Innovative Methods Tame Multi-Diameter Microtunneling Project

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Ross Rogers
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1 Innovative Methods Tame Multi-Diameter Microtunneling Project Mark H. Bruce Can Clay Corporation Clay Pipe Since 1906

2 City of Atlanta CSO Remediation Plan $3.9 billion Clean Water Atlanta program Consent Decree with Federal EPA End water quality violations resulting from CSO s Greensferry, Stockade and McDaniel basins exceeded $250 million on three separate contracts

3 Project Goals & Conditions Combined sewer separation Open Trench construction Microtunneling construction Urban settings September, 2007 Deadline

4 Stockade Basin Plan

5 Combined Sewer Separation Stockade & Greensferry Project Ruby Collins Reynolds EPR J.V. Microtunneling sub-contractors Westcon McCowein Rock Drilling McDaniels Project Rockdale, Inc. Microtunneling sub-contractor Huxted Tunneling, Inc.

6 Microtunneling Equipment Slurry Microtunnel Soltau Iseki Pilot Tube Microtunneling Akkerman, Hyd. Powered Head Soltau Tooling Microtunneling, Inc. Pin Lube Halco/McCowein Impact Hammers/Reamers

7 Slurry Microtunneling

8 Pilot Tube Microtunneling

9 Diverse Sizes of Microtunneling Pipe 8-inch, VCP 1312 ft 12-inch, VCP 2204 ft 18-inch, VCP 2233 ft 20-inch, VCP 200 ft 24-inch, VCP 1912 ft 30-inch, VCP 4963 ft 42-inch, VCP 2024 ft Total, VCP 14,848 ft

10 Extraordinary Challenges 24 Microtunneling drive to eliminate closing a school during session 18 Microtunneling drive in granite rock with + 50,000 psi compressive strengths Completing the projects for Consent Decree mandated deadline

11 New Techniques/Tools Pin Lube System innovative system that can reduce friction can lower jacking loads can increase distance Impact Hammer Microtunneling 18 diameter pipe 50,000 psi granite Guided to +- ½ accuracy

12 Pin Lube Site Modification to existing slurry machines First used in U.S. on this project 24 and 42 diameter slurry machines used by Westcon Microtunneling Initially installed on 42 machine with successful results Added to 24 machine to prior to attempting record drive length for this diameter System provided by Microtunneling, Inc.

13 Typical Slurry Microtunneling Machine Iseki Uncle Mole

14 Pin Lube System, Internal View Inset Pin Lube in 42 inch Soltau

15 Pin Lube Components Internal Threaded Head Mounted in 3 Staggered Rows Pins, Threaded Base No Threads on End Lubrication Ports in Front of Pins Injection valves controls lubrication separately from other lubrication to machine

16 Pin Lube System, External View Injection Port 3 Rows of Pins Pin Lube Location on Machine

17 Pin Lube Theory Plows soil around full circumference Not suitable for rock, boulder or cobble conditions Injection of lubricant at the pin locations with separately controlled injection ports Creates a ring of lubricant mixed soil for maximum lubrication benefit Creates a dam around the pipe to allow pressurization of lube around pipe

18 Challenge Keep School Open! Westcon Microtunneling was challenged to complete a drive at a school that was originally designed to be two drives The school would have had to be closed to achieve the original two drive plan The project mandated completion date of September, 2007 would be jeopardized by waiting until the school was closed during the summer.

19 Solution Attempt the World Record Length for a 24 Microtunnel Pipe Westcon, Ruby Collins Reynolds EPR JV and Can Clay reviewed the proposed conditions Can Clay s 24 Denlok jacking pipe was rated by 1008 tons by the manufacturer Westcon calculated the friction load to be a maximum of 403 tons using published engineering factors

20 Record Project Data Evaluated Can Clay reported significant jacking strengths above its 1008 ton rating & agreed to 403 ton load Safety factor evaluated at 2.5 : 1, the typical minimum General contractor reviewed the submittals by Westcon and Can Clay Project Engineer approved the record 750 ft length drive

21 Record Drive Attempted Westcon added the PIN Lube system to the microtunneling machine Westcon minimized downtime with near continuous operations Diligent steering was minimized to ASCE recommended 1:250, 0.23 deg. High amounts of lubricants were used

22 Record Achieved Jacking loads were only 37 tons!! International Record Drive length for 24 diameter pipe of any kind!! Everyone was happy!!

23 Surprise! Rock not Clay Soil Originally thought to have soils that were capable of being microtunneled with conventional machines Granite encountered 15 ft from surface Total shaft depth 40 ft 4 drives required from 1 shaft

24 Solution Try Something Never Before Done Tunnel a small diameter tunnel on line and grade 18 Diameter VCP design +- ½ line and grade deviation

25 Shaft Drilled The shaft was drilled in two weeks Four drives were jacked from one shaft Drilled Jacking Shaft, Unlined in Lower Portion

26 Shaft Construction Upper portion in clays Upper portion was lined Lower portion in rock Lower portion unlined Shaft; Upper Portion Lined, Lower Portion Unlined

27 Akkerman Pilot Tube 308 GBM

28 Really Hard Rock Small Tools 4.5 Pilot Tube Upsized to 16 Upsized to 26 Strengths were recorded at between 34,000 psi and 50,000 psi on the first 3 drives +50,000 psi compressive strengths were recorded on the 4 th drive

29 Tooling Required Custom Modifications on Site by Contractor

30 Video of Impact Hammer Pilot Tube Microtunneling

31 Drive Completed Lowering VCP Pipe

32 Installed 18 VCP 18 inch (450 mm) Pilot Tube Tunnel in Granite

33 Records Set on Atlanta s CSO Projects 24 X 750 ln ft Slurry Microtunnel International Record Granite 18 Diameter Guided +- ½ Line and Grade

34 Project Successes Completed on time Successful design Minimized urban disruptions Met EPA mandated requirements

35 Thank You! Questions? Mark H. Bruce President Can Clay Corp. Clay Pipe Since 1906

Pipe Jacking/Microtunnelling. Dr. Mark Knight. Centre for Advancement of Trenchless Technologies (CATT) University of Waterloo.

Pipe Jacking/Microtunnelling. Dr. Mark Knight. Centre for Advancement of Trenchless Technologies (CATT) University of Waterloo. Pipe Jacking/Microtunnelling Dr. Mark Knight Centre for Advancement of Trenchless Technologies (CATT) University of Waterloo 1 New Installations New Installations Non-Steering Methods Steering Methods