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Richard Graham - Salini Impreglio - NRW JV

Jan 14, 2017

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  • 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!