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Rural Highway Tunnel

Reshen Kalimash Motorway Project

Owner
General Road Directorate of Albania
Client
IGH - Institut Gradevinarstva Hrvatske/Alb DOT
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
Execution
Categories
Rural Highway Tunnel
Final cost
$1,000,000,000
Service areas
Rehabilitation & Tunnel Widening
Construction methods
NATM
Tunneling under
Road
Stabilisation measures: Backfill and fibre shotcrete "egg"
Ovoid shape emerging from horseshoe profile
Project number
428E
Final cost
$1 billion USD

Devil's Slide Tunnels

Owner
California Department of Transportation (Caltrans)
Client
California Department of Transportation (Caltrans)
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
November 01, 2007
Completion - Services
March 01, 2011
Location
585 Linda Mar Boulevard
Pacifica, CA 94044
United States
Geology description

The geological setting comprised quartz diorite, marine sandstone, conglomerate and clay-siltstone. Four main fault zones were encountered.

Geology types
Mixed face
Description

Devil's Slide is located south of the City of Pacifica in California along the coastal road of Highway 1. Landslides and grade subsidence in the Devil's Slide area along Route 1 have led to the road being closed for extended periods causing significant economic loss to the surrounding communities. The solution: Construct a tunnel through the mountain to bypass the dangers and reoccurring problems. Construction of 1250m twin tunnels, 9m wide, 6.8m high using Sequential Excavation Method (SEM). Additionally, drill and blast and roadheader excavation through weathered rock utilised.

Activity
Execution
Categories
Rural Highway Tunnel
Final cost
$273,000,000
Service areas
Site Supervision & CM, QA/QC
Construction methods
NATM
Special Construction techniques
Drill & Blast
Groundwater control
From within the Tunnel
Max Overburden
~250m
Tunnel length
1250m
Drill jumbo drilling blast holes in top heading advance face
Finished southbound tunnel with textured cast-in-situ concrete
Tunnel Portals
Aerial view of completed portals
Project number
272E
Min Overburden
<5m at portals
Final cost
$273 million USD

Graebnertunnel Westroehre

Owner
ÖSAG – Österreichische Autobahn und Schnellstrassen AG
Client
Poltnigg & Klanner
Service Performed
NATM Excavation and Support Design
Commencement - Services
July 01, 2001
Completion - Services
October 01, 2003
Location
Carinthia
Austria
Technical data

Two Lane Highway Tunnel Length: 7,047 ft (2,1km); Height: ~35 ft x ~29 ft; Section: ~840 ft2 (78.4m2) Excavation included 4 vehicular cross passages connecting existing east tunnel. Constructed using two headings from North (drill-blast) and South (mined-excavator); Grouted pipe arch for pre-support and rock anchors where needed.

Geology description

Difficult tunneling conditions as result of the presence of the Lavantal fault, un-favorable bedding and severe jointing of gneiss and mica schists.

Categories
Rural Highway Tunnel
Final cost
$38,000,000
Service areas
Tunnel Design & Specialities
Construction methods
NATM

Phase II - Allegheny Tunnel Traffic Relief Study

Owner
Pennsylvania Turnpike Commision
Client
Kimball & Associates
Service Performed
Preliminary tunnel improvement study including alignment and tunnel design
Commencement - Services
February 28, 1998
Completion - Services
December 30, 1998
Location
Allegheny, PA
United States
Technical data

Preliminary alignment study looking at four new tunnel options and rehabilitation of the existing tunnels. Design of two to four lane highway tunnels up to 6100 ft (1860 m) in length supported with rockbolts, reinforced shotcrete and lattice griders.

Geology description

Interbedded Shales and Sandstones with Limestone interbeds, Coal and Claystones. Decomposed to highly weathered fractured rock at the tunnel portals.

Geology types
Hard rock
Activity
Consulting
Categories
Rural Highway Tunnel
Service areas
Tunnel Design & Specialities
Plan showing the existing topography, roads and streams along with the four Alignment Options
Profile showing the existing topography along the Red Alignment Option - Westbound Tunnel

Bluewater Quarry Haulage Tunnels

Owner
Lend Lease (land owned by Blue Circle)
Client
Costain Civil Engineering
Service Performed
Detailed design and construction supervision
Commencement - Services
October 24, 1995
Completion - Services
November 29, 1995
Location
Nr. Dartford
Kent
United Kingdom
Technical data

Twin tunnels, 26 ft (8 m) span, length: 246 ft (75 m); 8 inch (200 mm) reinforced single pass shotcrete lining, 10 year design life.

Geology description

Head deposits overlying upper Chalk. Grades III/II at tunnel elevation.

Geology types
Hard rock
Categories
Rural Highway Tunnel
Final cost
$500,000
Service areas
Tunnel Design & Specialities
Marking of the future Tunnel Portals
Start of Excavation
Top Heading Reinforcement
Invert Reinforcement
Tunnel Portals during Excavation
Muck Traffic
Top Heading Final Lining
Installing of wire mesh
Preparation of portal
Fixing of reinforcement in invert
Top Heading excavation

Gannett Fleming PTC

Owner
Pennsylvania Turnpike Commision
Client
Gannett Flemming
Service Performed
Tunnel Inspection Services – Ventilation System Improvement Study
Estimated cost
$57,000
Commencement - Services
October 01, 1994
Location
Harrisburg, PA
United States
Technical data

Inspection of tunnel roof slab structure, existing ventilation system and safety/traffic flow monitoring systems. Produced Detailed Report including following: 1. Inspection report on existing tunnel conditions. 2. Longitudinal Ventilation System Study 3. Design of remedial waterproofing system with three alternatives. 4. Cost estimates for various alternatives/measures. Two lane highway tunnel located on the Pennsylvania Turnpike I-76, constructed in 1940, total length: 1,16 mile (1867m).

Activity
Consulting
Categories
Rural Highway Tunnel
Service areas
Inspection & Maintenance

Southwick Hill Tunnels

Owner
Department of Enviroment and Transport
Client
Burslem Engineering Associates, L.G. Mouchel and Partners Consulting Engineers
Service Performed
Feasibility study for NATM alternative construction, design safety checks, specialist NATM consultant for construction
Commencement - Services
December 29, 1992
Completion - Services
December 29, 1994
Location
Brighton
United Kingdom
Technical data

Two road tunnels, dual carriageway, length of 1,280 ft (390 m) each.

Geology description

Upper Cretaceous Chalk

Categories
Rural Highway Tunnel
Final cost
$10,000
Service areas
Tunnel Design & Specialities
Reinforcement, L.G. and wire mesh
Canopy, shotcrete portal
Typical Cross Section
Portal Structure and Start of Excavation
Shotcrete Application for Face Stabilization
View of Excavation Face showing Support Works

Eisenhower Tunnel

Owner
Colorado Dept. of Transportation (CDOT)
Client
Kirkl. & Ellis
Service Performed
Tunnel Inspection/Technical Summary Report and Expert Witness Services
Estimated cost
$25,000
Commencement - Services
March 01, 1990
Completion - Services
July 01, 1990
Location
Denver, CO
United States
Technical data

The Eisenhow tunnel is the highest highway tunnel in the world with an average elevation of 11,100ft. As a result, it is subject to sever weather conditions throughout the year. Cross Sections:(2) 48 ft. width x 40 ft. height Length: 8,941 ft. (7,789 ft. mined in rock) CDOT submitted a claim against the manufacturer of pre-fabricated till wall panels that failed due to excessive water/ice build-up. DSC provided on-site inspection of both tunnels then produced a comprehensive technical report on remedial solutions to counter water/ice inflows within tunnels

Geology description

75% granite, 25% gneiss, pockets of augite diorite; presence of faults and sheer zones as well as solid bedrock.

Categories
Rural Highway Tunnel
Service areas
Site Supervision & CM, QA/QC

Cumberland Gap Tunnels

Owner
Federal Highway Administration, Federal Lands Division
Client
Benesch & Co., Chicago, IL; Vaugh & Melton, Middlesboro, KY
Service Performed
Value engineering studies on the structural design and ventilation design; specification and on-site inspection services.
Commencement - Services
September 01, 1990
Completion - Services
December 30, 1994
Location
330 W Broadway St # 264
Tennessee, KY 40601
United States
Technical data

Twin tube highway tunnels, 12 m x 9 m x 1249 m long. Constructed using NATM support categories Type I through IV. Remedial waterproofing system installed between shotcrete linng and final cast-in-place concrete lining.

Geology description

Quartz sandstone, siltstone, shale, mudstone (natural caverns).

Geology types
Hard rock
Description

The Cumberland Gap Tunnels are two dual-lane highway tunnels with a length of 1300m each, connecting Kentucky and Tennessee through the Cumberland Mountains. Because of the complex, variable geology and economic considerations, the New Austrian Tunneling Method (NATM) was chosen. The tunnel design included five excavation and support classes with rock dowels, lattice girders and reinforced shotcrete as primary lining. The final lining for the twin tunnels and 13 cross passageways was designed as cast-in-place (CIP) concrete with a flexible membrane waterproofing system.

Activity
Execution
Categories
Rural Highway Tunnel
Final cost
$85,000,000
Service areas
Site Supervision & CM, QA/QC
North portal
Cross passage CIP lining reinforcement and exposed waterproofing
Waterproofing System and CIP Final Lining
Tunnel Top Heading Excavation
Halmer Hans
Typical Cross Section
North Portal
Top Heading Excavation
Waterproofing Membrane and Reinforcement
Finished Waterproofing System and Final Lining
Cross Passage CIP Lining Reinforcement
oncoming traffic from manwalk in southbound tube of Cumberland Gap Tunnel. Taken in Sept 2002 by N. Wageley
Finished South Portal, Cumberland Gap Tunnels, KY/TN Taken 09-2002 by N. Wageley (film)
Project number
091E
Final cost
$85 million USD

Lehigh Tunnels

Owner
Pennsylvania Turnpike Commision
Client
GSGSB Clarks Summit
Service Performed
NATM design, instrumentation and construction supervision services; waterproofing system design and rehabilitation support services.
Commencement - Services
March 25, 1987
Completion - Services
December 25, 1991
Location
Route 283, Eisenhower Blvd
Allentown, PA 17034
United States
Technical data

New highway tunnel, two lanes, 28 ft (8.5 m) x 40 ft (12.1 m) x 4,265 ft (1300 m). Constructed using NATM with drill and blast excavation measures. Installation of PVC membrane and thermal insulation in air duct of the 50 year old, two lane road tunnel during rehabilitation. Tunnel lenght: 4,138 ft (1260 m); waterproofed area: 117,000 sqft (10870 m²).

Geology description

Sandstone, shale, siltstone.

Geology types
Hard rock
Description

The Lehigh Tunnel No.2, part of a 4-lane motorway running East-West through Pennsylvania, was one of the first tunnels in the US built using NATM. Capacity problems of Lehigh Tunnel No.1 caused delays during peak times. The new tunnel was excavated using top heading, bench and invert excavation with shotcrete support. To achieve a completely dry tunnel a PVC membrane was installed between primary shotcrete lining and the final cast-in-place lining. Tunnel rehabilitation including the installation of a PVC membrane and thermal insulation in the air duct was performed to the original tunnel.

Activity
Design
Categories
Rural Highway Tunnel, Tunnel Rehabilitation
Final cost
$25,000,000
Service areas
Rehabilitation & Tunnel Widening, Waterproofing & Water Control
Ventilation duct with ice build-up
Installation of waterproofing system
Typical Cross Section
View of exisiting Tunnel Portal
Preparing Tunnel Portal to start Excavation
Tunnel Face with Shot Holes ready to blast
Formwork for Cast-in-Place Final Lining
Final Lining and Invert Drain Trench
Lehigh Tunnel No. 2 - Completed Southbound Portal
Lehigh Tunnel No. 1 - before Rehabilitation
Frozen Water Leakage in Upper Air Duct
Drainage
Lehigh Portals Tunnel No. 1 (left) and the new Tunnel No. 2
Preparations
Spiles and anchor
Spiles and anchors
seeping water
Profile check
Carrier
Essembling the formwork
Incident doing form essembling
Glossy tunnel walls
Glossy tunneling
Finished tunnel
Reinforcement of roadway
Pipes
Northportal
Lehigh Tunnel #1 & #2 South Portal
Project number
115D
Final cost
$25 million USD