The Robbins Company. Bheri Babai Diversion Multipurpose Project (BBDMP) Company Facts. Headquarters

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1 Bheri Babai Diversion Multipurpose Project (BBDMP) Presented by Jim Clark, Projects Manager India The Robbins Company THE ROBBINS COMPANY THE ROBBINS COMPANY Company Facts More than 50 years of innovation and experience, More than 900 Employees worldwide Annual sales exceeding $300 million We hold almost 90% of TBM tunneling world production records Headquarters Front of office building SOLON, OHIO, USA Solon, Ohio, USA Facilities include: Administration USA Equipment production Engineering staff Field service staff

2 THE ROBBINS COMPANY Facilities in 11 Countries Worldwide Robbins Europa -- Italy Roboretec -- Romania Robbins China -- Shanghai Robbins China -- Guangzhou Robbins Asia Pacific Hong Kong Brisbane Robbins GmbH -- Germany Robbins India New Delhi Robbins España Madrid Robbins Mexico Mexico City Robbins TBM Korea Seoul Representatives in 35 countries Robbins Experience in India ROBBINS EXPERIENCE IN INDIA Almost 70 km of tunnels bored to date Metro Water Transfer Hydro Electric Power 300 Employees 25 expats AMR Water tunnel

3 ROBBINS EXPERIENCE IN INDIA Alimineti Madhava Reddy Water Tunnel 2 x 10.0 m Diameter double shield TBMs Length 43.5 km. Longest tunnel in the world without intermediate access. Granite & Quartzite, UCS up to 300 MPa Robbins responsible for all TBM related activities Mumbai Water tunnel ROBBINS EXPERIENCE IN INDIA ROBBINS EXPERIENCE IN INDIA Mumbai Water tunnel Mumbai Water tunnel Tunnel length 8.3 Km 6.25 m Open Gripper machine Shaft depth 109 m Continuous conveyor system Vertical conveyor system Bored over 8 km in 18 months Over 60 m bored in 24 hours Indian record of 870 meters in a month

4 ROBBINS EXPERIENCE IN INDIA Jaipur Metro Jaipur Metro TBM s bored beneath heritage structures Only 5 m of cover Robbins provided key personnel & operators Took full responsibility for boring beneath the gate ROBBINS EXPERIENCE IN INDIA ROBBINS EXPERIENCE IN INDIA Chandpole gate Foundations made up of irregular size stone blocks Limited resistance to settlement Lime mortar joints in poor condition Riddled with cavities Contract limit of 4 mm settlement Jaipur Metro whoever destroys, injures, mutilates, defaces, alters, removes, disperses, misuses, imperils or allows to fall into decay a protected monument, or removes from a protected monument any sculpture, carving image, bas-relief, inscription or other like object, shall be punishable with imprisonment for a term which may extend to six months with a fine which may extend to five thousand rupees or with both

5 TBM SELECTION BBDMP TBM Selection Geology and overburden Mostly sandstone & Mudstone Some conglomerate Two thrust/shear zones Babai thrust (100m from portal) Bheri thrust (5,800m from portal) Up to 800m overburden Shielded machine best suited to geology TBM SELECTION TBM SELECTION Construction Schedule Necessity to finish the project in 54 months Absence of intermediate adits boring and lining must proceed concurrently High Performance Double Shield TBM is required Benefits of Double shield TBM Rapid tunnel and lining progress Secure the immediate stabilization of the tunnel walls Act as a final lining, not requiring any further working phase Immediately reducing any water inflow into the tunnel

6 TBM SELECTION TBM Specifications TBM Manufacturing, Delivery and Assembly TBM MANUFACTURING, DELIVERY & ASSEMBLY TBM MANUFACTURING, DELIVERY & ASSEMBLY Manufacturing & Assembly Critical components are manufactured in the USA and Europe Shipped to Robbins facility in Shanghai for assembly Testing, Disassembly & Shipping Full factory testing of machine (FAT) Machine then disassembled and shipped by sea to Kolkata Then 1,300 km overland from Kolkata to the project site

7 TBM MANUFACTURING, DELIVERY & ASSEMBLY TBM MANUFACTURING, DELIVERY & ASSEMBLY Site Assembly Site Assembly Machine arrived on site the first week of September 2017 Assembly of the TBM commenced 10th September 6 weeks taken to complete assembly, commissioning and push machine to the face of the starter tunnel PRODUCTION TO DATE Production to Date Learning curve A learning curve is factored into all production predictions for TBM driven tunnels. Prediction for this tunnel was a learning curve of 3 months at 250m production per month (750m total) Boring commenced Early November 2017 TBM completed 330m of boring in November By Mid December after only 6 weeks of tunneling the TBM passed the 750m in 3 months learning curve target. Excellent achievement by any standards.

8 PRODUCTION TO DATE First 6 months The machine has completed almost 4 km during the first 6 months of boring Best 24 hours 52.9m Best week 285m Best month/30 day period 1057 m Challenges Ahead? CHALLENGES AHEAD CHALLENGES AHEAD Main Areas of Concern Inundation Squeezing ground Slabbing/Spalling ground Jointed and blocky rock Water ingress Bheri thrust/shear zone estimated to be 400m wide

9 PROBE DRILLING/GROUND TREATMENT Probe Drill Probe Drilling/Ground Treatment The probe drill is used for probe and grout holes It can also be used to relieve hydrostatic pressure at the face By drilling relief holes through the segmental lining behind the machine PROBE DRILLING/GROUND TREATMENT PROBE DRILLING/GROUND TREATMENT Grout Packers Mechanical packer Can be inserted to approx 4-5m. May not be long enough to prevent grout return into bored tunnel in fractured rock Inflatable packer Can be extended and inserted up to 10m+. Can be placed ahead of the tunnel face to prevent grout return. Operations carried out in 2 separate phases Primary holes drilled first Packers inserted into holes Pressure gauge is connected to the packer in any hole that shows water ingress. Water pressure is measured Injections begins from lowest holes Injection pressure is dictated by hydrostatic pressure

10 PROBE DRILLING/GROUND TREATMENT Secondary phase begins once primary phase completed Secondary or control holes drilled. Experienced geologist must monitor the drilling Observe the effects of the primary injection Packers inserted in selected holes if required Injection sequence repeated Squeezing Ground SQUEEZING GROUND SQUEEZING GROUND TBM Shields becoming trapped CHD Diameter 5,060 mm -Diameter of Front/ Telescopic Shield 4,990 mm (70 mm clearance) Diameter of Gripper Shield/ Tail Shield 4,910 mm (80 mm clearance) 35 mm of radial overcut is also available TBM Shields becoming trapped Single shield mode TBM gripper shoes are retracted Main thrust cylinders closed up Auxiliary thrust cylinders are utilized to push machine By thrusting off the segmental lining 40% additional thrust 38,475 kn

11 BURSTING and SPALLING GROUND Shield Design Bursting and Spalling Ground Designed to deal with bursting or spalling ground Cope with extreme loading Protect the tunnel personnel Provide support to the ground continually Up until erection of segmental lining BURSTING and SPALLING GROUND Cutterhead design Low profile muck buckets Reduce possibility of pulling in loose rock Large capacity and smooth throat Able to handle the large amount of broken rock produced in high speed production. BBDMP Summary

12 SUMMARY Selected correct Machine for the Job Initial 500m excavated by Robbins plus training Experienced contractor Good site set up Experienced project team Production to date is very good Caution required when approaching Bheri thrust Zone First TBM project in Nepal has exceeded target Now expected to be huge success TBM can be refurbished and utilized on other projects. Questions?