High-speed rail line through the Alps-Europe

Tunnel

1. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Gotthard Base Tunnel:
High-Speed Rail Line Through the Alps
presented by: presented by:
Michael Rehbock, Michael Rehbock, M. Sc. Mining EngineerM. Sc. Mining Engineer
Member of the Board, Member of the Board,
Head of Tunnelling Department Amberg Head of Tunnelling Department Amberg
Engineering Ltd., Regensdorf, SwitzerlandEngineering Ltd., Regensdorf, Switzerland
SEMINAR ON PRACTICAL TUNNEL DESIGN AND
CONSTRUCTION

2. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Content
1. Project overview
4. Excavation in fault zone Sedrun
2. State of the works
3. TBM excavation with open gripper TBM
5. Special planning aspects
Special geotechnical aspects, experience from the
site  Rolf Stadelmann

3. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Content
1. Project overview
4. Excavation in fault zone Sedrun
2. State of the works
3. TBM excavation with open gripper TBM
5. Special planning aspects

4. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
The Alp Transit Scheme
Bern
Solothurn
Basel
Neuchâtel
Lausanne
Genève
Sion
Zermatt
Chur
St. Moritz
Bellinzona
Luzern
St. Gallen
Zürich
Baden
Schaffhausen
GBT
Gotthard
Base Tunnel
LBT
Lötschberg
Base Tunnel
F
D
F
I
I
A
Lugano

5. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Longitudinal Profile
ExistingGotthard-
RailwayTunnel
ExistingCeneri-
RailwayTunnel
Existing
Zimmerberg-
RailwayTunnel
ExistingGotthard-
RailwayTunnel
ExistingCeneri-
RailwayTunnel
Existing
Zimmerberg-
RailwayTunnel

6. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Gotthard Base Tunnel, Alignment and Tunnel Lots
Total length: 57 km
Three intermediate points of attack
5 Construction sections

7. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Evaluated Tunnel Systems

8. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Tunnel System

9. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Gotthard Base Tunnel, Overview

10. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Longitudinal, Geological Profile and Investigations

11. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Geology and Heading Sections of the GBT
Drill and Blast

12. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Design Joint venture
Amberg is involved in the project since 1990
The work is done in an engineering joint venture together with
Lombardi SA and Pöyri Ltd.
The JV is responsible for all design works from the first studies to the
drawings “good for construction” and the site management

13. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Content
1. Project overview
4. Excavation in fault zone Sedrun
2. State of the works
3. TBM excavation with open gripper TBM
5. Special planning aspects

14. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
GBT, State of Excavation June 1st, 2006
Southportal
Bodio
already excavated
excavation and lining
accomplished
tunnels still to be excavated

Of the total of 153.5 km of
access passages, shafts and
main tunnels 94.1 km or 61.3 %
have already been excavated

15. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Erstfeld

16. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Erstfeld
Beginning of work: July 2004
Beginning of the TBM excavation: 2006

17. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Amsteg

18. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Amsteg, Tunnel Boring Machine
At June 1st, 2006
TBM east reached the end of
the section (length 11.3 km)
TBM west about 1.5 km to the
border

19. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Sedrun

20. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Sedrun

21. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Sedrun, Logistic Concept
Sedrun shaft
Portal installation
field
Northern drives
Foot of shaft
Concrete plant, silos
Access tunnel
Pipeline for
pneumatic
cement conveying
Depth ~800 m
Trackbound transport
Counterweight
Gotthard Base Tunnel
Trackbound transport
Southern drives
Head of shaft
- carrying persons
- excavated material
Cage for:
- construction material
Ventilation tunnel

22. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Sedrun, Shaft Cross Section
Fresh air
Waste
7.75 m
8.60-9.00 m (cross section = 63m )
2
air
Pipes for dewatering
Additional man riding hoist
Counter weight
Pipes for supply
Separation wall
In situ concrete lining
Big Cage 5.5 x 2.8 m

23. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Sedrun, Shaft Bottom

24. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Sedrun, Logistic Problems

25. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Method of Shaft 2

26. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction of Shaft 2, Pilot and Raise Boring

27. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction of Shaft 2, Shaftboring Machine

28. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Sedrun, Northern Tunnels
1.5 km excavated
About 500 m to go for
breakthrough towards
Amsteg section

29. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Sedrun, Southern Tunnels
Suspended Platform
Mucking and work at the
invert at the same time
2.5 km excavated
About 3 km to be excavated

30. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Sedrun, Back-up Installations

31. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Sedrun, Investigation Drilling
Preventer:
Shear Preventer
Pipe Ram
Roto Pac

32. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Faido

33. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Faido, Model of Multifunctional Station

34. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Faido, Cross Cavern,
Unexpected Downfall April 2002

35. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Faido, fault Zones
Original layout
Revised layout
Move of large caverns into better
geological conditions

36. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Bodio

37. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Bodio, Steel Arch of TBM

38. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Bodio, Installation of Sealing

39. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Bodio, Curing

40. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Bodio, Completed Single Track Tunnel
14.5 km excavated
< 1 km to be excavated
Breakthrough to Faido in
September
70 % of the final lining
finished

41. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Content
1. Project overview
4. Excavation in fault zone Sedrun
2. State of the works
3. TBM excavation with open gripper TBM
5. Special planning aspects

42. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Overburden at the GBT and the Channel Tunnel

43. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Special Conditions and Requirements of long and deep-
lying tunnels
High overburden and changing rock conditions

 different types of rock support necessary
 quick reaction to the actual geological situation necessary
 flexible equipment on the tunnel face necessary
 open TBM, no shilded TBM in this section

44. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
TBM in Squeezing Conditions
L* L*
1 2
u
r
p
a
DeformationDeformation
Support pressureSupport pressure
Resistance PrincipleResistance PrincipleYielding principleYielding principleFlexible Principle Resistance Principle

45. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Amsteg
Installation of flexible support
After
Deformation
15
Ortbetonverkleidung
min. Stärke = 35 cm
ø 9.20 m
ø 9.50 m
15
SOK
Segment 1. Ring: TH 44 (6 Stk.)
Segment 2. Ring: TH 44 (6 Stk.)
Ausbruchsicherung
Deformation = 15 cm
max. Stärke = 30 cm
Länge = 4.72 m
Länge = 4.75 m
Before
Deformation
1
1
ø 9.50 m
SOK
Segment 2. Ring: TH 44 (6 Stk.)
Segment 1. Ring: TH 44 (6 Stk.)
Länge = 4.72 m
Länge = 4.75 m

46. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
TBM Ecavation, Brittle Failure after Cutterhead
Picture: Vereina Tunnel

47. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
TBM Ecavation, Brittle Failure after Cutterhead
Picture: Vereina Tunnel

48. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
TBM Ecavation, Buckling and Spalling Effects at TBM Face
Picture: Lötschberg Tunnel

49. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
TBM Cutterhead
Vereina Tunnel, domed Gotthard Base Tunnel, flat

50. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
L
Z
0
1
#
5
7
2
4
8
Investigation, Prediction
•Additional Investigations ahead the tunnel front are necessary

•Investigation drilling (percussion and core drilling)  takes time
• TSP-Measure  little interruption of the excavation work
TBM Experience

51. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
L
Z
0
1
#
5
7
2
4
8
TBM Experience, Exploratory Drilling through Cutterhead

52. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
L
Z
0
1
#
5
7
2
4
8

53. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Crossing fault zone
Hydrothermally
weakened Rock
 TBM West blocked in fault zone
in June 2005

54. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Crossing fault zone, Counter attack
East Tube
West Tube
Injections
Counter attack
Access and injection tunnel
from east tube

55. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Crossing Fault Zone, Revised Cutter Head
 Restart TBM West end of 2005

56. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Crossing Fault Zone, Restart of Cutter Head

57. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Content
1. Project overview
4. Excavation in fault zone Sedrun
2. State of the works
3. TBM excavation with open gripper TBM
5. Special planning aspects

58. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Longitudinal, Geological Profile and Investigations

59. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Sedrun, Full Face Excavation
Tavetsch Intermediate Massiv
Squeezing rock conditions with expected deformations up
to 1 m over a length of more than 1‘000 m
Choosen Excavation System
Full Face Heading with intensive face anchoring and
yielding steel support

60. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Sedrun, Face Bolting

61. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Sedrun, Standard Cross Sections
Exc.diameter: 9 m
Exc. diameter: 13 m
Deformations: 20 cm
Inner lining: 30 cm
Deformations: 80 cm
Inner lining: 120 cm

62. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Sedrun, Support Placement Rig

63. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Construction Section Sedrun, Flexible Steel Arches TH 44
Radial Deformations up to 80 cm
Average advance rates of 90 cm/day
 Support System and full face
heading proved itself

64. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Content
1. Project overview
4. Excavation in fault zone Sedrun
2. State of the works
3. TBM excavation with open gripper TBM
5. Special planning aspects

65. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Overburden at the GBT and the Channel Tunnel

66. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Forecast Rock Temperature at Base Tunnel Level

67. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Special Conditions and Requirements of long and deep-
lying tunnels
High rock temperatures
 Cooling during construction and perhaps during operation
 special requirements for the shotcrete and the concrete

68. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Amount of Excavation Material

69. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Material Preparation Plant and Processing Steps
Requirement for concrete
lining: 100 years without
major maintenance
Use of excavated material
as concrete aggregates

70. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Concret and Shotcrete Prequalification,
Test Gallery Hagerbach, Sargans
Installation of
Simulating
Transport
Conditions
Agreements in contract for
necessary adjustments
during construction
Prequalification of concrete
systems

71. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Heatable Gallery, Part of Test Gallery Hagerbach, Sargans

72. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Test Gallery Hagerbach, Sargans
Hagerbach test Gallery belongs to
Amberg Group
5 km of galleries and tunnels

73. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Safety aspects
During construction
 Overall safety concept for each section (with SUVA)
 Reduce risk and be prepared in case of an accident or fire
During operation
 Two Multifunctional stations and cross cuts all 300 m
 Ventilation for different possible events

74. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Fire Event with Blocked and without Blocked Staff at the Front
with
blocked
staff
without
blocked
staff

75. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Impressions of the Safety Concept during Construction
Safety control centre Exercises with the
external fire brigade

76. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Faido Multifunctional Station, Layout

77. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Multifunctional Station, Emergency Stations
Self rescue within 45 minutes
External rescue within 90 minutes

78. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Faido Multifunctional Station, Ventilation during Construction
fresh air
exhaust air

79. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Fresh and Exhaust Air System for Fire Events

80. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Normal concrete
Without any special fire protection
measures
After 20 minutes
Concrete disturbed (11.5 cm deep)
Fire Protection Tests, Test Gallery Hagerbach, Sargans

81. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Fire Protection Tests, Test Gallery Hagerbach, Sargans
2 kg PP-fibres:
4 cm chips
3 kg PP-fibres:
1 cm chips
1 kg PP-fibres:
6 cm chips
2 kg PP-fibres:
4 cm chips
2 kg PP-fibres:
4 cm chips
3 kg PP-fibres:
1 cm chips
3 kg PP-fibres:
1 cm chips
1 kg PP-fibres:
6 cm chips
1 kg PP-fibres:
6 cm chips

82. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Break Through

83. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
Thank you for
your attention!

84. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
TBM versus D & B, Comparison of Heading Time for Faido
TBM
D&B
Contractor I Contractor II Contractor III Contractor IV
month

85. SEMINAR ON PRACTICAL TUNNEL DESIGN AND CONSTRUCTION 26/06/06
TBM versus Drill & Blast, Comparison of Costs for Faido
Offered Price Lot Faido, GBT
 3 %
 3 %
 9 %
 0 %
Contractor I Contractor II Contractor III Contractor IV
TBM
D&B
Tender Price