Lect 10 Week 11 - Dam & Tunnel Construction

EGB273
2017 – Semester 2
PRINCIPLES OF CONSTRUCTION
Lecture 11 — Dam & Tunnel Construction
R EGB273–2017 Semester 2
a university for the real world Lecture 10 Week 11 - 1
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BIRRINJUCK DAM
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ARCH CONCRETE DAM
TEMPORARY DIVERSION
ABUTMENT
DIVERSION SEALED WHEN

TEMPORARY COFFERDAM DAM COMPLETED
FLOW
PONDED WATER
FLOOD FLOW DISCHARGED

THROUGH PENSTOCKS WHEN
DAM IN SERVICE
PENSTOCKS
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MATERIALS HANDLING
TOWER
CONCRETE CABLEWAY
BATCHING
PLANT
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SEQUENCING
CONCRETE DAM
TRAINING WALLS SECTION B
SPILLWAY CREST
SECTION LEFT LOW

TO PASS FLOOD
DIVERSION TUNNEL
SEALED WITH
JOINTS STAGGERED CONCRETE
SECTION A
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CONCRETE DETAILS
Inserts cast into

previous pour
reinforcing
SECTION A SECTION B
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SEQUENCING
EARTH DAM
WATER COMMENCES TO STORE
ROCK FACING (RIPRAP)
ROCKFILL DRY WEATHER

CLAY CORE FLOW LEVEL
INSTALL BULKHEAD
DIVERSION PIPE
EARTH COFFER DAM
STRIP SOFT ROCK BULKHEAD CHAMBER RIVER BED

DIVERSION FLOW CEASES CONCRETE CUTOFF WALL
GROUT CURTAIN
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CONCRETE FACED
ROCK GRAVITY DAM
CONCRETE FACING TO
RETAIN WATER
ROCK DAM PROVIDES MASS TO

RESIST LOAD FROM WATER
DRY WEATHER
FLOW LEVEL
INSTALL BULKHEAD
DIVERSION PIPE
UPSTREAM COFFER DAM
River bed
STRIP SOFT ROCK BULKHEAD CHAMBER
DIVERSION FLOW CEASES CONCRETE CUTOFF WALL
GROUT CURTAIN
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DIVERSION FOR MAJOR STREAM FLOW
DIVERSION TUNNEL
UPSTREAM
EARTHFILLED
COFFERDAM
FLOW
PONDED WATER
DOWNSTREAM
EARTHFILLED
SPILLWAY COFFERDAM
•FLOW IS TOO LARGE TO PASS THROUGH A PIPE TOP OF DAM LEVEL
•EARTHFILL DAM CANNOT TOLERATE OVERTOPPING
•DIVERSION TUNNEL MAY BE AS LARGE AS 3M DIA SPILLWAY CREST LEVEL
•A PERMANENT CONCRETE CHUTE CONTROLS LEVEL
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SPILLWAY CHARACTERISTICS
OVERFLOWING
LEVEL
TRAINING WALLS
HIGH VELOCITY
CREST
DISCHARGE
ENERGY REDUCED
BEFORE DISCHARGE
INTO WATERCOURSE
FLIP BUCKET
OR SKI JUMP
DISSIPATION
BLOCKS
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EFFECT OF SLOPE ON CONCRETE PLACING
CONCRETE SLUMPS
AFTER FINISHING
HAND FINISHING
TO JOINTS
RATE OF POUR MATCHED

TO INITIAL SET OF CONCRETE
UP TO 30 deg
WITH CARE
JUMP FORMING TECHNIQUE
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GROUT CURTAIN
DRILL GROUT PUMP

SECONDARY GROUTING
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SEQUENCE OF ACTIVITIES
ROLLER COMPACTED DAM
CONCRETE
SPILLWAY
WATERTIGHTNESS ACHIEVED BY NORMAL
CONCRETE SEAL AT U/S FACE
CONCRETE FACING ROLLER COMPACTED CONCRETE

TO SPILLWAY AREA
CONTROL CREST
AND SLOPE
NORMAL CONCRETE
REAR FACE SHAPED WITH EXCAVATOR

AS WORK PROGRESSES
ROLLER DOZER TRUCK
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ROLLER COMPACTED CONCRETE
• USES LOW STRENGTH CONCRETE (10 MPa)
• PLACED WITH EARTHMOVING EQUIPMENT
• USES LOCAL MATERIAL
• VERTICAL FACE ONLY FORMED
• NORMAL CONCRETE SPILLWAY
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BARREL ARCH DAM
BARREL ARCHES
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BUTTRESS FORMWORK
ARCH FORMWORK
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CRITICAL EXCAVATION
JULIUS DAM
SECTION
PRESPLITTING HOLES
CONTROL OVERBREAK
x CONCERN ABOUT
FRACTURED ROCK
UPLIFT MOMENT ABOUT THIS POINT IN CRITICAL ZONE
DUE TO EXPLOSIVES
SECTION THROUGH DAM
PLAN OF EXCAVATION
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WEIRS
A B
A B
STEEL FLOOD
SHEET PLIING GATES RAISED
CUT OFF WALL
TOP WATER
LEVEL
POTENTIAL OVERTOPPING
SITUATION
SECTION A-A SECTION B-B

SEEPAGE CONTROL FLOOD CONTROL
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PUMP STATION
PUMP HOUSE
ACCESS BRIDGE
TOP STORAGE LEVEL

OUTLET
PIPES
CONCRETE WALLS
600 MM THICK
SCREENS
INLET PIPES
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PUMP STATION DETAILS
CRANE OPTIONS TOWER CRANE
EXCAVATION FOR BASE
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PUMP STATION DETAILS
CRANE OPTIONS STIFFLEG
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FORMWORK
CANTILEVER
BRACKETS
FLOOR FORMWORK
CLIMBING FORM SCAFFOLD

(JUMP FORM) CLIMBS WITH
NO ACCESS FROM FORMWORK
OUTSIDE
WALL FORMWORK
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TUNNEL
CONSTRUCTION
Types of Tunnel Construction
• Cut and Cover Tunnels

• Bored Tunnels
• Immersed Tube Tunnels
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Definition of a tunnel
A tunnel is an underground passageway, completely
enclosed except for openings for ingress and egress
- diameter vary widely 1m to > 12m
Examples where a tunnel may be used:
• pedestrian underpass
• vehicular traffic,
• rail traffic
• feed for hydroelectric power stations
• public utility plant
• sewers, water supply, power, telecommunication etc
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Geotechnical investigation
A tunnel project must start with a comprehensive

investigation of ground conditions
(boreholes, geophysical studies)
An informed choice can then be made with respect to

excavation method, cost effective machinery selection,
extent of ground support required
Risks include:
inconsistent material, fault zones, ground water
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Tunnel Construction
Tunnels are constructed all types of materials

- soft clay through to hard rock
The method of construction depends on such factors:
• ground conditions
• ground water conditions
• the length and diameter of the tunnel
• the depth of the tunnel
• the logistics of supporting the tunnel excavation
• the final use and shape of the tunnel
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Tunnel Construction
There are three basic types of tunnel construction:
• Cut and cover tunnels

constructed in a shallow excavation and then covered
over
• Bored tunnels
constructed in situ without removing the ground
above
• Immersed tube tunnels

sunk into a body of water
sit on or are buried just under sea bed
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Tunnel Construction
Cut-and-cover is a method of construction for

shallow tunnels. Two basic forms of cut-and-cover
tunnelling are:
• Bottom up method
 A trench is excavated, with ground support as necessary, and
the tunnel structure is constructed.
 The structure is then back-filled and the surface is reinstated
constructed in a shallow excavation and then covered over.
• Top down method
 Construct tunnel walls from existing ground level
‒ bored piling, diaphragm walling
 Tie wall structure together by way of capping beams
 Construct tunnel roof
‒ precast beams or in situ concrete
 Waterproof structure then reinstated surface
 Excavation then takes place within tunnel
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Bottom Up Method:
Advantages
Cost effective compared to bored tunnelling methods
Conventional construction techniques utilised
Not capital intensive
Disadvantages
Requires sufficient space to undertake excavation
Requires removal of existing structures on the surface
Load limits on finished structure (restrict use above tunnel)
Top-down method
Advantages
Cost effective compared to bored tunnelling methods
Conventional construction techniques utilised
Reduced foot print of land required to construct
Not capital intensive
Disadvantages
Requires removal of existing structures on the surface
Load limits on finished structure (restrict use above tunnel)
Challenges with respect to waterproofing the structure
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Tunnel Construction
There are many different ways to excavate a tunnel, including

manual labour, explosives, tunnelling machinery or a
combination of these methods.
The opening of the tunnel is a portal.

The "roof" of the tunnel is the crown.
The bottom is the invert.
The basic geometry of the tunnel is a continuous arch.

Because tunnels must withstand tremendous pressure
from all sides, the arch is an ideal shape (the arch simply
goes all the way around).
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Tunnel Construction
Mining Technique:
1. Erect steel “set”

2. Excavate
3. Remove “muck”
4. Install next steel “set”
5. Install infill boards
6. Install ventilation
7. Install lighting
8. Return to Step 2.
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Tunnel Construction -
Road Header, is a piece of equipment used to

excavate tunnels consisting of a boom-mounted cutting
head, a loading device usually involving a conveyor,
and a crawler travelling track to move the entire
machine forward into the rock face
The cutting head can be varied to suit the ground

conditions.
Road headers are used in competent ground where the

tunnel can stand up with minimal additional support.
Support may include localised rock bolting, steel mesh,

shotcrete lining etc.
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Tunnel Construction
A bored tunnel is constructed using a tunnel boring machine

(TBM) which is used to excavate tunnels with a circular
cross section through a variety of soil and rock strata -
anything from hard rock, clay, sand and water-bearing
ground.
(diameters have ranged from 1m to 19.25 m)
Utilising a TBM eliminates the disruption and disturbance at

the surface
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Tunnel Construction
Key factors when designing method of construction:
Stand-up time is the amount of time a tunnel will support itself

without any added structures.
Knowing this time allows the engineers to determine how

much can be excavated before support is needed.
The longer the stand-up time is the faster the excavating will
go, generally rock and clay will have the greatest stand-up
time, and sand and fine soils will have a much lower stand-up
time.
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Bored Tunnels
Advantages
Speed of excavation once TBM mobilised
Eliminates disturbance of the surface
Eliminates land purchase required for alternative
methods
Construction is out of sight except at portals
Ability to deal with variety of ground conditions
Disadvantages
Expensive
Long lead time to procure TBMs
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Immersed Tube Tunnel
An immersed tube is a underwater tunnel composed of segments,

constructed elsewhere and floated to the tunnel site to be sunk into
place and then linked together. They are commonly used for road
and rail crossings of rivers and harbours.
The segments of the tube may be constructed from steel or cast

iron tubes which are then lined with concrete or reinforced
concrete box.
Immersed tubes are often used in conjunction with other forms of

tunnel at their end, such as a cut and cover or bored tunnel, which
is usually necessary to continue the tunnel from near the water's
edge to the tunnel portal at the surface.
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The tunnel is made up of separate elements, each

prefabricated in a manageable length.
The tunnel bed needs to be prepared by dredging and

grading to fine tolerances.
The next stage is to position the elements, typically floated

in and then sunk into the final location. This being a critical
stage to ensure each segment is aligned correctly.
With all segments correctly located and joints watertight the

tunnel can be backfilled with armour rock for protection and
then dewatered. The internal fitout can commence.
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Advantages
Cost effective compared to other tunnel techniques
Speed of construction
Minimal disruption to waterway
Safety of construction (work in a dry dock)
Flexibility of profile
Disadvantages
Design of the connection between segments
Waterproofing of joints
Anchor strike
Environmental impact on existing sea bed
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EGB273

Lecture 11 — Dam & Tunnel Construction

DIVERSION SEALED WHEN

FLOOD FLOW DISCHARGED

SECTION LEFT LOW

Inserts cast into

WATER COMMENCES TO STORE

ROCK FACING (RIPRAP)

ROCKFILL DRY WEATHER

STRIP SOFT ROCK BULKHEAD CHAMBER RIVER BED

ROCK DAM PROVIDES MASS TO

DIVERSION FLOW CEASES CONCRETE CUTOFF WALL

•FLOW IS TOO LARGE TO PASS THROUGH A PIPE TOP OF DAM LEVEL

•EARTHFILL DAM CANNOT TOLERATE OVERTOPPING

•DIVERSION TUNNEL MAY BE AS LARGE AS 3M DIA SPILLWAY CREST LEVEL

•A PERMANENT CONCRETE CHUTE CONTROLS LEVEL

RATE OF POUR MATCHED

JUMP FORMING TECHNIQUE

DRILL GROUT PUMP

CONCRETE FACING ROLLER COMPACTED CONCRETE

REAR FACE SHAPED WITH EXCAVATOR

ROLLER DOZER TRUCK

• USES LOW STRENGTH CONCRETE (10 MPa)

• PLACED WITH EARTHMOVING EQUIPMENT

• USES LOCAL MATERIAL

• VERTICAL FACE ONLY FORMED

• NORMAL CONCRETE SPILLWAY

SECTION A-A SECTION B-B

TOP STORAGE LEVEL

EXCAVATION FOR BASE

CLIMBING FORM SCAFFOLD

• Cut and Cover Tunnels

Examples where a tunnel may be used:

A tunnel project must start with a comprehensive

An informed choice can then be made with respect to

inconsistent material, fault zones, ground water

Tunnels are constructed all types of materials

The method of construction depends on such factors:

There are three basic types of tunnel construction:

• Cut and cover tunnels

• Immersed tube tunnels

Cut-and-cover is a method of construction for

There are many different ways to excavate a tunnel, including

The opening of the tunnel is a portal.

The basic geometry of the tunnel is a continuous arch.

1. Erect steel “set”

Road Header, is a piece of equipment used to

The cutting head can be varied to suit the ground

Road headers are used in competent ground where the

Support may include localised rock bolting, steel mesh,

A bored tunnel is constructed using a tunnel boring machine

(diameters have ranged from 1m to 19.25 m)

Utilising a TBM eliminates the disruption and disturbance at

Key factors when designing method of construction:

Stand-up time is the amount of time a tunnel will support itself

Knowing this time allows the engineers to determine how

An immersed tube is a underwater tunnel composed of segments,

The segments of the tube may be constructed from steel or cast