design of Emergency Egress Shafts

Full Multidisciplinary Design

Track works

Systems

Stations and Tunnels Fit-Out

Design Scope:

Tunnel Design

Total number of more than 9000 rings

Hybrid Solution: 40kg/m3 of reo + 40kg/m3 fibers

High Fire resistance

Configuration 5+1

Durability of 120 years

Double Convex system for Lining Segments

Double Gasket System

Bolting and Secondary Grouting

Coating of Segmental Lining

50 MpA Concrete

Tunnels are connected with CP approx. 330m apart. Treatments for the CP:

7 CP with full jet-grouting treatment

1 with jet-grouting treatment (only crown)

3 CP with ground freezing;

1 CP with half face freezing (only crown)

Total 12 CP

Cross Passages Design

Cross Passage Design

Cross Passage Data Base Specification

Jet Grouting Treatment (Full) 7

Jet Grouting Treatment (Crown) 1

Freezing Treatment (Full) 3

Freezing Treatment (Crown) 1

Cross Passage Design Pre-treatment from surface

with Jet-grouting columns

Bi-fluid treatment

Cross Passage equipped with temporary steel support

Instrumentation and Monitoring Design> 8000 instruments to be installed along the alignment

2 Variable Density TBMs

Less than 10 such machines in world

7.10m diameter

Unique technology of double mode operation:

Slurry excavation

EPB excavation

Nominal Thrust 50,600 kN

Nominal Torque 51,100 kNm

Main Drive Power 1440 kW

Key Equipment

EPB vs. Mix-shield TBMs

Variable Density TBM

Difference between traditional Slurry TBM and Variable Density TBM:

No opening in submerged wall - Special supply lines

MSVs:

Capacity 60t two rings transportation

Capacity 30t personnel and equipment

Multi Service Vehicles

Total maximum capacity: 500m3/h

12 Booster Slurry Pumps in Tunnel (600kW each)

Min Environmental Impact max Recycling

Slurry Treatment Plant

Off-site Shed for Plant rented

Carousel System

9 sets of moulds

24 Rings /144 segments / day

Casting rate: 8 mins per

segment

Steam Curing for 6h 420

degree C

22MpA after 6 hrs

Precast Segment Lining Plant

ExecutionStations:

Top-Down Sequence

D-Walls and Barrettes

Cross Passages:

Jet-Grouting

Freezing

ExecutionCurrent Progress:

Site Mobilization commenced

Approvals Applications submitted

All main equipment ordered and under manufacture

Progress of Design: more than 20% ready by October 2016

Jet Grouting Trials due to start next week

Ready for Start of Diaphragm Walls in Forrestfield Dive Structure November 2016

First TBM due on Site in May 2017 start of boring July 2017

Summary

The FAL Project:

Very tight Programme

Technically Challenging

Assembled Team with great Competencies & Experiences

Design Progressing to Schedule

Constant collaboration with PTA and PAPL (Perth Airport Authority)

Formal working Group to encourage Aborigine Business participation

Numerous Critical Stakeholders

Strict environmental controls for all the Works

Thank You !!

Together

We build value!