Challenges and results of Using hand mining to tunnel the mcalpine creek relief sewer
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1 96 th Annual NC AWWA-WEA Conference Chuck Shue, PE McKim & Creed, Inc. Senior Project Manager Challenges and results of Using hand mining to tunnel the mcalpine creek relief sewer
2 OUTLINE Project overview NCDOT Permitting Geotechnical investigations/reports Contract Documents Tunnel Construction
3 The project
4 Phase 3 tunnels Four NCDOT roadways, three CDOT roadways and CSX Railway Colony Road: Providence Road: Old Providence Road: Sardis Road: Monroe Road: CSX Railway: Independence Blvd. MCRS: Independence Blvd. ICRS: 66 Pipe (108 LF of 108 ID Tunnel) 60 Pipe (205 LF of 102 ID Tunnel) 54 Pipe (234 LF of 96 ID Tunnel) 54 Pipe (351 LF of 96 ID Tunnel) 54 Pipe (344 LF of 90 ID Tunnel) 54 Pipe (200 LF of 90 ID Tunnel) 36 Pipe (243 LF of 72 ID Tunnel) 42 Pipe (204 LF of 84 ID Tunnel)
5 Tunnel permitting Start early
6 NCDOT Permitting Timeline 2011 March Initially submitted encroachment permit package for the Providence Road tunnel on March 24, Submittal requirements: Drawings, Specifications, Calculations and Geotechnical data Professional Engineer s certification that the construction of the proposed tunnel will be safe and not damage the roadway june november december february Review comments received: June 7, 2011 Main comment to provide settlement calculations. Additional geotechnical investigation(s) required in order to gather data necessary to prepare settlement calculations Resubmittal on November 11, 2011 Additional comments received on December 1, 2011 Remaining tunnels submitted to NCDOT on December 13, 2011 Final approval for Providence Rd. tunnel received on February 3, 2012 and on February 14, 2012 for remaining tunnels Total elapsed time: Eleven Months
7 CSX Railroad Permitting Timeline 2012 january Initial submittal to CSX Transportation Inc. made on January 9, 2012 along with a review fee of $6,000 march Statement of Fees received from CSX on March 29, 2012: Amount Due= $18, Project Coordination Fee - $150 General Liability Insurance Surcharge, if applicable - $6000 One-Time License Fee - $12,0000 Amount Due= $18,150 may Resubmitted executed Facility Encroachment Agreement with $12,150 fee (General Liability Insurance Surcharge waived) on May 17, january The fully-executed original of Encroachment Agreement received January 03, 2013 Total elapsed time: one year
8 Geotechnical investigations / reports Original geotechnical investigation report dated March, 2000 Number of bore holes o Generalized Subsurface Profile - an approximate subsurface stratigraphy along the proposed tunnel o Disclaimer statement that Partially Weathered Rock (PWR), intermittent rock lenses and boulders may be encountered
9 Geotechnical investigations / reports Generalized Subsurface Profile
10 Geotechnical investigations / reports Additional geotechnical investigation(s) required in order to gather data necessary to prepare settlement calculations. o An empirical method was used to calculate the ground surface settlement. Results indicated that maximum settlement anticipated would be non-damaging settlement to the existing pavement.
11 Contract documents
12 Prime contractors/subcontractors 16 Prime contractors and 3 tunnel subcontractors were prequalified. Discovered during bid process that one tunnel subcontractor was out of business and another was not going to bid. Added Tunneling Subcontractor s Qualifications Statement to the documents and allowed tunneling sub-contractors to submit qualifications at the time of the Bid.
13 Pay Item Description Sanitary Sewer Pipe Installed in Tunnels Lump Sum Price Bid shall include: o Rock excavation Include excavation and removal of any and all obstacles Establish pay item for unexpected delays
14 Tunnel construction
15 surveying Control Alignment and grade monitoring Settlement monitoring
16 control M&C set specific control point for each tunnel M&C set offsets for tunnel begin and end M&C set offsets for tunnel shaft excavation cut M&C transfer control points
17 Alignment and grade monitoring Alignment and grade check (approximately every 50 feet) Alignment adjustments
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19 Settlement monitoring Establish grid of points Along centerline Ten-foot offset Leica ScanStation C10 Provides High-Definition Surveying TM Scanner, battery, controller, data storage and video camera Data Presentation Spreadsheets and image
20 Settlement monitoring Image from scanner
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24 Work in railroad right-of-way Start early
25 CSX Railroad Permitting Timeline 2013 december December 9 - Submitted Outside Party Request Form to start the CSX tunnel installation process 2014 january January 9 Contacted Shannon & Wilson (CSX s Engineering Consultant) January 10 Submitted settlement monitoring plan etc., to S&W, FL January 13 Submitted same to S&W representative in SC S&W/CSX put out for bid for flaggers (tentative date for flagger availability January 23. January 14 Tunnel pre-installation meeting January 21 Allowed to proceed.
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27 Work in ncdot right-of-way Providence Road
28 Ncdot right-of-way providence road 2013 march may june Pre-Installation Meeting for the Providence Road Tunnel scheduled for March 27, 2013 No one from NCDOT attended McKim & Creed forwarded tunnel information, including planned procedures, to NCDOT McKim & Creed met NCDOT in the field, May 20, 2013 Noted pre-existing settlement/cracking of the pavement Tunneling operations commenced - soil conditions inside the tunnel were described as solid & dry, good dig-able material. Tunnel shaft was flooded June 20, 2013
29 Material in tunnel changes to wet, gray sandy material. June 20, Cracks in asphalt observed. NCDOT shut down the tunneling operation. Contractor installed an asphalt wedge as a temporary fix.
30 Results of GPR and auger core indicated no voids were present under slab
31 july July 8, 2013 NCDOT shut down the tunneling operations again until the reasons for the settlement and remediation actions for the settlement have been investigated. Settlement investigation started July 9, Soil characteristics of the existing subgrade were less than desirable. The existing fill beneath the roadway sampled in these investigations also consisted of sandy silt with a soft consistency. The alluvial soils beneath the fill soils consisted of silt with sand, indicating a very soft to soft consistency.
32 2013 july Numerous s, telephone calls and meetings between July 2013 and March 2014 Plan to monitor settlement and prepare a restoration plan to commence once tunneling was complete Extended until after dewatering in the vicinity was complete 2014 march Providence Road Approach Slab Pre-Installation Meeting - March 25, 2014 april April 24, 2014 Restoration Plan Remove/replace both south side approach slabs of the Providence Road Bridge Remove/replace the concrete median and sidewalks on both sides of the roadway. Remove/replace five (5) foot section of asphalt beyond the south side approach slabs june Actual restoration occurred June 20 th June 24 th
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36 Csx railroad monitoring
37 Flagman must be present
38 Csx railroad monitoring Contractor s surveyor daily basis McKim & Creed check weekly basis
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40 Adjusted methods based on monitoring results Increased frequency of grouting annular space Added grout injection points Re-grouted completed liner plates Sounded liner plates
41 Disposal of tunnel spoil CSX prefers the spoil be disposed of on their property Mecklenburg County FDP prohibits fill in floodplain Off-CSX property disposal requires soil be tested, transported, and disposed of in accordance with CSX policy managed by their environmental agent, CCR Environmental Solutions Not included in CLTWater s agreement with CSX
42 Identify Utility Conflicts Start Early Piedmont Natural Gas Pipeline at Colony Road Tunnel Colony Road Tunnel alignment conflict with PNG pipeline Request to re-locate approximately 300 feet of existing pipeline Charlotte Water and PNG agreement City of Charlotte City council approval Easement acquisition Relocation complete
43 Piedmont Natural Gas Pipeline at Sardis Road Tunnel Sardis Road Tunnel elevation conflict Sardis Road Tunnel Request to re-locate approximately150 feet of existing pipeline Charlotte Water and PNG agreement City of Charlotte City council approval Relocation complete
44
45 Thank you for the opportunity. Questions
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