AlpTransit Gotthard and Lötschberg Rowa s Contribution

Transcription

1 AlpTransit Gotthard and Lötschberg Rowa s Contribution

2 Contents Introduction Overall View Lötschberg and Gotthard Lötschberg Base Tunnel Mitholz Raron Gotthard Base Tunnel Amsteg Sedrun Bodio Membrane-placing Machine Brøyt The Human Being is the Focus of our Attention

3 AlpTransit Rowa takes part in it The new Gotthard and Lötschberg railway routes through the Alps are undoubtedly Switzerland s greatest construction projects of the 21 st century. Rowa, as a supplier of special installations for underground construction, was especially challenged by these projects. Rowa took up the challenge with success. This is what we would like to show you in this brochure. We are the experts. Rowa is one of the world s leading suppliers of back-up installations, special equipment for rock support, membraning and lining, logistics systems for supply and removal, as well as providing consulting and engineering services. Our installations have proven successful in over 150 important projects. Mechanization is the future. We are convinced that long tunnel headings be they effected by tunnel boring machine or by blasting can only be realized economically, quickly and safely with a high degree of mechanization. By following this principle, we were able to supply, for the Gotthard and for the Lötschberg projects, several complete systems adapted to the specific conditions of the projects. Investments result in a net profit. We are conscious of the need to realize an increased efficiency and profitability in order to justify the investment. Thanks to transparent and understandable productivity calculations and by optimizing the investment and operating costs, we have been able to convince our customers of the net profitability of our installations. The overall view is our strength. We don t just sell our products, but we see our Rowa installations as components of a complex construction process. Thanks to our know-how in the area of tunnel construction and in the design and manufacturing of equipment we are able to understand and solve the interface problems between the construction process and the installation. We take your problems into account at a very early stage. We studied the AlpTransit project during the planning stage. This enabled us to submit our innovative solutions to our customers in a very early stage of the tender procedure. Rowa s staff is highly motivated. We know that our success on the market depends on innovation, high performance and on putting the customer s interests first. Thanks to our expertise, our motivation and our spirit of responsibility we have created individual, fully developed and economically advantageous solutions. In practically all the headings for the Gotthard and the Lötschberg base tunnels there are Rowa installations working. In addition to our well-tried existing products we have realized some interesting new developments. Their range is impressive and comprises individual single components as well as complete logistics systems and back-up systems for tunnel boring machines and for tunnelling by blasting. We hope you will enjoy studying this brochure. Jürg Leuthold Chief Executive Officer

4 Rowa in the Lötschberg Frutigen Mitholz Multi-functional Advance Installations for three Drill & Blast Headings Logistics for three Headings with 18 km Conveyor Belt Ferden Two Brøyt Tunnel Excavators Membrane-placing Installation Advance Installation for 5 km Drill & Blast Heading Steg Raron

5 Rowa in the Gotthard Erstfeld Amsteg Two TBM High Performance Back-up Systems Four multi-functional Advance Installations Installation for the Excavation of the Cross Passages Sedrun Three Rotary Tipplers Brøyt Tunnel Excavator Four Membrane-placing Installations Access Tunnel Lot 552 Faido Shotcrete Robot Ventilation Installation and Infrastructure Train TBM Back-up System Bodio Muck Tunnel Lot 551

6 Lötschberg Base Tunnel Mitholz From the Rock Face to the Spoil Tip at the Touch of a Button The construction lot Mitholz plays a crucial role for the completion of the Lötschberg base tunnel within the agreed time. Two tunnels are driven 8.7 km to the south and one tunnel 6.9 km to the north. The three simultaneous, high efficiency advances, carried out by blasting come together at the low point Mitholz. Supply and removal for the three tunnels takes place here. Rowa has developed, for Arge SATCO Mitholz (Strabag, Rothpletz Lienhard, Walo Bertschinger, Dumez, Skanska International), a fully mechanized complete system with a logistics concept that caused quite a sensation, in spite of being still widely unknown. Only the continuous material flow from the rock face to the spoil tip made the desired performances possible. A conventional transport system would have considerably restricted the capacities. High-efficiency Advance Installation Rowa supplied 3 high-efficiency advance installations, which allow for top performances thanks to the high degree of mechanization. The suspended platform carries the necessary infrastructure equipment and allows the tunnel invert to be clear for construction a short distance behind the face. In addition, there is an area available for parking, for excavated material and for other equipment. An area crane, operating underneath the platform, makes it possible for all materials to be transloaded and brought to the respective workplaces without hindrance.

7 Lötschberg Base Tunnel Rowa-Highlights Continuous material transport Reduction of traffic on the construction site to a minimum Uninterrupted supply to the construction site Conveyor Installations Rowa developed the logistics system and supplied the entire conveyor installations with a total belt length of over 18 km for the removal of the excavated muck from the rock face to the spoil tip at the low point Mitholz. The removal of the excavated material for both parallel headings is by a continuous conveyor. A reversible conveyor transports the material through the cross passages to the main conveyor. The transverse conveyors can be relocated without the operations being interrupted. Initial Doubts A logistics system with such a high degree of mechanization as put forward by Rowa had never been realized before. Therefore, the people on the construction site initially had serious doubts about its feasibility. But, after some minor technical adjustments during the start-up period, the advance performances which could be achieved thanks to the Rowa system, filled the site management as well as the works personnel with enthusiasm. Dipl. Ing. Oskar Roittner, Strabag AG The complete system designed by Rowa represents a genuine innovation for the conventional advance by blasting. The performances which have been achieved with this system confirm that the decision to entrust Rowa with its supply was correct, technically as well as economically. Conveyor belts with a length of over 18 km transport the excavated material to the spoil tip from three advances by blasting. Return on Investment A mechanized advance means high investment. Thanks to detailed productivity calculations, Rowa was able to demonstrate to the customer that the investment for a Rowa system would be more than compensated by the corresponding return from high performances and optimized operating costs. Rear of the advance installation with airduct storage for fresh air and and evacuation of the explosive gases in the starting phase.

8 Lötschberg Base Tunnel Raron Maximum Performance, Workplace Safety and less Personnel Starting from the portals Raron and Steg, two tunnel boring machines have excavated the Lötschberg base tunnel to the Ferden section. For economic reasons, the 4.6 km long western tube starting from the portal Raron was excavated by blasting. Rowa refined the existing concept for the Mitholz installations and supplied to the Arge MaTrans (Marti, Balfour Beatty, Porr, Züblin, Walter Bau) a high-performance advance installation which comes up to the highest expectations. High-performance Heading Installation Rowa refined the installations of the Mitholz lot for the Raron construction site. The heading installation allowed to a large extent to complete the invert construction about 200 m behind the rock face. Extensive support measures can be carried out during the advance operation, without any adverse effects on the performance. Training The higher the degree of mechanization and systematization of the advance operation, the higher the demands on the personnel regarding control, maintenance and observance of the work cycles. Rowa trains the customer s personnel and thus contributes to safe operation, to accident prevention and to the best possible performance. The separation of fixed installations from the transport and excavation equipment increases considerably safety, quality of the workplace and performance. Dipl. Ing. FH François Bertholet, Project Manager Arge MaTrans The use of the suspension platform has proven to be successful. Thanks to the continuous material flow and to the availability of two working levels top performances could be achieved. At the same time, the suspension platform guarantees the maximum workplace safety. Rowa experts help staff and workers to get acquainted with the installation.

9 Gotthard Base Tunnel Amsteg Highest Performance and optimized Costs thanks to a well thought-out Complete System Starting from the intermediate point Amsteg, two tunnel boring machines are excavating about 11 km of the two tubes of the Gotthard base tunnel to the south, to the meeting point with the advance of the Sedrun section. Rowa supplied to Arge AGN (Strabag AG, Murer AG) two high-performance TBM back-up systems, as well as an installation for the excavation of the cross passages, which contribute to the highest possible advance performances while optimizing the operating costs. Highest possible availability the key success factor in mechanized tunnel construction. Rowa back-up systems guarantee functionality, quality and safety. Rowa-Highlights Continuous material flow for supply and removal Reduction of interdependencies to a minimum Separation of the working areas and processes High flexibility High-performance Back-up Installation In close cooperation with Arge AGN, Rowa developed the back-up system for the tunnel boring machine. A suspended monorail railway makes it possible for the material to be transported without transloading from the supply train to its destination. Thanks to the suspended platform and a double-track rail service up to the invert construction area, the invert can be built at the same speed as the advance progresses. A longitudinally movable shotcrete robot with a 360º working area applies shotcrete support to the excavated section.

10 Gotthard Base Tunnel Suspended Platform The tunnel invert is being constructed simultaneously with the advance. A suspended platform bridges the invert construction area. Thanks to the working area being clear the operations can take place in a flexible and efficient way, independent from the advance. The length of the suspended platform has been optimized, working together with the customer, for the planned performances and work processes. Independent Monorail The monorail is suspended from the tunnel crown and is independent from the rest of the back-up system. This allows for rock support material, shotcrete etc. to be transported without transloading from the supply train to the workplace. The idea of the monorail comes from the mining industry. Rowa has successfully adapted the system for tunnel construction. Dipl. Ing. Hans A. Treichl, Strabag AG AGN and Rowa have together developed a highly mechanized complete system, which has been perfectly adapted to the construction processes. Rowa has proven to be a highly competent and efficient partner for the solution of all logistics problems. Also the assembly and the start-up were carried out expertly and within the given time limits. Cross Passage Installation For the excavation of the cross passages, Rowa has developed a complete installation which makes it possible for cross passages to be excavated simultaneously with the main tunnel advance. With this installation, the cross passage excavation can be carried out efficiently, while protecting the installations of the main advance. The complete equipment can be moved on the rails of the back-up platform and thus transported from one cross passage to the next. Assembly In order to keep the launching chamber as short as possible, the tunnel boring machine started working with a rudimentary back-up system. After an advance of 500 m, the tunnel boring machine was stopped and the back-up installation was completed. Thanks to the meticulous preparation of the assembly and good logistics planning, the tunnel boring machine could resume its operations after a very short time. Thanks to a well thought-out pre-assembly, taking into account the cramped space conditions, the back-up systems could be assembled in record time. Direct Placing of the Order Whilst the tunnel boring machine and the backup system are usually supplied together by the manufacturer of the tunnel boring machine, Arge AGN Murer/Strabag preferred to place the order for the back-up system directly with Rowa. This has proven to function perfectly. The interface problems could be managed without any difficulties, and the contractor had an experienced logistics partner available.

11 Gotthard Base Tunnel Sedrun Know-how, Innovation and Closeness to the Customer help to find the best possible Solution At the intermediate Sedrun location of the Gotthard base tunnel two tubes are being driven through difficult geological zones, 1.5 km to the north and about 3.5 km to the south. The excavation takes place using heading anchors and radial anchors, with massive steel reinforcement and shotcrete. Deformations of the diameter of up to 1.5 m have to be expected. Supply and removal run through an access tunnel and two vertical shafts of 800 m depth. Rowa has developed, for Arge Transco-Sedrun (Batigroup, Frutiger, Bilfinger und Berger, Pizzarotti), a complete system for the four highly mechanized special advances and supplied, in addition, three rotary tipplers for the transloading of the excavated material at the portal. An uncompromising mechanization, also in a conventional heading, increases performance, productivity and safety. Rowa-Highlights Uncompromising mechanization of the excavation support Performance and safety thanks to two working levels Efficient supply with heavy-duty crane Creation of a second working level Multi-functional Heading Installation The installation consists of the special machine for rock support with working baskets, displacing arms, shotcrete robot etc., the loading installation for the loading of the muck trains, a 20 t heavy-duty crane for the supply to the workplaces, a suspended platform with installations for ventilation, cooling etc. and a supply train with infrastructure equipment.

12 Gotthard Base Tunnel Special Machine for Rock Support With the special machine for rock support the ring beams are placed by bundle and by segment. The installed shotcrete applicator seals the profile. With two cutting scissors the previously placed heading anchors can be removed efficiently and safely after every blast. Thanks to the suspended construction and the special machine for rock support the tunnel constructor has a second working level at his disposal, as well as a clear working, manoeuvring and parking space on the invert. Infrastructure and Supply Trains The infrastructure and supply trains, which have been designed in close cooperation with the contractor, are an important link in the chain of the mechanized advance operation. Infrastructure and material supply are at the correct location at the correct time, in correct quantities. Dipl. Ing. ETH Luzi Gruber, Batigroup AG The Sedrun project is extraordinarily challenging for the tunnel constructor as well as for the manufacturer of the installations. That s why we backed Rowa right from the beginning and developed together an installation which is made-to-measure for our construction contract. This installation will allow us to achieve the required performances, even under the most difficult conditions, while guaranteeing the maximum possible workplace safety. Rowa has taken our requirements into account in a very professional way. Rotary Tippler Rowa Rotary III Rowa designed three rotary tipplers for the discharge of the muck trains. The rotary tippler takes up two cars with 24 m 3 excavated material. The cars are centred and held automatically. The entire tippling process is controlled by the locomotive driver. During the tippling operation, the driver doesn t have to leave the driver s platform. Development not Invention Long tunnels can only be built efficiently with mechanized processes. Together with our customers, we analyse construction procedures and construction technology. We don t invent new things, but we look for known technologies and use them in tunnel construction. The concept of the special machine for rock support is being used in mining and was re-designed by Rowa in cooperation with experienced mining engineers of the GTA company, in order to be suitable for the Sedrun advance. The multi-functional advance installation during assembly. With the rotary tippler, Rowa Rotary III, the locomotive driver discharges a train with 150 tons of excavated muck in less than 10 minutes.

13 Gotthard Base Tunnel Bodio Rowa Products: competitive, safe and of the highest Quality Starting from Bodio and up to the intermediate point Faido, the Gotthard base tunnel is being excavated with two tunnel boring machines. They were transported into the mountain through a bypass tunnel and assembled in caverns. The excavated material is transported from the portal to the spoil tip through a muck tunnel. Rowa supplied to Arge LGV, (Pagani, Infra 2000), a tunnel boring machine back-up system for the lot 551 Bodio muck tunnel. For the access tunnel (lot 552) Rowa supplied to Arge Batigroup, Frutiger the ventilation installation and an infrastructure train. In the main advance of the lot Bodio/Faido the shotcrete robots developed by Rowa are in operation. Back-up System for the Muck Tunnel Rowa supplied the back-up system for the tunnel boring machine in the muck tunnel with a diameter of 5 m. The preconditions were a daily advance of m, the placing of ring beams, mesh reinforcement and anchors, as well as applying shotcrete. Rowa can also be considered a competitive supplier in the area of these well-tried installations. Shotcrete Robot Rowa supplied to SikaBau AG two longitudinally and radially displaceable shotcrete robots for the backup system of the main advance. The robots with their longitudinal pathway of 9 m and their ability to cover 270º are used for the area L2. Rowa designed a device consisting of two swivelling motors and two lifting cylinders which allows the operator of the nozzle to cover the whole area in a perfect way. Ventilation Installation and Infrastructure Train Equipment developed by Rowa is also being used in the area of supply and removal. Rowa supplied the ventilation installation for the access tunnel (lot 552) as well as an infrastructure train which is perfectly adapted to the specific construction procedures. Thanks to our know-how in construction technology and procedures we are in a position to optimize the logistics system. Back-up system for a hard rock tunnel boring machine of small diameter. Shotcrete robot for the back-up system of the Herrenknecht tunnel boring machine. The Rowa infrastructure trains are adapted to construction procedures, project and customer requirements.

14 Lötschberg and Gotthard Base Tunnel Membrane-placing Maschine Consistent further Development and Cooperation to the Advantage of the Customer In the project of the century AlpTransit safety and quality are essential. This is especially the case with regard to membrane lining in the tunnels. Hightech installations, the highest possible degree of mechanization and the uncompromising quality assurance process guarantee the requested quality as well as the highest performance. The Rowa membraneplacing installations of the 5 th generation were developed upon request of Arge IGS (SikaBau AG, Tecton AG) and are being used in the lot Bodio/Faido of the Gotthard base tunnel. Another membrane-placing installation was supplied by Rowa to the membraning joint venture Züblin, Schmutz for the Steg/Raron lot of the Lötschberg base tunnel. Membrane-placing Machine V The membrane-placing machine developed in cooperation with membrane specialists is designed for maximum performances and corresponds at the same time to the quality criteria. The installation is the result of the experiences of Rowa and of the cooperating membrane specialists from various tunnel projects. The Result of the Experiences of many Years Rowa has been manufacturing membrane-placing machines for the most varying tunnels and membraning systems. The equipment has been continuously refined in intensive cooperation with the customers and adapted to the newest developments in membrane lining technology and in the technology of plant manufacturing. The highest possible degree of mechanization increases performance, productivity, quality and safety in the area of membraning technology, too. Rowa membrane-placing machine V Dipl. Ing. ETH, lic. iur. Pius Weber, SikaBau AG In 1972 Rowa designed for the first time, upon request by SikaBau AG, a device for the placing of tunnel membranes. Its objectives were to substitute human labour by machinery and to increase the safety of the workers. Since then, the Rowa equipment was continuously refined and has been used widely throughout Europe, Latin America and Asia. Especially for the AlpTransit project Gotthard-Ticino and according to our preconditions Rowa developed membrane-placing machines of the newest generation. They are equipped with an electronically controlled hydraulic contact beam and a synchronous control of operator s basket and contact beam. All the participating parties, owner/construction management, the contractors joint venture TAT and the membraning joint venture IGS acknowledge the outstanding system and the quality of the Rowa-equipment.

15 Lötschberg and Gotthard Base Tunnel Brøyt The Tunnel Excavator as Part of the entire System The AlpTransit tunnels consist of two separate tubes. The resulting excavated cross sections of m 2 set space limits for the equipment to be used. The use of a compact, manoeuvrable muck-handling equipment which is still capable of top performances can determine the advance performance. Rowa evaluated the optimum muck-handling equipment for various construction lots, came up with the Brøyt tunnel excavator as the best solution and proved it by the subsequent experiences. A Brøyt ED600 operated successfully in the lot 552 of the Gotthard base tunnel (Access tunnel Bodio, Arge Batigroup, Frutiger). Rowa supplied two additional excavators to Arge Ferden (Losinger, Prader, Bouygues and group LEDIT) of the Lötschberg base tunnel. Brøyt Tunnel Excavator The Brøyt is acknowledged to be one of the most robust and capable muck-handling equipment for tunnel construction. Especially in the cramped space conditions of the AlpTransit tunnels, the manoeuvrability of the Brøyt stands out. Rowa provides Evidence Rowa provided first-hand evidence for the capability of the Brøyt tunnel excavator to a gathering of tunnel construction experts in the Bodio bypass tunnel. Brøyt and Muck-handling by Conveyor? Rowa developed an economic solution for the feeding of crushing machine and belt conveyor, so as to be able to also use the Brøyt in headings with muck-handling by conveyor. 300 m 3 /h, no problem for the Brøyt even in tunnels with small cross section.

16 Lötschberg and Gotthard Base Tunnel The Human Being is the Centre of our Attention: qualified and highly motivated Heinz Jenni, Overall Project Manager Sedrun It is a unique challenge to have the opportunity to contribute to the construction project of the century. With the Sedrun heading installation, which we developed in cooperation with Arge Transco, we can make an important contribution to overcoming the problems of one of the geologically most difficult sections of the project. Jost Wenk, Overall Project Manager Amsteg We are not inventors... Long tunnels can only be built efficiently with mechanized procedures. Together with our customers we analyze constructional technology and construction procedures. We don t invent new devices, but we use well-tried technologies and adapt them to the specific conditions of tunnel construction. Hansruedi Bart, Project Manager Assembly The customer expects a high degree of availability of the equipment right from the start. Usually, the assembly has to take place in a cramped space and under difficult logistical conditions. Therefore, detailed assembly and logistical planning is essential, as well as a close cooperation with the customer and third parties and a continuous controlling of quality and deadlines. Urs Thali, Project Manager Design Membrane lining know-how, tunnel construction logistics and plant manufacturing technology have to come together in the design of membrane-placing machines. Thanks to the intensive cooperation with the customer we were able to develop an installation which meets all the requirements regarding quality, performance, safety and profitability. Mariano Targa, Structural Engineer Suspended platforms have to be distortion-free and must resist the highest stresses in tunnel construction. Thanks to their flexibility the loads can be distributed in an optimum way, and therefore economic solutions are possible in spite of extremely high loads. Rinaldo Geronimi, Project Manager Design In all our designs, the aspect of user-friendliness is essential. Equipment used in tunnels has to be simple, sturdy and safe. Good accessability and simple handling are equally important. In the case of complex installations, every design detail has to be studied and approved by the customer, not only the overall concept of the installation.

17 We look ahead... Prof. Dr. Ing. h.c. Robert Fechtig and go ahead... Rowa Tunnelling Logistics AG, Leuholz 15, CH-8855 Wangen SZ Phone +41 (0) , Fax +41 (0)