Aydogmus Crossrail Thames Tunnel

Crossrail C310 Thames Tunnel
CROSSRAIL C310 THAMES TUNNEL

Geotechnical & tunneling related specifics in urban
tunneling & a river crossing with low overburden.
Dr. Taner AYDOGMUS, Technical Director

Riku Tauriainen, MSc., Project Director
Frank Wiegand, MSc., Technical and Risk Manager
Tunneling Short Course 2016, 09/15/2016, Boulder, CO | Dr. Taner AYDOGMUS One Team, One Spirit 1
Outline | 1. Overview | 2. Challenges | 3. River Crossing | 4. Design Elements | 5. Summary
OUTLINE
1. Project Overview
2. Challenges
3. River Crossing
4. Design Elements
5. Summary
Tunnel btw. Plumstead and Woolwich
Box
CROSSRAIL Project – Moving London Forward

• Crossrail is a rail line that will run from Reading and Heathrow Airport in the West, through
new twin-bore tunnels under central London to Shenfield and Abbey Wood in the East;
• Total 118km (73mile) new railway, 42km (26mile) tunnels and 40 stations of which 8 will be subterranean;
• It will bring an additional 1.5 million people within 45 minutes commuting distance of London's
key business districts and increase London's rail-based transport network capacity by 10%;
• Overall 8 TBMs in operation (6 EPB + 2 Mix-shield);
• Investment approx. £14.8 Billion = $19.5 Billion (excluding “Rolling Stock”).
C310 Thames Tunnel

Tunnel Alignment & Portals
N
Thames
London City Airport
North Woolwich Belmarsh

Portal
River
Thames
Woolwich
Box Plumstead
Portal

North Woolwich
Thames Barrier
Portal
City Airport
Woolwich
Box
Belmash Prison
Plumstead
Portal
Thames Barrier
North Woolwich City Airport

Portal
Geotechnical Conditions
North Woolwich Cover Woolwich Cover Plumstead
Portal ca. 12m (39.3’) Box ca. 20m (65.6’) Portal
10m GWL
CP 19
CP 16
CP 18
+
Pump Sump
CP 17
+
Pump sump
TBM Drive Direction
TBM Selection
• Contract allowed for
both Mix-Shield &
EPB Technology
• Decision was based
on risk assessment:
– Low overburden
– Geology
– Settlements
– Chalk disposal
– Program security
– Cost
• Mix-Shield
technology is more
expensive but in
overall scoring of risk
assessment
Mix-Shield “Sophia” at factory acceptance July 2012 outperformed EPB
Programme
• Procurement – 03/18/2011
• TBM Breakthrough – 05/13/2014
• Completion – 06/10/2015
Advantages of TBM Reception

with sealing pot:
• no grout block – one slurry wall
panel only
• no risks of leak by means blow
off the compressed air when
run in the sealing
• reusable
Challenges at Plumstead Portal

• Close proximity to Operational
Railway;
• Unknown utilities,
Marmadon Road Sewer;
• White Hart Road Bridge;
• Sensitive Equipment within

Cathedral Substation;
• Cross Passage CP19

low Chalk overburden;
Ground Engineering Techniques for Portal Construction
60m (197’) CFA piles
Secant Wall
(Cased CFA)
180m (591’) Secant Pile Wall 193m (633’) Diaphragm Walls

(cased) 18m (59’) depth up to 22m (72’) depth
Tension Piles / Rotary Bored

Piles up to 38m (125’) depth
Plumstead Portal
433m (1,420-ft) long
Four Piling Rigs & Five Attendant Cranes at One Time
Top-Down Construction of Portals
• Internal dewatering
• Recharge outside of portal foot print
• Two levels of temporary propping
• Bulk excavation
• Portal in-situ concrete slab
Dewatering well
• Real time monitoring
Hydraulic temporary propping
Lifting Operations Next to Operating Railway Line

Risk: proximity of the portal works
to the Network Rail (NR):
• >3m (9.8’) away from a
running line; not compliant
with existing NR regulations;
700 to crane at headwall • Trains one every 3 minutes;
• 8 months to develop a
workable solution w/ NR;
• Slew restrictions;
• Reinforced concrete piling
Tandem lift – D-wall platform;
cage • 3 full-time protection staff on
rail line & automatic crane
collapse alarms.
Deep Excavation in Close Proximity to Operational Railway

Shape Accelerator
Arrays (SAA) in D-wall
• show real time

movement of the box
structures over the full
depth;
• Effects of Dewatering,
Excavation, Props and
structural loading of
area adjacent to box.
SAA strand in D-wall
TBM Tunneling Interface at Cathedral Substation
Cathedral
Substation
Compensation Grouting at Cathedral Substation

Low overburden, Gravel and below GW
GW
- 6.0m 4.5m
Gravel (19.6’) (14.8’)
Lev
el
Grout Shaft
TAM Drillings
Challenges at North Woolwich Portal

• Late site possession due to
complicated service diversions on
the portal footprint;
• Risk of cross contamination due to

dewatering and recharge
operations for portal excavation;
• Sheet piles extending into the

tunnel envelope below a 2.4m
(7.9’) Thames Water sewer;
Store Road Sheet Pile Removal
TW Pumping Station
Sheet piles
extending to
tunnel
envelope
Store Road Sheet Pile Removal Existing pipe demolition

New Cofferdam
Removal old sheet piles New DN 2.4m (7.9’) pipe installation
River Crossing
• Tunnel length
underneath
Thames approx.
480m (1,574’)
(between flood
Woolwich
Box protection walls);
Flood
Protection
Walls • Approx. 300 rings
CP 17
to build
underneath
Woolwich Ferry Thames;
• Cross Passage
CP17 to build
underneath
North Woolwich
Portal
Thames.
First Thames Tunnel by Marc Brunel – 1826 to 1846
Brunel‘s Tunnel, 1828 (Mathewson)
River Crossing – Tidal Impact
Closed Face
Mixshield TBM
with Double Chamber
• Control of Face-
pressure
• Reduction of
Settlements
Slurry
Balance 1. Submerged Wall.
Control
2. Working Chamber.
3. Air Cushion.
4. Pressure bulkhead.
River Crossing – Tidal Impact

Real Time Data from River Thames, Damping effect in Chalk
Variation of tide approx. 8m (26.2’)
2 tide cycles in 24 hours
TBM Tunneling – Compressed Air Intervention at CP19
Value Engineering Phase

Post Contract Award
• Special 4-weeks phase to evaluate specifications

• Technical & contractual
• Identify possibilities for optimization
• Identify weak points in contract
• Identify critical issues to pay attention for
SFRC Pre-Cast Segmental Lining

Segmental Lining Design –
Double tapered Universalring (7 plus 1)
Keystone
Counterstone
Longitudinal
Joint
Circumferential Joint
(Smooth/Hardboards
and plastic dowels)
Use of EPDM Gasket with
additional blackswell
Segmental Lining Production in Ireland
Segment
Tracking
C310 - Thames Tunnel
X1-C-4-130912
Pre-Cast Segmental Lining

Concrete Mix design, large scale fire tests at MFPA Leipzig
PP-fibre 0.75 kg/m3 PP-fibre 1.5 kg/m3
Successful fire test with 1.5kg HPR

(high performance) Baumhüter PP-fibres
start ca. 1 year in advance to

segment production (!!)
Innovation – TBM Launching with Movable Rig

“Flying Launching System”
TBM Launching – “Flying Start”

Movable Rig System
for a TBM Launch
(HOCHTIEF Patent
Solution)
• Easy, quick & safe

Launching Operation;
• No temp. rings or other
means;
• Improved Health &
Safety;
• Less space required.
Alternative Cross Passage Construction – SCL
• Alternative to Clients proposal with cast-iron rings

• High demanding geology with water bearing fissures
• Low overburden, i.e. CP19
• Constraints from available working space
additional steel-
ring-support with
emergency
floodgate
Cross Passage Construction – SCL

Segment Removal
• Coring & Cutting in Segment Joints
• Removing Key Stone
• Removal of Segmental 2K-Grout
Top Heading Excavation
Bench Excavation

Shotcrete Application
Waterproofing Membrane

Cross Passage completed
Secondary Lining – Central Section completed
Monitoring Tilt Meter
Advanced Tunnel Drive Steering (ATDS) Real-Time Monitoring System

 All appropriate structures within our works corridor are manually and/or
automatically monitored
 Shape accelerator arrays, hydrostatic levelling cells and tilt meters
are installed on all sensitive structures
 Piezometer for ground water levels
 All monitoring date is shown real time in one system (ATDS)
 Confidence to all stakeholders enabling consents &
permissions being granted to pass under/over sensitive
structures
 Full control of source data and its management on site
 Compliance with best practice in tunnelling and project
insurance requirements
Cathedral
Hydrostatic Levelling Cell
Sub Station
White Hart
Screenshot ATDS
Road
Bridge
Conclusions
• Optimized Contractors Involvement (OCI) drives and

Deep Excavation
motivates innovations as well as people;
• Third Party interface management requires early

involvement and detail knowledge of construction
techniques; Mix Shield
• Deep excavation next to Operating Railway line is

feasible but requires robust control measures;
• Application of Mix-Shield was the right choice for

C310. STP with Filter presses
• SCL-lining is feasible solution for temporary lining in

Chalk for Cross Passages.
SCL in Chalk
Summary
A technically challenging project like C310 with many

interfaces and challenges can be delivered to the original
completion date.
Effective collaboration between the PM, Designer and

Contractor’s technical and operational teams is delivering
improved quality.
Evolution of TBM Tunneling under Thames since 1825
Thank you for your Attention!
“If I could start again, I would build it better”
Marc Brunel
(1769 – 1849)

Aydogmus Crossrail Thames Tunnel

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Crossrail C310 Thames Tunnel

CROSSRAIL C310 THAMES TUNNEL

Dr. Taner AYDOGMUS, Technical Director

Crossrail C310 Thames Tunnel

Crossrail C310 Thames Tunnel

CROSSRAIL Project – Moving London Forward

• Overall 8 TBMs in operation (6 EPB + 2 Mix-shield);

• Investment approx. £14.8 Billion = $19.5 Billion (excluding “Rolling Stock”).

C310 Thames Tunnel

Crossrail C310 Thames Tunnel

Tunnel Alignment & Portals

North Woolwich Belmarsh

Crossrail C310 Thames Tunnel

Tunnel Alignment & Portals

Crossrail C310 Thames Tunnel

Tunnel Alignment & Portals

North Woolwich City Airport

Crossrail C310 Thames Tunnel

TBM Drive Direction

Crossrail C310 Thames Tunnel

Crossrail C310 Thames Tunnel

Advantages of TBM Reception

Crossrail C310 Thames Tunnel

Challenges at Plumstead Portal

• White Hart Road Bridge;

• Sensitive Equipment within

• Cross Passage CP19

Crossrail C310 Thames Tunnel

Ground Engineering Techniques for Portal Construction

60m (197’) CFA piles

180m (591’) Secant Pile Wall 193m (633’) Diaphragm Walls

Tension Piles / Rotary Bored

Crossrail C310 Thames Tunnel

Four Piling Rigs & Five Attendant Cranes at One Time

Crossrail C310 Thames Tunnel

Top-Down Construction of Portals

Hydraulic temporary propping

Crossrail C310 Thames Tunnel

Lifting Operations Next to Operating Railway Line

Crossrail C310 Thames Tunnel

Deep Excavation in Close Proximity to Operational Railway

• show real time

SAA strand in D-wall

Crossrail C310 Thames Tunnel

TBM Tunneling Interface at Cathedral Substation

Crossrail C310 Thames Tunnel

Compensation Grouting at Cathedral Substation

Crossrail C310 Thames Tunnel

Challenges at North Woolwich Portal

• Risk of cross contamination due to

• Sheet piles extending into the

Crossrail C310 Thames Tunnel

Store Road Sheet Pile Removal

Crossrail C310 Thames Tunnel

Store Road Sheet Pile Removal Existing pipe demolition

Removal old sheet piles New DN 2.4m (7.9’) pipe installation

Crossrail C310 Thames Tunnel

Crossrail C310 Thames Tunnel

First Thames Tunnel by Marc Brunel – 1826 to 1846

Brunel‘s Tunnel, 1828 (Mathewson)

Crossrail C310 Thames Tunnel

River Crossing – Tidal Impact

Crossrail C310 Thames Tunnel

River Crossing – Tidal Impact