Moncton Watermain Relocation Moncton, New Brunswick. TRS 2010 Dr Mark Knight University of Waterloo

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1 Moncton Watermain Relocation Moncton, New Brunswick TRS 2010 Dr Mark Knight University of Waterloo

2 Presentation Outline Overview of the project Design and construction Issues Trenchless construction Lessons Learned 2

3 3 Moncton New Brunswick

4 Moncton and Riverview New Brunswick Causeway with gate on Riverview side Petticodiac River 4 Petticodiac Lake

5 Petticodiac River Flows into Bay of Fundy Tidal estuary World s largest tides ±40 feet every 5.5 hours Unique tidal bore (up to 2m high wave pre 1960 s) 5

6 6 Petticodiac River The river is 129 km long and has a 3,000 km² drainage basin. Largest River basin in Eastern Canada Commercial fishing industry existed on the Petticodiac until the late 1960s Atlantic Salmon, Gaspereau (Alewife), Smelt and Sturgeon

7 7 Moncton Ship Building

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10 Causeway Construction Controversial construction of causeway begins

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17 Impact of Causeway Construction Petticodiac Lake Headpond is formed Volume of water (tidal prism) is substantially reduced Volume of sediment in the river is increased dramatically 17

18 18 Impact of Causeway Construction

19 19 Impact of Causeway Construction

20 20 Impact of Causeway Construction

21 Impact of Causeway Construction Post causeway Tidal bore a few centimetres to 0.75m high Pre causeway up to 2m high No fish passage Loss of estuary, rare shell fish and fish... 21

22 River Restoration Project Remove causeway and gates and replace with bridge 22

23 Three Stage Project Stage 1 protection and preparatory works Relocate watermain located in front of gates dykes, riprap, design, and baseline monitoring $20 million Stage open gates during spring flush and monitor Stage construct and operate the bridge and monitor Total project cost estimate $68 million 23

24 Project Overview Moncton Former Landfill Existing Watermain Causeway Gates 24 Moncton Watermain Relocation Riverview

25 Project Requirements Moncton Riverview Conceptual Transmission Line 25 Moncton Watermain Relocation

26 Project Requirements Open cut Connection Moncton Trenchless Connection Open cut Riverview 26 Moncton Watermain Relocation

27 Key Project Requirements Install new 762mm (30in) ID watermain Conceptual pipe alignment length is approx. 550m Minimum top of pipe depth is -6m for scour protection under new channel Trenchless Pipe test pressure is 1655kPa (240psi) Open cut pipe test pressure is 1379kPa (200psi) 27 Moncton Watermain Relocation

28 Key Project Requirements Design and build contract to include: Trenchless and open pipe installation Connection to existing watermain Watermain commissioning Critical commission date is February 28, 2010 Need spring runoff to clean out sediment deposits in Petticodiac River 28 Moncton Watermain Relocation

29 PROJECT DESIGN TEAM Project Client New Brunswick Department Supply and Services Consultant Consortium AMEC Causeway Project Lead Paul Belyea P.Eng. Geotechnical Engineer ADI Limited Watermain Reconstruction Project Lead Boyd Touchie Project Manager Dr. Mark Knight Trenchless Expert Jacques Whitford Associates (Stantec Consulting) Geotechnical Lead Dr. Arun Valsangkar P.Eng. 29 Moncton Watermain Relocation

30 Project Design Approach 1. Prequalify contractor Ensure have equipment and experience to complete project Ensure completed similar projects in the past. 2.Contractor design build project Ensure project constructible using contractor equipment 3. June 11, 2009 issue Request for Qualification (RFQ) documents 4. June 29, 2009 RFQ closed Three responses submitted and one late submission Design team reviewed and rated submissions No contractor qualified 30 Moncton Watermain Relocation

31 Project Design Approach Phase II Design-Build is best contract approach to ensure project completed on time and budget Design team will complete construction design review to determine costs and construction issues Will invite three contractors to respond to request for proposals Design team will recommend three contractors to bid Design team will prepare RFP for October 2009 contract award Each contractor will be paid $40,000 for submission of a complete bid package 31 Moncton Watermain Relocation

32 Proposed Project Milestones Proposed Date August 14, 2009 September 1, 2009 September 15, 2009 October 2, 2009 October 5, 2009 October 19, 2009 December 29, 2009 February 5, 2009 February 28, 2009 Milestone Description RFP to Proponents Bidder Meeting and Provision of Information Package Submission of RFP to NBDSS Contract Award Placement of Pipe Order Equipment Mobilization and Commencement of Site Works Commencement of Trenchless and Open Cut Pipe Works Completion of Pipe Installations and Pipe Connections Watermain Commissioning 32 Moncton Watermain Relocation

33 Design Brief To ensure successful on budget and on time project Design Team needed to identify: construction risks and challenges project costs 33 Moncton Watermain Relocation

34 Design Brief Looked at three construction options: 1. A1 Horizontal Directional Drilling (HDD) 40in Steel then slipline with 36in OD HDPE product pipe 30in Ductile Iron as product pipe 2. A2 Horizontal Directional Drilling (HDD) Install two 24in steel casing and slipline with 24in HDPE 3. B Microtunnel 34 Moncton Watermain Relocation

35 Inferred Site Geology Along Conceptual Alignment 10.0m 0 m 100m 200m 300m 400m 500m 600m BH27 BH26 BH25 Sand BH24 BH7 BH23 BH6 BH22 0.0m -10.0m Till Head Pond Fill (Gravel) Silt Silt Sand -20.0m Bedrock Till Sand with gravel -30.0m 35 Moncton Watermain Relocation

36 Option A1 - HDD to -8m Install steel casing: slip line with 762mm(30in) product pipeline BH m Sand 0 m 100m 200m 300m 400m 500m 600m BH6 BH26 BH25 BH24 BH7 BH23 BH22 0.0m -10.0m -20.0m Till Bore reamed to 1321mm (52in) Bedrock Head Pond Fill (Gravel) Silt Silt Till Sand Sand with gravel -30.0m 36 Moncton Watermain Relocation

Option A1 - HDD to -8m Install steel casing then slip lined with 762mm(30in) product pipeline Pipe length = approx 530m (1739 feet) Drill entrance angle 17 degrees Drill exit angle 8 degrees Drill

37 Option A1 - HDD to -8m Install steel casing then slip lined with 762mm(30in) product pipeline Pipe length = approx 530m (1739 feet) Drill entrance angle 17 degrees Drill exit angle 8 degrees Drill exit before drainage ditch Causeway Existing Ditch Headpond Sand Till Very Loose Silt Silty Sand Bore ream to 1321mm (52in) Till Sandstone/Mudstone bedrock Fill Fill Very Loose Silt Sand and Gravel 37 Moncton Watermain Relocation

38 Option A1 - HDD to -8m Install steel casing: slip line with 762mm (30in) product pipe Install 1016mm (40in) steel casing 12.7mm (0.5in) thick in a 1321mm (52in) reamed borepath Required to withstand installation forces Eliminates post construction decontamination issues Estimated required drill rig pipe pullback force: 1505kN (338,500lbs force) with rollers and pipe buoyancy 2962kN (666,000lbs force) with no rollers and pipe buoyancy 38 Moncton Watermain Relocation

39 Option A1 - HDD to -8m 914mm (36in) DR-11 HDPE product pipe 914mm (36in) DR-11 HDPE (PE3408) product pipe approved by AWWA 1103 kpa (160 psi) working pressure - Max test pressure is 1655 kpa (240psi) which meets City design criteria Pipe ID is 738mm(29.06in) with OD =914mm (36in) Diameter less than 762mm (30in) required Pipe price quoted at $305,000 Pipe fusion price quoted at $25,000 Currently new PE4710 (new resin) is not AWWA approved for potable water therefore not considered for this project 60-day lead time required for pipe delivery 39 Moncton Watermain Relocation

40 Option A1 - HDD to -8m 762mm(30in) Ductile Iron Product Pipe 762mm(30in) ductile iron with Flexi-joint as product pipe 1724kPa (250psi)working pressure- max test pressure is greater than 2069kPa (300psi) exceeds design requirements Pipe ID is 785mm(30.9in) with bell joint OD of 937mm(36.9in) Will fit inside 1016mm (40in) steel pipe 85 days lead time required for pipe delivery Pipe cost $452,000CAD ($400,725USD) Corrosion protection and monitoring needs to be addressed in design and construction 40 Moncton Watermain Relocation

41 Option A1 - HDD to -8m Construction Risks Major risk is bore collapse in silty sand on Moncton side Risk can be reduced by: Soil characterization of lower fill Using smallest diameter bore Installation of conductor steel casing Careful selection/monitoring of drill fluids Inadvertent drill fluid release Risk can be reduced by: Monitoring bore drill fluid pressure and drill procedures 41 Moncton Watermain Relocation

42 Option A1 - HDD to -8m Cost Estimate $5 to 6 million Includes pipe materials, drilling, site preparation and pipe installation Does not include open trench pipe construction, concrete valve chambers and connections 42 Moncton Watermain Relocation

43 Option A2 - HDD to -8m Install two 711mm(28in) steel casings Slip line with 610mm(24in) product pipe 10.0m 0.0m -10.0m BH27 0 m 100m 200m 300m 400m 500m 600m Till Sand BH26 BH25 Till -20.0mBore reamed to 1016mm (40in) Bedrock Bore reamed to (40in) BH24 BH7 BH23 BH6 Head Pond Fill (Gravel) Silt Silt BH22 Sand Sand with gravel -30.0m 43 Moncton Watermain Relocation

44 Option A2 - HDD to -8m Install two 711mm(28in) steel casing then slip lined with 610mm(24in) product pipe 1016mm (40in) reamed bore path required Option is not considered feasible as it requires drilling two bores of similar diameter to option A1 610mm (24in) is not significantly less than Option A1 762mm (30in) product pipe Installation of two pipes will require complex connection issues 44 Moncton Watermain Relocation

45 10.0m Drive shaft 0.0m -10.0m Option B - Microtunnel BH27 Reception 0 m 100m 200m 300m 400m shaft 500m 600m Till Sand BH26 BH25 BH24 BH7 BH23 BH6 Head Pond Fill (Gravel) Silt Silt BH22 Sand -20.0m Bedrock Till Sand with gravel -30.0m 45 Moncton Watermain Relocation

46 Option B - Microtunnel Option B requires two shafts 18m (59ft) deep drive shaft on Riverview side at BH21 18m (59ft) deep reception shaft on Moncton side at BH16 Drive distance approx 500m (1640ft) Drive will require at least two internal intermediate jacking stations (IJS) to complete drive 46 Moncton Watermain Relocation

47 Option B - Microtunnel Distance of drive is approaching current laser technology limits Alignment passes through mixed ground conditions Bedrock, till, silty sand and sand/gravel At least 1524mm (60in) boring machine required for person entry and access to machine face Machine diameter limited to contractor availability Person entry/face access requires safety issues 47 Moncton Watermain Relocation

48 Option B Microtunnel Shafts Moncton side shaft design and construction challenging due to: Soft soils and upward gradients Resisting hydrostatic and earth pressures will require robust bracing system Grouting of bedrock required to control hydraulic gradients Need testing and monitoring to determine effectiveness Sheet piles must be driven to bedrock even for shaft base at elevation - 8 to -10m Cost estimate $3.0 to $4.0 million Construction could take several months to complete Risk of major delays due to shaft construction difficulties 48 Moncton Watermain Relocation

49 Option B Microtunnel Risks Mixed face and variable ground conditions Wear on cutters Safety requirements for personnel to access face and remove intermediate jacking stations Limit of laser alignment technology offline and grade will significantly increase jacking force 49 Moncton Watermain Relocation

50 Cost Estimate Shafts Total cost for construction of two shafts $3 to $4 million Pipeline installation $5 to $7 million Function of diameter of machine used and difficult to estimate Total pipeline cost estimate $8 to $11 million 50 Moncton Watermain Relocation

51 Others Considerations Looked at HDD into bedrock as proposed in RFQ Construction will require 30m (98ft) plus shaft at BH-16 Method deemed not constructible due to: Need to construct deep shafts Pumping and operation issues resulting from deep shafts Cost 51 Moncton Watermain Relocation

52 Summary HDD Option A1 Microtunnelling Trenchless Pipeline Construction Cost $5 to 6 million $5 to 7 million Shafts None required Moncton and Riverside $3 to 4 million total Auxiliary construction* $1.2 million $0.8 million Total Cost $6.2 to 7.2 million $8.8 to 11.8 million *Includes: open trench pipe laying, connections, concrete chambers, and site works 2 million project budget needed to be increased 52 Moncton Watermain Relocation

53 Risk and Material HDD Option A1 Microtunnelling Pipeline Installation: Risk of Failure Shafts : Risk of Construction Delay Low-medium in silty sand Low in till and bedrock None Medium to High High Pipe Product Ductile Iron PCCP, Ductile, HDPE Casing 1016mm (40in) steel 1524mm (60in) concrete or steel 53 Moncton Watermain Relocation

54 Design Issues Proposed bridge embankment will induce loads on pipe Embankment loads need to be considered in the pipe design Any minor changes in location of bridge abutment will have direct impact on the watermain design and performance Data from BH 36 indicates coarse rock fill may exist to elevation -11m Geotechnical boring data critical to successful project 54 Moncton Watermain Relocation

55 RFP Three companies selected and requested to bid on RFP $40,000 provided to companies to cover bid costs provided complete bid package submitted Required stamped engineering design drawings Two bids received $6.4 and $7.2 million Michels Canada awarded contract Used detailed bid review scoring system (cost 20 percent) Each design team member reviewed bids independently 55 Moncton Watermain Relocation

56 Construction Bore depth -10m Install casing on Moncton and Riverview Complete an intersect bore using American Augers DD220 Moncton side (pipe entrance) American Augers DD330 Moncton side (pipe entrance) Estimated Max pull back 152,000lbs with buoyancy and 325,000lbs with air in pipe Install 36in HDPE pipe 56

57 Intersect Bore Construction 10.0m 0 m 100m 200m 300m 400m 500m 600m BH27 BH26 BH25 Sand BH24 BH7 BH23 BH6 BH22 0.0m -10.0m Till Head Pond Fill (Gravel) Silt Intersect Point Silt Sand -20.0m Bedrock Till Sand with gravel -30.0m 57

58 58 Construction

59 59 Construction

60 60 Construction

61 61 Push-Pull Ream Construction

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63 Construction Project completed on time and budget No significant construction issues Geotechnical data was accurate Contractor stated project with best geotechnical data Causeway Gates opened April 14, Moncton Watermain Relocation

64 Lessons Learned Formation of design team was critical Project required to be contractor design build Meet tight construction details Geotechnical data critical for route selection Completion of design review critical to identify critical issues Geotechnical issues Project cost Pipe order and delivery issues Project schedule Trenchless construction requires design by experienced engineers 64 Moncton Watermain Relocation

65 Questions

APPENDIX I. Conceptual Design - Salem Road and McKay Road Trunk Watermain and Sanitary Sewer

APPENDIX I. Conceptual Design - Salem Road and McKay Road Trunk Watermain and Sanitary Sewer APPENDIX I Conceptual Design - Salem Road and McKay Road Trunk Watermain and Sanitary Sewer THE CITY OF BARRIE PROJECT NO. 15M-00594-01 CONCEPTUAL DESIGN SALEM ROAD AND MCKAY ROAD TRUNK WATERMAIN AND SANITARY