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Page 1: Richard Graham - Salini Impreglio - NRW JV
Page 2: Richard Graham - Salini Impreglio - NRW JV

CONTRACTOR’S UPDATE

• About SI-NRW JV

• Key Challenges

• Design

• Key Equipment

• Execution

• Summary

Page 3: Richard Graham - Salini Impreglio - NRW JV

• 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

Page 4: Richard Graham - Salini Impreglio - NRW JV

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

Page 5: Richard Graham - Salini Impreglio - NRW JV

● Largest Italian Contractor, ranked #27 in ENR’s 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

Page 6: Richard Graham - Salini Impreglio - NRW JV

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

Page 7: Richard Graham - Salini Impreglio - NRW JV

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!

Page 8: Richard Graham - Salini Impreglio - NRW JV

NRW - Local construction knowledge

Civil Infrastructure Mining

Page 9: Richard Graham - Salini Impreglio - NRW JV

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

World record for TBM able tooperate with pressures up to

18 bars!

Page 10: Richard Graham - Salini Impreglio - NRW JV

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

Page 11: Richard Graham - Salini Impreglio - NRW JV

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!

Page 12: Richard Graham - Salini Impreglio - NRW JV

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

Page 13: Richard Graham - Salini Impreglio - NRW JV

Passing under of fully operational Perth Airport:

• Twin Tunnels below Runways

• No access for intervention from Top!

• Settlements lower than 10mm!

Page 14: Richard Graham - Salini Impreglio - NRW JV

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

Page 15: Richard Graham - Salini Impreglio - NRW JV

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

Page 16: Richard Graham - Salini Impreglio - NRW JV

• 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:

Page 17: Richard Graham - Salini Impreglio - NRW JV

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

Page 18: Richard Graham - Salini Impreglio - NRW JV

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

Page 19: Richard Graham - Salini Impreglio - NRW JV

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

Page 20: Richard Graham - Salini Impreglio - NRW JV

Cross Passage Design• Pre-treatment from surface

with Jet-grouting columns

• Bi-fluid treatment

• Cross Passage equipped with temporary steel support

Page 21: Richard Graham - Salini Impreglio - NRW JV

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

Page 22: Richard Graham - Salini Impreglio - NRW JV

• 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

Page 23: Richard Graham - Salini Impreglio - NRW JV

EPB vs. Mix-shield TBMs

Page 24: Richard Graham - Salini Impreglio - NRW JV

Variable Density TBM

Difference between traditional Slurry TBM and Variable Density TBM:

• No opening in submerged wall - Special supply lines

Page 25: Richard Graham - Salini Impreglio - NRW JV
Page 26: Richard Graham - Salini Impreglio - NRW JV

MSVs:

• Capacity 60t –two rings transportation

• Capacity 30t –personnel and equipment

Multi Service Vehicles

Page 27: Richard Graham - Salini Impreglio - NRW JV

• Total maximum capacity: 500m3/h

• 12 Booster Slurry Pumps in Tunnel (600kW each)

• Min Environmental Impact – max Recycling

Slurry Treatment Plant

Page 28: Richard Graham - Salini Impreglio - NRW JV

• 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

Page 29: Richard Graham - Salini Impreglio - NRW JV

ExecutionStations:

• Top-Down Sequence

• D-Walls and Barrettes

Cross Passages:

• Jet-Grouting

• Freezing

Page 30: Richard Graham - Salini Impreglio - NRW JV

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

Page 31: Richard Graham - Salini Impreglio - NRW JV

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

Page 32: Richard Graham - Salini Impreglio - NRW JV

Thank You !!

Together

We build value!


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