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Hard rock

Leesburg Inter-Quarry Tunnel - Execution

Service Performed
Site supervision on behalf of Luck Stone Corporation including supervision of all SEM activities, quality assurance services, cost and schedule control and design coordination on site.
Commencement - Services
April 01, 2018
Completion - Services
March 01, 2019
Location
Leesburg Plant
20210 Luck Lane
Ashburn, Virginia, VA 20147
United States
Geology description

Located within the Culpeper Basin, a sedimentary rock formation characterized to be of Lower Mesozoic Age. The existing Luck Stone quarry is situated in a Diabase intrusion (dyke) of this sedimentary rock.

Geology types
Hard rock
Description

Luck Stone Corporation (LSC) is the nation's largest family owned and operated producer of crushed stone, sand and gravel. At their plant in Leesburg, Virginia, Luck Stone Corporation acquired a new quarry, which is located to the West of Goose Creek river. An inter-quarry tunnel was constructed to link the existing South-Eastern pit with the new West pit. The tunnel's cross section is approximately 45 feet in diameter, and the tunnel's length is approximately 1275 feet. The tunnel crosses the Goose Creek river approximately 50 feet beneath. The excavation method was drill and blast in hard rock (diabase).

Activity
Special Construction techniques
Tunneling under
Tunnel length
1275 feet
South-East portal - final stage
South-East portal - construction stage
Project number
242E
Final cost
$13 million USD

Leesburg Inter-Quarry Tunnel - Design

Service Performed
Conceptual design with various tunnel options. Final tunnel design consisting of drawings, specifications, and calculations. Client support during bid phase.
Commencement - Services
January 01, 2017
Completion - Services
April 01, 2018
Location
Leesburg Plant
20210 Luck Lane
Ashburn, Virginia, VA 20147
United States
Geology description

Located within the Culpeper Basin, a sedimentary rock formation characterized to be of Lower Mesozoic Age. The existing Luck Stone quarry is situated in a Diabase intrusion (dyke) of this sedimentary rock.

Geology types
Hard rock
Description

Luck Stone Corporation (LSC) planned to open a new quarry on the Western side of Goose Creek river, a component of the Virginia Scenic Rivers System. A tunnel was envisioned to connect the new Western quarry with the existing South-Eastern one below the river. The rock cover between the tunnel and the river was approximately 50 feet. The tunnel is 1275 feet long with a diameter of 45 feet. It is designed to accommodate large scale mining trucks as well as a conveyor belt for material transport which is scheduled to be installed in the future.

Activity
Construction methods
Special Construction techniques
Tunneling under
South-East portal excavation sequence
South-East portal excavation
Vertical bench drilling
Project number
242D
Final cost
$13 million USD

Luck Stone Fairfax Plant – Inspection Works

Service Performed
In-depth inspection of a connector tunnel in accordance with TOMIE manual and the SNTI manual of the U.S. Department of Transportation - FHWA.
Commencement - Services
July 01, 2016
Completion - Services
July 31, 2016
Location
15717 Lee Hwy
Centreville, VA, VA 20121
United States
Geology description

The prevalent rock type of the tunnel is diabase. The rock mass is moderately jointed, with closely to very closely spaced joints. The rock is slightly weathered.

Geology types
Hard rock
Description

Inspected tunnel connects two quarries at the Luck Stone Corporation Fairfax plant. The tunnel crosses beneath the Lee Highway (US Route 29), in a North-South direction. Built ca. 1975, the tunnel is partially unlined and in rock; approx. 190 feet long and approx. 22 feet wide and 22 feet high. As the Northern quarry side is already exhausted, the tunnel is rarely used with just one or two transits per day.
Dr. Sauer & Partners performed an in-depth inspection of a connector tunnel; assessed the tunnel condition and provided remedial measures.

Activity
Service areas
Construction methods
Tunneling under
Connector Tunnel - North Portal / Highwall
Connector Tunnel - South Portal / Highwall
Project number
242E1
Final cost
n/a

Brenner Base Tunnel - Lot H51 Pfons-Brenner

Owner
Service Performed
Dr. Sauer & Partners provided tender support services.
Commencement - Services
December 01, 2016
Completion - Services
April 18, 2017
Location
Innsbrucker Bundesstraße 67
5020 TYROL
Austria
Geology description

Located within the Alps, the geology comprises phyllite, schist, marble and gneiss including main fault zones as well as major water ingress sections combined with a maximum overburden of 1300m.

Geology types
Hard rock
Description

The Brenner Base Tunnel (BBT) is a 64km long railway tunnel connecting Austria and Italy. Once completed, it will be the world's longest rail link underground. In addition to the two main tubes, the project comprises a complex set up of exploration adits, crosscuts, emergency stops and additional access tunnels, excavated by TBM and SCL methods. Dr. Sauer & Partners provided tender support services for the 18km lot H51 Pfons-Brenner and was responsible for creating the bid documents as well as conducting QA/QC services. The documents covered issues such as TBM choice, annular gap filling, reuse of excavated rock, rail delivery of construction materials, construction logistics and pre-excavation grouting.

Activity
Categories
Construction methods
Max Overburden
1300
BBT alignment (courtesy of BBT SE)
Lot H51 alignment (courtesy of BBT SE)
Project number
486C
Final cost
€1.3 billion EUR

Los Bronces Mine

Service Performed
Dr. Sauer & Partners provided conceptual design and basic engineering.
Commencement - Services
August 01, 2009
Completion - Services
November 01, 2011
Location
Los Andes
Valparaíso
Chile
Geology description

The geological setting is dominated by the volcanic activities of the region and includes magmatic rocks such as monzonite, andesite, and dacite.

Geology types
Hard rock
Description

Los Bronces copper mine, an open-pit operation at an altitude of 3500m ASL in the Chilean Andes, planned to utilise a tunnel for further deposit exploration and development. The project consisted of an 8.2km tunnel link between Los Bronces and Confluencia, connecting two processing plants. By applying drill and blast methods, a chamber was prepared to launch a 4.5m diameter tunnel boring machine which took over further excavation. A difficult geological and hydrological setting, extreme weather conditions as well as the high altitude and the rough terrain, provided a challenging environment.

Activity
Final cost
$6,000,000
Construction methods
TBM Tunel Sur (http://www.construccionminera.cl)
Tunnel excavation with TBM
Project number
432C
Final cost
$6 million USD

Reshen Kalimash Motorway Project

Service Performed
Dr. Sauer & Partners in joint venture with iC Consulenten provided mitigation and tunnel stabilisation as well as NATM redesign following a tunnel collapse.
Commencement - Services
November 01, 2009
Completion - Services
July 01, 2010
Location
Sami Frasheri No. 33
Tirana
Albania
Geology description

The geological setting is influenced by the Alpine geosyncline resulting in a complex tectonic behaviour of a variety of igneous and metamorphic rocks cut by major fault zones.

Geology types
Hard rock
Description

A major collapse during construction of the Thierre Tunnel in 2009 led government officials to call on NATM experts to come up with an innovative fix for the 5.6km, two-lane twin tunnel, which is part of the new Reshen Kalimash Motorway. Recommended stabilisation measures by the Dr. Sauer/iC JV such as backfilling, ribs and fibre shotcrete were implemented and halted creep movements. An alternative design was developed and replaced the original horseshoe profile by an ovoid shape. Pre-treatment, excavation works and support installation were accompanied by extensive monitoring.

Activity
Final cost
$1,000,000,000
Construction methods
Tunneling under
Stabilisation measures: Backfill and fibre shotcrete "egg"
Ovoid shape emerging from horseshoe profile
Project number
428E
Final cost
$1 billion USD

Cigar Lake Operation

Owner
Service Performed
Site supervision services, consulting, monitoring and on-site design performed by senior engineer and two tunnel inspectors.
Commencement - Services
September 01, 2012
Completion - Services
August 01, 2015
Location
2121, 11th St W
Saskatoon, SK S7M 1J3
Canada
Geology description

Highly thermo hydraulically weathered metapelites in form of weak rock and clayey-silty-sandy soils, highly anisotropic, cut with slickensided graphitic planes.

Geology types
Hard rock
Description

Cameco Cigar Lake is the world's highest grade uranium deposit. It is considered one of the world's most technically challenging uranium deposits to mine. The ore body and the ground around has to be bulk frozen prior to extraction of the ore using high pressure water jets. Development of the freeze/production cross-cuts take place beneath the ore body in unstable, soil-like highly weathered and anisotropic rock. A flexible shotcrete lining with longitudinal slots of special yielding elements together with systematic rock bolting were utilized to cope with squeezing ground conditions.

Categories
Final cost
$50,000,000
Construction methods
Special Construction techniques
Pocket excavation in unstable ground conditions
Installed yielding elements prior to spraying shotcrete
Project number
455E
Project Type
Final cost
$50 million CAD
Completion date
Ongoing

Exchange Place Station - Path Line Improvements

Service Performed
Tunnel excavation geometries, lattice girder geometries and layout.
Commencement - Services
October 01, 2002
Completion - Services
October 01, 2003
Location
225 Park Ave S
New York, NY 10003
United States
Geology description

Heavy foliated gneiss, schist, schistose gneiss with pegmatite intrusions occasional amphibolite; transitional (slope/rise) rock.

Geology types
Hard rock
Description

Exchange Place is a key station on the PATH commuter rail service between New York and New Jersey. After the World Trade Center collapse, the station and river crossing running tunnels were closed. Precautions were taken to prevent flooding of the subway system from broken water mains and sewer lines. Turning existing elements into a terminus and extending the platform tunnels by 45m involved excavating new crossovers, modifying the 5 existing tunnels, raising the invert and crown up to 3m and back filling unneeded tunnel spaces to create the ground in which new spaces could be excavated.

Activity
Final cost
$25,000,000
Construction methods
3D Model of Exchange Place station
Lattice girder and shotcrete for support
Project number
355D
Final cost
$25 million USD

Léon-Asturias High Speed Rail, Pajares LOT 2

Service Performed
Construction inspection and scheduling for initial and final liner and waterproofing; analysing monitoring data and project's progress; daily site inspection and ground conditions reports.
Commencement - Services
May 01, 2006
Completion - Services
June 01, 2016
Location
Avda.Tenerife 4
28700 S.S. de los Reyes Madrid
Spain
Geology description

The predominant rock formation is the Lancara Formation consisting of dolomite, red limestone and gray limestone. The design groundwater head is 434 m.

Geology types
Hard rock
Description

The Pajares Rail Tunnel is part of the new Leon-Asturias High Speed Rail Line, and with a length of 25.7km one of the longest tunnels in the world. The project encompasses twin 10m dia. TBM hard rock tunnels, bifurcation chambers, cross passages, and emergency stops. The tunnel is lined with a pre-cast segmental lining made from high-strength with a thickness from 50 to 60cm. The connection between the access tunnel and the main tunnel requires the construction of a large-span Bifurcation Chamber and a short mined tunnel.

Activity
Categories
Final cost
$250,000,000
Construction methods
Special Construction techniques
Tunnel length
25.7 km
Numerical Analysis of Bifurcation Chamber
Completed Bifurcation Cavern
Project number
397D
Final cost
$250 million USD

High Speed 2

Service Performed
High level consulting and feasibility studies, coordination of common design approaches (Focus Group) and preparation of deliverable approach statement (outline design criteria).
Commencement - Services
April 01, 2012
Completion - Services
October 01, 2013
Location
1 Canada Square
London
E145AB
United Kingdom
Geology description

Mercia Mudstone

Geology types
Hard rock
Description

High Speed 2 (HS2) is a high-speed railway between London Euston, the English Midlands, North West England, Yorkshire, and there are plans to extend the line to North East England and the Central Belt of Scotland. The project is currently split to two phases, namely a first phase between London and Birmingham, then a second branched phase to Manchester Piccadilly via Crewe and Manchester Airport, furthe to Leeds via the East Midlands Hu and Sheffield. 

Activity
Categories
Construction methods
Groundwater control
Max Overburden
> 50 m
Max Excavation Area (m2)
90
Tunnel length
1400
Geological Section - Long Itchington Wood Tunnel
Running Tunnel Cross Section - Long Itchington Wood Tunnel
Project number
452D
Min Overburden
< 50 m

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