WELCOME YOU TO

PIRPANJAL RAILWAY TUNNEL

SITE THE LONGEST TRANSPORTATION

TUNNEL IN INDIA

2

• Location Overview

• Salient Features of The Tunnel

• Construction Approach

• Pre-construction Planning

• Usage Of NATM in T-80

• Construction Activities

• Quality Assurance

• Environment Issues

• Social Impact

PRESENTATION COVERS

LOCATION OVERVIEW

4

ALIGNMENT PLAN

JAMMU-UDHAMPUR-SRINAGAR-BARAMULLA RAIL

LINK

QAZIGUN

D

SADUR

A

ANANTNAG

BIJBEHARA PUNZGA

M

AWANTIPORA

KAKPORA

PAMPOR

E

SRINAGA

R

BUDGA

M

RAJWANSHE

R

PATTAN

HAMRE

SOPORE BARAMULLA

BANIHA

L ARPINCHALA

BHATTA

LOALE

KOHLI SANGALDAN

BARALA BASAND

A--DHAR

REASI

KATRA

CHAKARWAH

UDHAMPUR

SALAL

RAMNAGAR

ROAD

MANWA

L

SANGAR

BAJALT

A JAMM

U

SURUKOT

PIR PANJAL RAIL TUNNEL

Length 11100 mts.

South portal photo

SOUTH PORTAL

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6

SALIENT FEATURES OF T-80

• Total length – 11 Km

• Adit – 774 m (58 m2 exc. Area)

• Shaft : 55 m depth , 12 m dia

• Maximum overburden - 1.10 Km

• Tunnelling method :NATM (New Austrian Tunneling Method)

• Completed Cost – 1150 Crores

• Approx. 440 m below existing Jawahar Road Tunnel(2.75km)

• Underground excavation : 10 lac cubic meter

• Cross section Area : Excavation : 67 to 78 m2 ,

Finished Tunnel : 48 m2

• Investigation Bore Holes depth upto 640 m

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SALIENT FEATURES OF T-80

(Contd.)

• 3 m wide road in tunnel for maintenance, emergency rescue & relief.

• High mid point & sloping in both directions for drainage.

• Provision of system for ventilation, fire fighting & safety monitoring.

• Adit & shaft for parallel working, to be used for ventilation, maintenance & emergency relief during service.

• Extensive instrumentation for monitoring during tunneling

• Consultants : M/s Geoconsult-RITES JV

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MANY FIRSTS • The Longest Transport Tunnel In The Country

(11Km)

• Highest ‘Over- burden’ of 1100M

• Deepest ‘Drill holes’ for Geotechnical Investigations 640M

• First Large Scale Use of ‘New Austrian Tunneling Method (NATM)’ in India

• First Use of ‘Road header’ for ‘Tunnel Excavation’ in Railway Tunneling

CONSTRUCTION

APPROACH

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APPROACH TO CONSTRUCTION

NO ADIT

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Vertcal Shaft

55m deep,

12m dia

Cross Passage 55 m

Adit 788 m

APPROACH TO CONSTRUCTION

WITH SHAFT AND ADIT

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Tunnel

Cross

Section:

STRUCTURAL GAUGE

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TUNNELS SECTIONS USED ON KONKAN TRACK

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TYPICAL RAILWAY TUNNEL SECTION USED ON JAMMU-

UDHAMPUR RAIL LINK

SHOTCRETE(25mm+WIRE MESH +50mm)

OR 50mm SFRS

300 TH. C.C. LINING

ISHB 150 @ 500 C/C

50mm TH. R.C.C. LAGGING

Min. EXCAVATION LINE

75Ø @ 2000 C/C

MS PLATE 12mm THICKISHB150-2NOS.

INVERT STRUT ISHB150 @ 500mm

ISHB200 @ 750 C/C

1676

R26

00

43

70

13

12

150

150

Max.

150(max)

50M20

1 in 40

RAIL LEVEL

FINISH LINE

PAY LINE 150 TH. FROM Min. EXCAVATION

25 mm Ø 3 to 5m ROCK BOLTS

AS PER SITE REQUIREMENT

ISHB 150 @ 750 c/c

PRESSURE RELIEF HOLES 5m DEEP @

3m c/c LONGITUDINALLY AS PER SITE

REQUIREMENT

150

PAY LINEMIN. EXCAV. LINE

BASE PLATE

12mm THICK

R3000

ISH

B 1

50

@ 5

00 c

/c

SH

OT

CR

ET

E25m

m +

WIR

EM

ES

H+

50m

m O

R 5

0m

m S

FR

S

50

TH

. R

.C.C

. LA

GG

ING

150

PR

ES

SU

RE

RE

LIE

F H

OLE

S 5

m

DE

EP

@ 3

m c

/c L

ON

GIT

UD

INA

LLY

AR

AS

PE

R S

ITE

RE

QU

IRE

ME

NT

BA

CK

FIL

LIN

G M

-10

50

FIN

ISH

LIN

E

30

0 T

H.

CO

NC

. LIN

ING

M-2

0

150

100

900

BLOWER

8Ø @ 150 C/C

50 675 150

100

65

675

25

mm

Ø 3

mto

5m

RO

CK

BO

LT

AS

PE

R S

ITE

RE

QU

IRE

ME

NT

SE

C. A

T A

-A

75

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LOADING DIAGRAM FOR TUNNEL TOP PRESSURE-15000KG/M

AND SIDE PRESSURE-5000KG/M

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BENDING MOMENTS DIAGRAM FOR

D-SHAPE TUNNEL TOP PRESSURE-15000KG/M AND SIDE PRESSURE-5000KG/M

MAX BENDING MOMENT = 137KN-M

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BENDING MOMENT DIAGRAM FOR ELLIPITCAL TUNNEL

TOP PRESSURE 15000KG/M AND SIDE PRESSURE 5000KG/M

MAX. BENDING MOMENT = 35.80KN-M

COMPARISION BETWEEN D-SHAPED AND ELLIPTICAL TUNNEL

DESCRIPTION MAX.

AXIAL

FORCE

MAX.

BENDING

MOMENT

MAX.

SHEAR

FORCE

MAX.

DISPLACEMENT

WITH TOP PRESSURE 15000 KG/M & SIDE PRESSURE

5000 KG/M

D-SHAPED

TUNNEL

412.5KN 137KN-M 15129 KG 0.083 M

ELLIPTICAL

TUNNEL

567 KN 35.80KN-M 9025 KG 0.024 M

WITH TOP PRESSURE 15000 KG/M

D-SHAPED

TUNNEL

412.5KN 48.10 KN-M 8565 KG 0.03 M

ELLIPTICAL

TUNNEL

639 KN 35.65 KN-M 9635 KG 0.028 M

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CONSTRUCTION METHOD

SELECTION

• DRILL AND BLAST

• ROAD HEADER

• TUNNEL BORING MACHINE (TBM)

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DRILL AND BLAST

• CONVENTIONAL, ART

WHICH COMES WITH

EXPERIENCE

• GOOD IN HARD ROCKY

STRATA

• WITH EXPERIENCE, CAN

DELIVER GOOD PROGRESS

• NON CONTINUOUS- CYCLE

INVOLVES VARIOUS

ACTIVITIES IN SEQUENCE

• MAY SPRING SUDDEN

SURPRISES

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ROAD HEADER • CONTINUOUS ADVANCE-

LESS SURPRISES

• MORE CONTROLLED

EXCAVATION- LESS

OVERBREAK/CAVITY

FORMATION

• SUITABLE FOR MEDIUM

HARD ROCK

• CAN BE WITHDRAWN

MID WAY TO GIVE WAY

FOR OTHER METHODS

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TUNNEL BORING MACHINE

• CONTINUOUS ADVANCE

• CIRCULAR SECTION

• NOT SUITABLE UNDER SQUEEZING CONDITIONS

• CANNOT BE WITHDRAWN MIDWAY TO GIVE WAY TO OTHER METHODS

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WHY NO TBM

• Likelihood of Mixed Geology

• Heavily Faulted Areas and/or Wide Fault Zones

• High Squeezing Anticipated in middle with High Overburden (1100 mts.)

• Heavy Water Flow in Lime Stone Zone with High overburden

• TBM may be Trapped by Ground Movement Behind the Face

PRE-CONSTRUCTION

PLANNING

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PRE-CONSTRUCTION

PLANNING • Engagement of Consultant

– QCB System Of tendering

• Survey and Investigation

• Head start by Taking up ADIT and shaft

works in advance

• Tender Planning

– Key dates

– Multi Method Approach

• Road Header/ D&B

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USAGE OF NATM IN T-80 • Suitable for poor and Varying Geology of

Himalayan Region

• X-Section designed to develop Maximum Self Supporting Capacity

• Face Mapping, Probe Hole & Instrumentation data input for Initial Support Design – RESS – Primary Support System

• Resilient enough to Accept the deformations and readjustment of stresses and Strong enough to take the loads

• Deformation Monitoring to assess the stress redistribution, and stabilization before final lining

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INSTRUMENTATION To provide early information about tunnel behaviour in order to optimize

excavation & support activities during construction and to recognize the requisite remedial measures.

Instrumentation data is basic input of the NATM, the observational approach.

Instrumentation in Pir Panjal Tunnel:

Optical 3 D monitoring: With bi-reflex targets to monitor deformation in tunnel on daily basis

Extensometers: To measure stresses in surrounding rock mass

Radial Pressure Cells: To measure pressure of rockmass on shotcrete lining

Shotcrete Strain meter: To monitor stresses in shotcrete lining

Piezometer: To monitor hydrostatic pressure during tunneling

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CONSTRUCTION ACTIVITES

• Open excavation & portal development

• Tunnel mining & primary lining

• Water-proof membrane installation +

drainage system.

• Secondary lining.

• Ventilation, system and safety

installations

• Track laying

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QUALITY ASSURANCE

• Laid down responsibilities, procedures and checklists for various activities through:

–CPM, CQM, SH&EM

–PPM, PSM

–Organogram

–QAP

– ITP

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QUALITY ASSURANCE (contd…)

• Availability of relevant documentation and defining the manner of execution of various activities

• Maintaining compliance through appropriate monitoring

• Ensuring adequate support facilities for successful & scheduled execution of work.

• Availability of competent/trained personnel to carry out various activities

• Compliance of statutory/regulatory requirements related to safety, environment etc.

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Quality Assurance (contd…)

Check Lists and Forms for Process Control During Execution of Works:

• Required Excavation and Support Sheet (RESS)

• ATSS/ Shift Report/Blasting clearance report/ R/Bolt Installation report

• Shotcrete testing by Penetrometer test, Core crushing test, thickness verification etc.

• Geological mapping (Geological face mapping sheet)

• Lining Air Permeability Test

• All Material Testing at Site Lab

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ENVIRONMENT ISSUES

• Identified Muck Dumping areas

• Recycling of Excavated Rocks

– aggregate for concrete constn.

• Effluent Settling Tank

– Fit for agriculture discharge

• Ventilation during Construction Stage

– Gas Analyser for air quality monitoring

• Controlled Blasting below Inhabited areas

• Lined Waterproof Tunnel

– No long term impact on water table/ Aquifers

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SOCIAL IMPACT • All weather link, Alternate to Jawahar

Tunnel

• Even at Construction stage, given a

boost to

– local construction-industry

– Employment

– Transportation business

• A boost to Local economy of Banihal

35 Time Line

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PIR PANJAL TUNNEL-

EXCAVATION PROGRESS Year Excavation

(mts.)

Remarks

2006 722 Two Faces

2007 1876 Start From 4 Faces

2008 2475

2009 2533

2010 1739 Two Faces after Jan’10

2011 947 High overburden,

Squeezing, Shale

2012 63

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Miles to go……

“A thing should be made as simple as possible, but not simpler”. Einstein

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THANKS !

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ENGAGEMENT OF CONSULTANT

• Investigations for Tunneling Methodology Assessment

• Initial Design

– Usage of NATM

– Usage of Water proof Membrane for Semi Dry Tunnel

– Development of 4-Arc Tunnel X-Section

– Additional Access through ADIT and Shaft

– Portal Location Review

• Real Time Monitoring / Instrumentation and Design Support

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INVESTIGATIONS & PLANNING 2003 Geological L-Section Profile Submitted by M/s

RITES based on GSI data.- Used to decide the Bore hole Location.

2003-04 Bore holes by RITES/ MECL- To Confirm Geological Mapping inference

2004 Consultants engaged in Feb. 2004 Geological Surface Mapping along the entire alignment by -

For Detailed Geological Section

2004 Data input for Tendering and a Decision Support System for

ADIT and Shaft decision

– Adit & Shaft Work Awarded in June 2004

2004 Detailed Topographical Survey for Portal

Location

2005 Main Tunnel Construction Work Awarded in

August 2005

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BASIC PRINCIPLES OF NATM

• Rock Mass is the major load bearing member

• Primary Support shall

maintain the integrity & strength of Rock Mass

light, have good and area contact (shotcrete)

strengthen Rock Mass (bolt, grouting)

provide protection to workers (steel rib, mesh)

installed quickly

• Provide always an effective ring closure, if necessary by an invert if rock is not suitable

BASIC PRINCIPLES OF NATM (Contd.)

• Rounded shape of Cross-Section

• Continuous control of system behaviour

by monitoring

• Inner lining shall be installed only after

balance of stresses („zero“ deformation)

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50 3D Monitoring Targets

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52

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EXTENSOMETER

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FACE MAPPING

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PROBING SHEET

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57

58

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Deformation

Monitoring in Primary

Lining Before start of

Secondary Lining

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61

62 Charging of Face

63 Ventilation Duct

64 Mucking

65 Wire mesh & Lattice Girder Erection

66

Face sealing

Face sealing by Shotcrete

67 Drilling for Forepoling

68 Rock Bolting

69

TUNNEL MINING

Activity Cycle Time (hr.) 2 mt.

RC IV

Cycle time (hr.) 1.25

mt. RC V

Drilling & Excavation 1.7 0.9

Charging , Blasting

& Defuming 2.7 1.5

Mucking 1.1 0.8

Wire Mesh & Lattice

Girder 2.4 2.3

Shotcrete 0.9 0.8

Rock Bolting 1.8 1.0

Preparation of new

face 0.3 0.3

Maintenance 1.6 1.1

Forepoling 1.6 1.7

Total 14.1 10.4

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71

Kicker Beam Casting

72 Geotextile Fixing

73 PVC Membrane Fixing

74 Membrane Stitching

75 Reinforcement for Overt Lining

76 Reinforcement Cage for Inner Lining

77 Concrete Lining Gantry

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View of Finished Lining Concrete

79

Profile Checking with Total Station

80 Core Cutting

81 Testing of Joints (Membrane)

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Sedimentation Tank

83

Effluent Quality

Test Report

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