Tunnelling works: - VINCI Construction Grands Projets

Tunnelling works:world class innovativesolutions

Combining experiencewith innovation” On a worldwide basis, the potentialof unused underground resourcesis colossal. ”Yann Leblais, vice president of ITA-AITES(International tunnelling and underground space association)VINCI Construction Grands Projets,a subsidiary of VINCI, the world’sleading concession and constructiongroup, designs and builds majorcivil engineering structures andbuildings throughout the world.Our Tunnelling Division is devoted to theconstruction of all forms of undergroundworks on all continents.We bring to project teams our expertresources who provide all services fromconceptual design through to construction.Through value engineering and innovationwe strive to deliver the optimum buildablesolution for our Clients.A PARTNERSHIP APPROACHTunnelling contains inherent risks due tothe uncertain nature of the ground. We workproactively in partnership with our Clientsand partners to identify and minimise risks.Our preference is to establish long termworking relationships which are based ontrust and openness. In doing so all partnersderive mutual benefits and continuousimprovement on every project.02 TUNNELLING WORKS: WORLD CLASS INNOVATIVE SOLUTIONS

Innovation for our ClientsA86 Duplex example: from basic design principles to highly detailed solutions. The A86 project is a fantastic exampleof our ability to innovate at every stage in the special ring project development process to deliver technicalexcellence.CONCEPTUAL INNOVATIONThe A86 Duplex was the first tunnel designed with two superimposed levels of traffic, each level consisting of two lanes plus an emergency lane.Safety considerations were incorporated from the outset of the design process and resulted in a number of provisions (refuges, traffic monitoring,system, etc.) which will ensure public safety in the case of accidents.By reducing the travelling time from 45 to 10 minutes, the tunnel will significantly contribute to a reduction of CO 2emissions.Special ring:equipping thestructure at theopening level withbicones providesextra strengthBicones insertedinto the ring aroundhalf the perimeterRecess for biconesBicones embedded in segmentsPinsSof-Shear® pins1 An innovative TBMWe developed a ‘multi-mode’ TBM capableof working in two different modes: EPB fortunnelling through clay and slurry for sandyground. This is one of the many innovativeconcepts which contributed to the successfuldelivery of the tunnel.2 Inner structures: exceptional methodsDesigning the inner structures, in particulartheir connection with the lining, anddeveloping the construction methods forbuilding these inner structures concurrentlywith the tunnel drive, was a major challengesuccessfully overcome by our team.3 Construction of the safety nichesThe utilisation of the bicone Sof-Shear®,developed by VINCI ConstructionGrands Projets in partnership with Sofrasar,eased the creation openings in the segmentlining, by minimising the amount of temporaryworks.1ExtractionBlowingSafety nichesStaircase transferExtractionBlowing0 1 2 3 4 m2 3TUNNELLING WORKS: WORLD CLASS INNOVATIVE SOLUTIONS 03

Technical expertise to findthe right solutionOur considerable knowledge of tunnelling techniques and our ability to capture our Clients’ vision for a project in ourconceptual designs sets us apart from others.The major factor influencing boththe design of underground structuresand the tunnelling methods to beused is the nature of the ground itself.Having completed over 1,000 km of tunnels,shafts and caverns, we have mastered everykind of tunnelling technique, from deployingconventional methods to driving state of theart tunnel boring machines.On each and every project, our experts reviewand evaluate the ground conditions and drawon the range of available proven techniques todevelop and implement the most suitable andbuildable solution.We then work with our Clients and theirrepresentatives to develop the optimumdetailed design.IN-HOUSE DESIGN CAPABILITIESWe are able to combine our practicalconstruction knowledge with the engineeringexpertise necessary to develop the bestsolutions to the most difficult tunnellingchallenges.We have an in-house team of qualified andexperienced engineers, who develop projectsfrom initial optioneering through to thedevelopment of detailed drawings andspecifications used to realize the constructionworks.Typically our in-house engineeringteam can:Evaluate the options for excavatingthe tunnels.Develop the proposed excavation methods.Design temporary supports and thepermanent lining.Design ground treatments such as grouting,ground freezing or others.Specify and monitor the manufacture andcommissioning of the TBMs and relatedequipment including slurry treatment plants.04 TUNNELLING WORKS: WORLD CLASS INNOVATIVE SOLUTIONS

Working across the worldFORGING STRONG LOCALPARTNERSHIPSWe are keen to develop long lastingpartnerships with Clients and local contractors.This enables us to continue to improve theservice we provide by understanding Clients’needs and local conditions wherever we work.United Kingdom: A partnership of overten years with Morgan EstVINCI Construction Grands Projetsoperates all over the world. Whereverthere is an underground challengewe are keen to work with Clients tofind a cost effective solution.We have a core team of experiencedand qualified tunnellers (from minersto project managers) who are used toworking overseas. They have a provenability to adapt to new environmentsand different cultures. Our approachis to establish a core project team ofexperienced people and recruit andtrain local personnel to bring benefitsto the local economy.Our relationship with British contractor MorganEst (formerly Miller) began in 1997 when wewere selected to construct 14 km of tunnelsunder London’s Heathrow Airport. The JointVenture was also awarded two contracts on theChannel Tunnel Rail Link including the NorthDowns tunnels.These prestigious and successful projectsformed the basis of a long term relationshipthat has delivered motorway widening, multispanbridges and railway infrastructure. Overa decade of continuous cooperation later, bothcompanies have derived significant benefitsfrom the relationship.We were recently awarded a major tunnellingcontract as part of an upgrade to London’ssewerage network and will continue to pursuefuture projects together.Egypt: A thirty year partnershipwith the National Authority for TunnelsVINCI Construction Grands Projets has, since1981, participated in the construction of allthree lines of the Cairo underground system anddelivered major road infrastructure improvements.From 1981 to 1987, VINCI Construction GrandsProjets participated within a consortium todeliver Line 1 under a turnkey contract. Line 2commenced in 1993 and required the use ofslurry machines, a relatively rare technique atthat time. As Line 2 works concluded in 1998the opportunity arose to transfer all resources toconstruct the El Azhar road tunnels. Since 2008,we have led the consortium constructing Line 3.Over the years, our Clients have greatlyappreciated our ability to collaborate with them toreliably deliver high quality projects in a spirit oftrue partnership.Projects underway and major achievementsof VINCI Construction Grands Projets in tunnelling worksTUNNELLING WORKS: WORLD CLASS INNOVATIVE SOLUTIONS 05

Mastering all tunnelling techniquesMaliakos-Kleidi road tunnel,GreeceTrans Manche Link,United KingdomA86 Duplex tunnel, France06 TUNNELLING WORKS: WORLD CLASS INNOVATIVE SOLUTIONS

to serve all types of projectsXiaolangdi undergoundpower plant, ChinaA86 Duplex emergency well,FranceMagenta metro station in Paris,FranceTUNNELLING WORKS: WORLD CLASS INNOVATIVE SOLUTIONS 07

From Tunnel Boring Machines toFrom smallest to largest, from soft ground to hard rock, we have already driven Tunnel Boring Machines (TBM’S)in all conditions.Tunnel Boring MachinesWe deployed our first hard-rock TBM in 1981on the Grand-Maison dam located in Franceand our first slurry TBM in 1982 on a metro linein Lyon, France. Since then we have remainedat the forefront of international tunnellingtechniques.From remote project locations, to tunnellingunder the busiest airport in the world, we arecapable of adapting our tunnelling techniquesto suit all our Client’s constraints.Our teams have experts in all aspects of TBMoperations, from segments manufacturing toTBM breakthrough. We use our longstandingrelationships with specialised suppliers toensure we are fully familiar with state ofthe art developments in products,techniques and equipment.Over many years VINCI Construction GrandsProjets has developed a significant portfolioof world class tunnels which includes all TBMtechniques.Lefortovo road tunnel - Moscow, RussiaThis 2.3 km long road tunnel was constructedusing a slurry shield. The combination of its largediameter (14.22 m excavated diameter) with thesensitive environment required a strict settlementmonitoring regime.A comprehensive scheme of real time monitoringand compensation grouting was implementedfor tunnelling underneath the Alexis MilitaryUniversity.Hallandsås rail tunnels - SwedenA key constraint associated with the constructionof this 10.9 km long rail tunnel was to keep at alltimes the water inflow in the tunnel within verystrict limits to avoid affecting the water table.To that effect, a hard-rock TBM capable ofworking also as a slurry machine was developedto ensure up to a maximum of 13 barsconfinement pressure.Water distribution networkBrightwater - Seattle, USALocated within very abrasive glacial deposits,the 5.3 m diameter TBMs suffered extensive wear.Maintenance and repair works required extensivehyperbaric interventions at high pressures, up to5.8 bars.Access tunnel to T5 terminalHeathrow Airport - London, United KingdomTo minimise the settlement on the surface whileconstructing this 9.2 m excavated diameter tunnelat a shallow depth under Heathrow Airport, a TBMcapable of working in Earth Pressure Balancemode or in compressed air was developed. Thetunnelling of these twin tunnels, each 1,250 mlong, was successfully completed without anyadverse effect on the airport operations.Over the past 20 years, our teams08 TUNNELLING WORKS: WORLD CLASS INNOVATIVE SOLUTIONS

conventional tunnellingWhether using traditional drill and blast techniques or mechanized methods in soft ground, we design and constructtunnels using NATM or SCL methods, including the design of ground improvement schemes, the installation ofwaterproofing and secondary lining.Conventional tunnellingLarge cavernsand shaftsDrill and blastSoumagne rail tunnel - BelgiumConstructed using the drill and blast technique,this 5,940 m long tunnel, east of Liege,is the longest existing rail tunnel in Belgium.LiningMitholz Rail tunnel - Lötschberg, SwitzerlandWith 26 km, the Mitholz tunnel, excavated usingdrill and blast technique, is the longest stretchof the Lötschberg tunnel (34.6 km) and serves topiggyback passengers and vehicles betweenthe cantons of Berne and Valais, in the heart ofthe Swiss Alps.The formation of large caverns and deepshafts is regularly required to house metrostations, waste storage, undergroundpowerhouses or similar facilities. Theseprojects often require bespoke solutionssuch as purpose-made equipment forshaft sinking and complex excavationsequences for large caverns. Our teamsdraw on past experience to develop thebest construction methods to meet theparticular challenges being faced.Mechanical solutionsNorth Downs TunnelsLondon, United KingdomThis 3.2 km long tunnel is part of the high-speedrail connection between the Channel Tunnel andLondon. This 155 m 2 tunnel was excavated insoft ground (chalk) using mechanised excavators.The primary support consisted of rock bolts andshotcrete and was subsequently covered by a castin situ concrete lining.have constructed 775 km of tunnels.Ground improvementGround freezing - Paris, FranceOn the A86 Duplex project in Paris, theconstruction of the safety niches in soft ground,under water, required the implementation ofa large variety of ground treatment solutions,ranging from grouting to ground freezing.Shafts of ANDRA - FranceFOCUSConstructing 500 m deep shaftsfor underground research laboratoryFeasibility study and construction oftwo shafts 500 m deep and a networkof 340 m of tunnels to access aresearch laboratory used for scientifictests for the underground storage ofradioactive waste. With a diameter of5 and 6 m, the excavation of these wellsrequired VINCI Construction GrandsProjets to develop specific tools.The surface of these wells hasnecessitated the establishment of10,000 m 3 of Self Compacting Concrete(SCC).TUNNELLING WORKS: WORLD CLASS INNOVATIVE SOLUTIONS 09

Safety first!Tunnelling is a particularly hazardous activity due to working in confined spaces, uncertain ground conditions andthe use of heavy equipment. It is therefore vital that we adopt our «Safety first!» policy on all our projects.Our strategy is to ensure that all of our employees are actively involved in making their worksites safer.(A)LIVE ON SITE(A)live on site is a safety program developed by VINCI Construction Grands Projets.It is designed to ensure that everyone recognises the role they have to play in deliveringprojects safely and involves familiarisation with the site specific risks.Video footage is recorded on site tocapture good and bad safety practices.This is then screened in the local languageat compulsory site meetings attendedby all staff, subcontractors and workforcepersonnel. By demonstrating the key issues usingthis powerful communication method,VINCI Construction Grands Projets raisesawareness of the site specific safety issues.It also invites discussions on best practiceand improvements and encourage teams toformalise results into firm commitments.(A)live on site was implemented on sevenprojects in 2008, in French, English and Arabic.Results show a direct correlation to a reductionin the accident frequency and gravity rates.By the end of 2009, 1,100 people had benefitedfrom the program, now available in 9 differentlanguages.At the VINCI 2009 Innovation Awards,the Safety prize was awarded to (A)live on site.Innovating to improvesafetyFOCUSVINCI Innovation Awards winningmotorised rescue chamberFire is one of the main risks faced bytunnellers. In Sweden, as part of theworks for the Hallandsås tunnels, theproject team developed the first selfsufficientrescue chamber mountedon rails which can be driven in a toxicatmosphere. This chamber can hold20 people, protecting them fromsmoke and harmful gases, providinga highly efficient facility in the eventof underground fire. This idea won theEquipment prize at the VINCI 2007Innovation Awards.Accident frequency rate over a 12 month period10 TUNNELLING WORKS: WORLD CLASS INNOVATIVE SOLUTIONS

VINCI Construction Grands Projets5, cours Ferdinand-de-Lesseps92851 Rueil-Malmaison Cedex - FranceTél. : (+33) 1 47 16 47 00Fax : (+33) 1 47 16 33 60www..vinci-construction-projets.com- April 2010 – 1,000 copies - Photo credits: Alex Béraud, BAA plc, Claude Cieutat, Cyrille Dupont, Francis Vigouroux, Liesse Communication, Pascal Slitter/Agence REA, Ros Orpin, Sue Bednarz Photography, Thierry Duvivier, Véronique Paul/Graphix, VINCI and subsidiaries photos libraries, all rights reservedIllustration: Lorenzo Timon/Stéphane Jungers – Printed on PEFC/FSC paper with vegetables inks.