1. Presentation to Institution of Engineers, Malaysia Electrified Double Track Project Ipoh to Padang Besar PIPE ARCH TUNNEL by Mr. Don R. Hall Head of Tunneling Division, Gamuda Engineering Sdn Bhd May 2010
2. Outline of Presentation: General Project Information – Berapit Tunnel Pipe Arch Tunnel – Geological Profile & Concept Pipe Arch Tunnel – Chronology of Construction Construction of Triple Cell 3m Ф Drainage Culvert Demolition of Existing 3m x 3m Twin Box Drainage Culvert Pipe Arch Tunnel Construction Catastrophe Summary and Q&A
12. Pipe Arch Tunnel – Chronology of Construction 1. Triple 3mФcell drainage culvert at KM 232.6 of PLUS North-South Highway to replace existing 3m x3m twin box culvert Northbound Southbound railway tunnel Southbound Northbound railway tunnel 2. Existing 3m x 3m twin box drainage culvert to be demolished & replaced 3. Twin pipe arch tunnel crossing underneath PLUS North-South Highway KM 232.7 Plan Layout of Twin Pipe Arch Tunnel
13. 12 Pipe Arch Tunnel – Chronology of Construction 1. Triple 3mФcell drainage culvert at KM 232.6 of PLUS North-South Highway to replace existing 3m x3m twin box culvert Southbound Northbound 2. Existing 3m x 3m twin box drainage culvert to be demolished & replaced 3. Twin pipe arch tunnel crossing underneath PLUS North-South Highway KM 232.7 3-D View of Twin Pipe Arch Tunnel
15. Construction of Triple Cell 3m Ф Drainage Culvert Jacking Length = 45.5m LONGITUDINAL SECTION CROSS SECTION
16. Construction of Triple Cell 3m Ф Drainage Culvert First drive of jacking works of 3m Ф concrete pipes ongoing. Second & third drives awaiting for jacking with prepared entrance rings Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine
17. Construction of Triple Cell 3m Ф Drainage Culvert Jacking works ongoing Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine
18. Construction of Triple Cell 3m Ф Drainage Culvert Breaktrough of the first drive Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine
19. Construction of Triple Cell 3m Ф Drainage Culvert Lifting of microtunneling machine after breakthough of first drive Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine
20. Construction of Triple Cell 3m Ф Drainage Culvert Close up of RASA microtunneling machine Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine
21. Construction of Triple Cell 3m Ф Drainage Culvert Completed construction of triple cell drainage culverts Construction of Triple 3m Ф Cell with Soft Ground CutterheadMicrotunneling Machine
24. Demolition of Existing 3m x 3m Twin Box Drainage Culvert Existing twin box culvert at KM 232.7 PLUS North-South Expressway before demolition Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction
25. Demolition of Existing 3m x 3m Twin Box Drainage Culvert Demolition by coring & hacking to rid of reinforcement within existing twin box culvert for pipe arch tunnel construction Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction
26. Demolition of Existing 3m x 3m Twin Box Drainage Culvert Demolition by coring & hacking to rid of reinforcement within existing twin box culvert for pipe arch tunnel construction Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction
27. Demolition of Existing 3m x 3m Twin Box Drainage Culvert Sealing of existing twin box culvert for pipe arch tunnel construction 2. Demolition of Existing 3m x 3m Twin Box Culvert for Pipe Arch Tunnel Construction
31. Pipe Arch Tunnel – Concept Site picture of project by Metropolitan Atlanta Rapid Transit Authority in USA Construction Sequence 1. Execution of sheet piles 2. Execution of the pipe arch microtunneling 3. Mined excavation of tunnel with steel ribs with bullflex, reinforced shotcrete & fibre glass elements 4. Casting of permanent concrete lining
32. Pipe Arch Tunnel Construction LONGITUDINAL SECTION CROSS SECTION
33. Pipe Arch Tunnel Construction Limits of PLUS North-South Expressway (NSE) Receiving Pit Jacking Pit Top of Soil Support Pipes Southbound NSE Northbound NSE Fill Fill 0 Cut & Cover Section Cut &Cover Section Residual Soil Direction of Microtunneling 5 Weathered Rock 10 Bottom of Structure Rock 15 20 Scale in Meters 0 5 10 Jacking Length up to Toe of Highway Embankment= 90 m
34. Pipe Arch Tunnel Construction (Right Bore) Limits of PLUS North-South Expressway (NSE) Receiving Pit Jacking Pit Top of Soil Support Pipes Southbound NSE Northbound NSE Fill Fill 0 Cut & Cover Section Cut &Cover Section Direction of Microtunneling Residual Soil Weathered Rock 5 10 Rock Bottom of Structure 15 20 Scale in Meters 0 5 10 Jacking Length up to Toe of Highway Embankment= 92 m
35. Pipe Arch Tunnel Construction Cardox System – Non-explosive blasting
36. Pipe Arch Tunnel Construction Cardox Gas Filling Cardox Drilling & Connection Cardox Blasting Pipe Arch Tunnel Construction
38. Pipe Arch Tunnel Construction AVN500 Microtunneling machine with retraction mechanism in case of rock face encountered Pipe Arch Tunnel Construction
39. Pipe Arch Tunnel Construction 10mm Pipe Wall Thickness Jacking Direction 780mm OD Pre-welded Line-up Band Pipe joint detail Pipe Arch Tunnel Construction
40. Pipe Arch Tunnel Construction Construction & staged excavation of bored pile jacking pit Pipe Arch Tunnel Construction
41. Pipe Arch Tunnel Construction Coring of reinforcement of shotcreted bored pile wall to prepare soft eye for microtunneling machine advance Pipe Arch Tunnel Construction
42. Pipe Arch Tunnel Construction Construction of thrust wall for jacking of microtunneling machine Pipe Arch Tunnel Construction
43. Pipe Arch Tunnel Construction Microtunneling machine preparing to jack Pipe Arch Tunnel Construction
