Australian Tunnelling Services are a consortium that has been formed to offer specialist underground services to both clients and contractors in the Civil Engineering, Mining & Building Industries. The range of services offered are construction, specialist plant hire, project management, consultancy and engineering design, bid management, tunnel survey and specialist tunnel equipment sales. The range of operations and services span throughout Australasia and SE Asia in metropolitan & remote areas. Our aim is to offer our customers the best service possible in achieving their underground construction requirements. This area of construction is complex and undertaking this type of work requires skilled and experienced personnel. The consortium that has been formed can provide these skills from the beginning of a project up until its completion. Please contact Australian Tunnelling Services for early discussions and a reliable source of information for all underground construction activities. Tel: 03 9740 7007 Neil: 0437 362 117 Tony: 0418 325 599 Email: neil@austun.com.au Website: www.austun.com.au
CONTENTS CONSTRUCTION SERVICES Caisson Shaft Sinking. 3 Shaft Sinking in Cohesive Ground Conditions 4 Drilling & Blasting Services 5 Rock Support 6 Pipejacking & Microtunnelling 7 Specialist Trenchless Services.. 8 Specialist Services Pressure Grouting. 9 Tunnel Lining. 9 Deep Excavation Works. 9 Provision of Tunnelling Operatives 10 Specialist Engineering Solutions.. 10 SPECIALIST PLANT HIRE Separation Plants. 11 Shaft Sinking & Tunnelling Equipment. 11 Tunnel Boring Machines. 12 SALES SPECIALIST TUNNELLING EQUIPMENT Palmieri Equipment.... 13 Trolex.... 14 FP McCann... 15 Mudtech...... 15 MANAGEMENT SERVICES Supply of Specialist Personnel. 16 Bid Management 16 Temporary Works Design. 16
CCAISSON SHAFT SINKING Australian Tunnelling Services has many years experience in sinking shafts in soft ground conditions. When a shaft needs to be sunk underwater or in wet ground that has no stand up time then this method of construction is the ideal solution. Two methods of construction are offered. The first method is to sink the caisson using hydraulic rams and precast concrete segments as the primary support. This is ideal for shafts to be used as access for tunnelling operations and future manholes. Shafts up to 25m in diameter can be constructed by this technique. The concrete lining remains in the ground after construction is complete. This photo shows a typical general arrangement for a caisson constructed using precast concrete rings. In this case an 8m diameter shaft is being pushed down below the water table using 6 number 75t hydraulic rams. The picture below is the scene inside the shaft as the first bucket of the day is being removed from the water. For pumping station and manhole construction an alternative technique is to use a steel lining as the caisson which remains in place during the construction of the permanent works. Once complete the steel lining is pulled out of the ground leaving the permanent structures in place.
CSHAFT SINKING IN COHESIVE GROUND CONDITIONS In ground conditions where the ground has a stand up time and ground water is minimal or can be controlled by sump pumping our method of shaft sinking is by Underpinning. Using this technique the shaft is constructed by removal of the ground using excavators and cranes followed by the installation of precast concrete segments which hang from the previously constructed ring. This method has advantages over the caisson technique due to the minimal set up time and costs, and control over the shaft position and orientation. The photo above shows a completed 10.5m diameter shaft that has been constructed by underpinning. Ground conditions were clay with negligible groundwater encountered. The shaft contains a corbel ring to be used for an intermediate landing slab in the future pumping station. The photo below is taken from the bottom of a 30m deep, 7.5m internal diameter underpinned shaft. Segmental rings are available from 2.5m internal diameter up to 25m internal diameter. They are popular for tunnel construction access, with the inclusion of tunnel eyes for TBM launch and removal plus excellent thrust walls for pipejacking operations. Their robust nature also makes appropriate permanent works structures possible once tunnelling activities have been completed.
Drill & Blast is a specialist area in Civil & Mining and part of the ATS consortium is to provide this service for Shaft & Tunnel Construction, Quarrying & Underground Mining activities. There are three types of explosive classification in which ATS can offer their services. Conventional explosives providing all the necessary power for traditional rock breaking, low scale explosives and non explosive rock breaking technology. The use of low scale explosives and non explosive rock breaking are becoming more and more popular in sensitive areas. ATS has the experience to carry out this type of work including blast design, drilling and shotfiring. The photo on the left shows the charging of a low scale explosive being used to break sandstone for the sinking of a 4.7m shaft. The shaft was being constructed in a residential area where the use of conventional explosives was not permitted. The massive nature of the rock enabled support methods to be limited to the use of rockbolts and mesh only. The shaft was sunk to a depth of 35m using this drill and blast method.
ROCK SUPPORT TUNNELS, SHAFTS, MINES, CUTTINGS All of these types of excavation often require permanent or temporary support when a rock face is exposed. Our experience in mines and tunnel construction has enabled ATS to be able to provide one or a combination of various types of rock support. Whether it be rockbolting, mesh, lattice girders and shotcreting or a combination of these support methods then ATS will be able to supply the skilled personnel and equipment to install your geotechnical requirements. The photo above shows a basalt rock face being supported with split sets, geo mesh and shotcrete. The excavation was 8m deep with a plan area of 20m X 6m to be used for the construction of 7 parallel pipejacked tunnel drives.
PIPEJACKING & MICROTUNNELLING Depending on project requirements ATS are able to offer solutions to all types of tunnel construction using pipejacking as the tunnel support mechanism. The range of tunnel sizes that we specialise in using Pipejacking techniques is between 1000mm & 3000mm pipe diameters. Our expertise allows for tunnel construction in all ground types ranging from water bearing sands and gravels through to hard rock. We have experience in the use of Slurry type TBMs, Earth Pressure Balance Machines, Open Faced tunnelling equipment and for short length drives, hand driven shields or timber heading. The picture on the right is taken from a recent contract whereby twin 2m ID pipes were pipejacked to construct part of a new drainage system in SE Melbourne. The excavation was carried out by hand using traditional tunnelling methods.this type of tunnel construction is still popular for short or blind drives and where ground conditions are favourable. The photo on the right shows is taken from a contract in Darwin where ATS provided Project Management Services. The mts Perforator slurry type TBM tunnelled through rock to install a 1000mm OD GRP Pipe. Tunnel drives up to 150m were constructed as part of this sewage scheme for Power & Water. In this photo the machine has just been launched, the trailing can protruding from the launch eye. The hydraulic rams were aable to provide up to 250-t of force to push the pipeline in to the ground. At peak production 10 pipes per shift were installed using this tunnelling technique.
SPECIALIST TRENCHLESS SERVICES There are a number of other trenchless techniques available for underground tunnel construction. Two techniques that Australian Tunnelling Services specialise in are auger boring and the installation of square or rectangular culverts by pipejacking. Auger bore diameters range from 300mm to 1500mm and are most common for trenchless crossings as part of long pipeline installations. This method of trenchless technology is a very fast and cost effective way to install pressure pipes under roads, rivers and rail lines. More designers are nowadays looking to install precast concrete culverts by trenchless methods. As this method becomes more popular in urban areas Australian Tunnelling Services can now offer the service of jacking these units in to place. Support varies from bespoke shields or pre installed canopy tubes using small diameter auger bores. Both methods offering a solution to the often difficult problem of installing culverts. The photograph above shows the inside of a 1500mm casing shortly after the breakthrough of a 25m long auger bore. The drive, through a weathered rock using a Robbins head, was installed over 1 day after the initial site establishment.
SPECIALIST SERVICES PRESSURE GROUTING TECHNIQUES Many underground structures require specialist grouting once the lining has been installed or as part of rehabilitation works. Using specialist plant Australian Tunnelling Services are able to carry out pressure grouting for the filling of pipeline annuluses, structural improvement of existing underground structures and grouting in the ground as part of ground treatment techniques. Using cementitious material or specialist chemicals our range of grouting capabilities will be able to offer clients and contractors a solution to many complex problems associated with underground pressure grouting requirements. TUNNEL LINING Many older structures can be rehabilitated using tunnel lining methods to save on the cost of installing new tunnels and pipelines. There are a number of relining techniques available and Australian Tunnelling Services specialise in the insertion of new linings by pushing new pipes in to existing pipelines or relining using shotcrete or in-situ concrete lining. Whatever the choice of the asset owner existing tunnels over 1000mm in diameter can be relined at a fraction of the cost of installing new pipelines. Whether the relining is used in conjunction with the in house pressure grouting facility or a one pass structural lining this method of pipe rehabilitation can be designed and constructed by Australian Tunnelling Services. For deep excavations our range of services includes spoil excavation, shoring installation base construction (dry or underwater & tunnel eyes. This service is offered for the contractor who has pre-installed extensive ground shoring, e.g. sheet piled cofferdams or secant piled shafts, and requires the expertise to complete the shaft construction works. Most designs of this type are unique and ATS are able to offer the most cost effective solution by using specialist plant and equipment and skilled labour. DEEP EXCAVATION WORKS
PROVISION OF TUNNELLING OPERATIVES Using its extensive network throughout the Tunnelling Industry ATS are able to supply skilled personnel for all types of tunnelling projects. There are a number of key personnel that make up a successful tunnelling team, including TBM & roadheader operators, shotfirers, ring builders, TBM fitters and electricians, grouters, loco drivers, pit bottom operatives, tunnel liners and dogmen. Whether a contractor requires one or a number of operatives for their tunnelling project then ATS will be able to supply these key personnel. SPECIALIST ENGINEERING SOLUTIONS Underground construction requirements often require solutions that require specialist input to solve. There is always more than one method for the construction of an underground asset however the best solution is regularly overlooked. The main reason for this is that people are unaware of the solutions available to them. The result can be expensive both financially and damage to a company s reputation can occur when these operations go wrong. Using their many years experience and the knowledge gained from many underground operations ATS are always able to provide the best solution for complex underground construction. Using any of the methods available from their construction services or a combination a solution will be available. The solution will ensure that a project is delivered on time, on budget and in compliance with all the various legislation that exists in relation to the construction process. The photograph above shows a TBM in the process of a new skin being fitted for the installation of 1650mm ID Concrete Jacking Pipes. ATS carried out all of the engineering works for this complex procedure. The main challenge ensuring that when the TBM returned to site it could immediately go into production without any delays. The tunnelling project was successfully completed with no delays due to its new size and detail.
Australian Tunnelling Services have a range of plant available for hire specific to shaft sinking and tunnelling operations. Our plant is hired out at very reasonable rates, well below the normal market values. This, coupled with the excellent maintenance programme that all of our plant undergoes, makes the hiring of plant and equipment a simple choice for contractors. Most tunnelling plant and equipment is available directly or through our worldwide network of suppliers. All enquiries are welcome as all types of equipment are available. Enquiries for any equipment that is required but not listed below can be made to ATS and availability and price will be sourced. Separation Plants; The MAB range provided by Schauenburg are available for sale or hire through Australian Tunnelling Services. The MAB series of Separation Plants caters for all tunnel sizes that are using slurry TBMs for tunnel construction. These units are an excellent choice for service & reliability which is essential for maintaining maximum production. These units are often the preferred choice of tunnelling contractors throughout the world as an essential element for successful tunnel construction. SHAFT SINKING AND TUNNELLING EQUIPMENT; Australian Tunnelling Services hire out a wide range of equipment including; Manboxes Gas Detectors Shaft Sinking Rams, Gallows & Power Packs Caisson Cutting Edges Colloidal Pumps & Mixers Muck Handling Skips Tunnel Rail, Locos & Bogeys Hausherr H11 Picks & FL22 Clay Diggers Specialist Pressure Grouting Plant Pipejacking Equipment (Pit Bottom Rams, Interjacks, Bentonite Stations)
TBMs: Australian Tunnelling Services can offer the hire or sale of TBMs. Whether it be closed face machines such as slurry type or earth pressure balance machines or open faced machines ATS will be able to offer solutions to a contractors TBM requirements. For any enquiries regarding technical advice or availabilty and price then ATS are ready to assist with TBM selection and procurement.
We have exclusive arrangements with a number of overseas suppliers who specialise in tunnelling, shaft sinking and many other underground construction related products. Palmieri www.palmierigroup.com Palmieri manufacture and supply microtunnelling machines, tunnel equipment, TBM cutterheads, back up systems, rolling stock and muck haulage products, belt conveyors and segment handling systems and vertical drilling systems (blind boring & raise boring)
Trolex www.trolex.com
FP McCann www.fpmcann.co.uk FP MCann manufacture precast shaft segments for caisson and underpinned shaft construction. Their range is far greater than current local suppliers have to offer and shaft diameters range in size from 3.66m to 15m. Mudtech www.mudtech.co.uk Mudtech specialise in the research, development and supply of specialist products for EPB tunnelling and conditioning of soils for successful excavation and muck handling.
PROJECT MANAGEMENT SERVICES SUPPLY OF SPECIALIST PERSONNEL Tunnelling is a skilled profession. Unfortunately too many contractors and clients underestimate the importance of hiring skilled people to manage a tunnelling project. Results of such ventures can often be calamitous when tunnelling projects go wrong. Australian Tunnelling Services realise the importance of providing key personnel for complex underground operations. Project Managers, Engineers and Tunnel Surveyors are all available for tunnelling projects. BID MANAGEMENT Our experience in all sizes of Tunnelling Projects enable Australian Tunnelling Services to offer estimating and programming input to all types and sizes of project. We have the resources to provide estimates for complex projects and smaller scale operations. Shafts, tunnels, drainage schemes, deep excavations and associated civil engineering works can all be included in our estimates. Whether a client requires estimates for planned schemes and projects, check estimates from contractors or assessment of contractors claims then ATS will be able to assist. For contractors we can offer estimates that include experienced productivity input, a large network of worldwide tunnelling suppliers from where to source specialist equipment and a realistic estimate for tender purposes. DESIGN & PROCUREMENT Many solutions exist for an underground construction project. Using an experienced contractor to design your underground requirements should be the first task an inexperienced contractor or client undertakes before committing to a complex project. Temporary works design is one of the most important elements in the construction of underground infrastructure. There are far too many cases of projects where temporary works has been used to suit a contractor s existing assets instead of the design being based upon the project conditions. ATS will offer a design solution to a complex project and be able to provide all of the specialist equipment required for the construction process.