Tunnel T80 across Pir Panjal Mountain Range: The Longest Transportation Tunnel In India

The Presentation Covers the General Technical Features of Tunnel T 80 across Pir Panjal Mountain Range, for Kashmir Rail Link. This presentation was made at Civil Engineering Society, IIT Kanpur on 30th September 2013.

1. WELCOME YOU TO
PIRPANJAL RAILWAY TUNNEL
SITE
THE LONGEST TRANSPORTATION TUNNEL
IN INDIA

2. 2
•Location Overview
•Salient Features of The Tunnel
•Construction Approach
•Pre-construction Planning
•Usage Of NATM in T-80
•Construction Activities
•Quality Assurance
•Environment Issues
•Social Impact
PRESENTATION COVERS

3. LOCATION OVERVIEW

4. 4
ALIGNMENT PLAN
JAMMU-UDHAMPUR-SRINAGAR-BARAMULLA RAIL
LINK
QAZIGUN
D
SADUR
A
ANANTNAG
BIJBEHARA
PUNZGA
M
AWANTIPORA
KAKPORA
PAMPOR
E
SRINAGA
R
BUDGA
M
RAJWANSHE
R
PATTAN
HAMRE
SOPORE
BARAMULLA
BANIHA
LARPINCHALA
BHATTA
LOALE
KOHLISANGALDAN
BARALA
BASAND
A--DHAR
REASI
KATRA
CHAKARWAH
UDHAMPUR
SALAL
RAMNAGAR
ROAD
MANWA
L
SANGAR
BAJALT
A
JAMM
U
SURUKOT
PIR PANJAL RAIL TUNNEL
Length 11100 mts.
South portal photo
SOUTH PORTAL

5. 5

6. SALIENT FEATURES OF T-80
•Totallength–11Km
•Adit–774m(58m
2
exc.Area)
•Shaft:55mdepth,12mdia
•Maximumoverburden-1.10Km
•Tunnellingmethod:NATM (NewAustrian
TunnelingMethod)
•CompletedCost–1150Crores
•Approx.440mbelowexistingJawaharRoad
Tunnel(2.75km)
•Undergroundexcavation:10laccubicmeter
•CrosssectionArea:Excavation:67to78m
2,
FinishedTunnel:48
m2
•InvestigationBoreHolesdepthupto640m
6

7. SALIENT FEATURES OF T-80
(Contd.)
•3mwideroadintunnelformaintenance,
emergencyrescue&relief.
•Highmidpoint&slopinginbothdirectionsfor
drainage.
•Provisionofsystemforventilation,firefighting&
safetymonitoring.
•Adit&shaftforparallelworking,tobeusedfor
ventilation,maintenance&emergencyrelief
duringservice.
•Extensiveinstrumentationformonitoringduring
tunneling
•Consultants:M/sGeoconsult-RITESJV
7

8. MANY FIRSTS
•TheLongestTransportTunnelInTheCountry
(11Km)
•Highest‘Over-burden’of1100M
•Deepest‘Drillholes’for Geotechnical
Investigations640M
•FirstLargeScaleUseof‘NewAustrianTunneling
Method(NATM)’inIndia
•FirstUseof‘Roadheader’for‘TunnelExcavation’
inRailwayTunneling
8

9. CONSTRUCTION APPROACH

10. 10
APPROACH TO CONSTRUCTION
NO ADIT

11. 11
Vertcal Shaft
55m deep,
12m dia
Cross Passage 55 m
Adit 788 m
APPROACH TO CONSTRUCTION
WITH SHAFT AND ADIT

12. 12Time Line

13. PIR PANJAL TUNNEL-
EXCAVATION PROGRESS
Year Excavation
(mts.)
Remarks
2006 722Two Faces
2007 1876Start From 4 Faces
2008 2475
2009 2533
2010 1739Two Faces after Jan’10
2011 947High overburden,
Squeezing, Shale
2012 63 13

14. Tunnel
Cross
Section:
14
STRUCTURAL GAUGE

15. 15
TUNNELS
SECTIONS
USED ON
KONKAN
TRACK

16. 16
TYPICAL
RAILWAY
TUNNEL
SECTION
USED ON
JAMMU-
UDHAMPUR
RAIL LINKSHOTCRETE(25mm+WIRE MESH +50mm)
OR 50mm SFRS
300 TH. C.C. LINING
ISHB 150 @ 500 C/C
50mm TH. R.C.C. LAGGING
Min. EXCAVATION LINE
75Ø @ 2000 C/C
MS PLATE 12mm THICK
ISHB150-2NOS.
INVERT STRUT ISHB150 @ 500mm
ISHB200 @ 750 C/C
1676
R 2600
4370
1312
150
150
Max.
150(max)
50M20
1 in 40
RAIL LEVEL
FINISH LINE
PAY LINE 150 TH. FROM Min. EXCAVATION
25 mm Ø 3 to 5m ROCK BOLTS
AS PER SITE REQUIREMENT
ISHB 150 @ 750 c/c
PRESSURE RELIEF HOLES 5m DEEP @
3m c/c LONGITUDINALLY AS PER SITE
REQUIREMENT
150
PAY LINE
MIN. EXCAV. LINE
BASE PLATE
12mm THICK
R3000
ISHB 150 @ 500 c/c SHOTCRETE25mm + WIREMESH+50mm OR 50mm SFRS 50 TH. R.C.C. LAGGING
150
PRESSURE RELIEF HOLES 5m DEEP @ 3m c/c LONGITUDINALLY AR AS PER SITE REQUIREMENT
BACK FILLING M-10
50
FINISH LINE 300 TH. CONC. LINING M-20
150
100
900
BLOWER
8Ø @ 150 C/C
50675 150
100
65
675
25mmØ 3mto5m ROCK BOLT AS PER SITE REQUIREMENT
SEC. AT A-A
75

18. 18
LOADING DIAGRAM FOR TUNNEL
TOP PRESSURE-15000KG/M
AND SIDE PRESSURE-5000KG/M

19. 19
BENDING MOMENTS DIAGRAM FOR
D-SHAPE TUNNEL
TOP PRESSURE-15000KG/M AND SIDE PRESSURE -5000KG/M
MAX BENDING MOMENT = 137KN-M

20. 20
BENDING MOMENT DIAGRAM FOR ELLIPITCAL TUNNEL
TOP PRESSURE 15000KG/M AND SIDE PRESSURE 5000KG/M
MAX. BENDING MOMENT = 35.80KN -M

21. COMPARISION BETWEEN D -SHAPED AND ELLIPTICAL TUNNEL
DESCRIPTION MAX.
AXIAL
FORCE
MAX.
BENDING
MOMENT
MAX.
SHEAR
FORCE
MAX.
DISPLACEMENT
WITH TOP PRESSURE 15000 KG/M & SIDE PRESSURE
5000 KG/M
D-SHAPED
TUNNEL
412.5KN 137KN-M 15129 KG 0.083 M
ELLIPTICAL
TUNNEL
567 KN 35.80KN-M 9025 KG 0.024 M
WITH TOP PRESSURE 15000 KG/M
D-SHAPED
TUNNEL
412.5KN 48.10 KN-M 8565 KG 0.03 M
ELLIPTICAL
TUNNEL
639 KN 35.65 KN-M 9635 KG 0.028 M

22. CONSTRUCTION METHOD
SELECTION
•DRILL AND BLAST
•ROAD HEADER
•TUNNEL BORING MACHINE (TBM)
22

23. DRILL AND BLAST
23
•CONVENTIONAL, ART
WHICH COMES WITH
EXPERIENCE
•GOOD IN HARD ROCKY
STRATA
•WITH EXPERIENCE, CAN
DELIVER GOOD PROGRESS
•NON CONTINUOUS -CYCLE
INVOLVES VARIOUS
ACTIVITIES IN SEQUENCE
•MAY SPRING SUDDEN
SURPRISES

24. ROAD HEADER
•CONTINUOUS ADVANCE -
LESS SURPRISES
•MORE CONTROLLED
EXCAVATION-LESS
OVERBREAK/CAVITY
FORMATION
•SUITABLE FOR MEDIUM
HARD ROCK
•CAN BE WITHDRAWN
MID WAY TO GIVE WAY
FOR OTHER METHODS
24

25. TUNNEL BORING MACHINE
•CONTINUOUS ADVANCE
•CIRCULAR SECTION
•NOT SUITABLE UNDER
SQUEEZING
CONDITIONS
•CANNOT BE
WITHDRAWN MIDWAY
TO GIVE WAY TO
OTHER METHODS
25

26. WHY NO TBM
•Likelihood of Mixed Geology
•Heavily Faulted Areas and/or Wide Fault
Zones
•High Squeezing Anticipated in middle with
High Overburden (1100 mts.)
•Heavy Water Flow in Lime Stone Zone
with High overburden
•TBM may be Trapped by Ground
Movement Behind the Face
26

27. PRE-CONSTRUCTION
PLANNING

28. PRE-CONSTRUCTION PLANNING
•Engagement of Consultant
–QCB System Of tendering
•Survey and Investigation
•Head start by Taking up ADIT and shaft
works in advance
•Tender Planning
–Key dates
–Multi Method Approach
•Road Header/ D&B
28

29. USAGE OF NATMIN T-80
•Suitable for poor and Varying Geology of
Himalayan Region
•X-Sectiondesigned to develop Maximum Self
Supporting Capacity
•Face Mapping, Probe Hole & Instrumentation data
input for Initial Support Design –RESS
–Primary Support System
•Resilient enough to Accept the deformations and readjustment of
stresses and Strong enough to take the loads
•Deformation Monitoring to assess the stress
redistribution, and stabilization before final lining
29

30. INSTRUMENTATION
To provide early information about tunnel behaviour in order to optimize
excavation & support activities during construction and to recognize the requisite
remedial measures.
Instrumentation data is basic input of the NATM, the observational approach.
Instrumentation in Pir Panjal Tunnel:
Optical 3 D monitoring: With bi-reflex targets to monitor deformation in
tunnel on daily basis
Extensometers: To measure stresses in surrounding rock mass
Radial Pressure Cells: To measure pressure of rockmass on shotcrete
lining
Shotcrete Strain meter: To monitor stresses in shotcrete lining
Piezometer: To monitor hydrostatic pressure during tunneling
30

31. CONSTRUCTION ACTIVITES
•Open excavation & portal development
•Tunnel mining & primary lining
•Water-proof membrane installation +
drainage system.
•Secondary lining.
•Ventilation, system and safety installations
•Track laying
31

32. QUALITY ASSURANCE
•Laid down responsibilities,
procedures and checklists for various
activities through:
–CPM, CQM, SH&EM
–PPM, PSM
–Organogram
–QAP
–ITP
32

33. QUALITY ASSURANCE (contd…)
•Availability of relevant documentation and defining the
manner of execution of various activities
•Maintaining compliance through appropriate monitoring
•Ensuring adequate support facilities for successful &
scheduled execution of work.
•Availability of competent/trained personnel to carry out
various activities
•Compliance of statutory/regulatory requirements related
to safety, environment etc.
33

34. Quality Assurance (contd…)
Check Lists and Forms for Process Control During
Execution of Works:
•Required Excavation and Support Sheet (RESS)
•ATSS/ Shift Report/Blasting clearance report/ R/Bolt
Installation report
•Shotcrete testing by Penetrometer test, Core crushing
test, thickness verification etc.
•Geological mapping (Geological face mapping sheet)
•Lining Air Permeability Test
•All Material Testing at Site Lab
34

35. ENVIRONMENT ISSUES
•Identified Muck Dumping areas
•Recycling of Excavated Rocks
–aggregate for concrete constn.
•Effluent Settling Tank
–Fit for agriculture discharge
•Ventilation during Construction Stage
–Gas Analyser for air quality monitoring
•Controlled Blasting below Inhabited areas
•Lined Waterproof Tunnel
–No long term impact on water table/ Aquifers
35

36. SOCIAL IMPACT
•All weather link, Alternate to Jawahar
Tunnel
•Even at Construction stage, given a boost to
–local construction-industry
–Employment
–Transportation business
•A boost to Local economy of Banihal
36

40. 40
Miles to go……
“A thing should be made
as simple as possible,
but not simpler”.
Einstein

41. 41
THANKS !

42. ENGAGEMENT OF CONSULTANT
•Investigations for Tunneling Methodology
Assessment
•Initial Design
–Usage of NATM
–Usage of Water proof Membrane for Semi Dry
Tunnel
–Development of 4-Arc Tunnel X-Section
–Additional Access through ADIT and Shaft
–Portal Location Review
•Real Time Monitoring / Instrumentation and
Design Support
42

43. INVESTIGATIONS & PLANNING
2003 Geological L-Section Profile Submitted by M/s
RITES based on GSI data.-
Used to decide the Bore hole Location.
2003-04Bore holes by RITES/ MECL-
To Confirm Geological Mapping inference
2004 Consultants engaged in Feb. 2004
Geological Surface Mapping along the entire alignment by -
For Detailed Geological Section
2004
Data input for Tendering and a Decision Support System for
ADIT and Shaft decision
–Adit & Shaft Work Awarded in June 2004
2004 Detailed Topographical Survey for Portal
Location
2005 Main Tunnel Construction Work Awarded in
August 2005 43

44. 44

45. 45

46. BASIC PRINCIPLES OF NATM
•Rock Mass is the major load bearing member
•Primary Support shall
maintain the integrity & strength of Rock Mass
light, have good and area contact (shotcrete)
strengthen Rock Mass (bolt, grouting)
provide protection to workers (steel rib, mesh)
installed quickly
•Provide always an effective ring closure, if
necessary by an invert if rock is not suitable

47. BASIC PRINCIPLES OF NATM (Contd.)
•Rounded shape of Cross-Section
•Continuous control of system behaviourby
monitoring
•Inner lining shall be installed only after
balance of stresses (“zero“ deformation)

48. 48

49. 49

50. 50
3D Monitoring Targets

51. 51

52. 52

53. 53
EXTENSOMETER

54. 54
FACE MAPPING

55. 55
PROBING SHEET

56. 56

57. 57

58. 58

59. 59
Deformation
Monitoring in Primary
Lining Before start of
Secondary Lining

60. 60

61. 61

62. 62Charging of Face

63. 63
Ventilation Duct

64. 64
Mucking

65. 65
Wire mesh & Lattice Girder Erection

66. 66
Face sealing
Face sealing by Shotcrete

67. 67
Drilling for Forepoling

68. 68Rock Bolting

69. TUNNEL MINING
Activity
Cycle Time (hr.) 2 mt.
RC IV
Cycle time (hr.) 1.25
mt. RC V
Drilling & Excavation 1.7 0.9
Charging , Blasting
& Defuming
2.7 1.5
Mucking 1.1 0.8
Wire Mesh & Lattice
Girder
2.4 2.3
Shotcrete 0.9 0.8
Rock Bolting 1.8 1.0
Preparation of new
face
0.3 0.3
Maintenance 1.6 1.1
Forepoling 1.6 1.7
Total 14.1 10.4 69

70. 70

71. 71Kicker Beam Casting

72. 72Geotextile Fixing

73. 73PVC Membrane Fixing

74. 74
Membrane Stitching

75. 75Reinforcement for Overt Lining

76. 76Reinforcement Cage for Inner Lining

77. 77
Concrete Lining Gantry

78. 78View of Finished Lining Concrete

79. 79
Profile Checking with Total Station

80. 80
Core Cutting

81. 81
Testing of Joints (Membrane)

82. 82
Sedimentation Tank

83. 83
Effluent Quality
Test Report

84. 84

85. 85

86. 86

87. 87

88. 88

89. 89

90. 90

91. 91

92. 92

93. 93

94. 94

95. 95

96. 96

97. 97

98. 98

99. 99