Robert Ioffrida - Lend Lease

NorthConnex Technical Presentation13th Australian Tunnelling Conference

Presented by Robert Ioffrida, Project Director

Project Overview

Who is delivering NorthConnex?

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Project - Key Stakeholders

• Transurban, Canada Pension Plan and QIC

Client (Project Co.)

• Lendlease Bouygues JV (50/50)Contractor

• Aurecon SMEC JV (50/50)Designers

Lendlease Bouygues Joint Venture

Project - Key Dates

• 13 January 2015Project Approval

• 18 June 2015Start Construction

• 3rd Qtr 2015Start Tunnelling

• 4th Qtr 2019Completion

Lendlease Bouygues Joint Venture

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Project – Expected Project Personnel

• 400 +LLBJV Staff

• 160+LLB/UGL Alliance

Staff

• 500+ 300+ Tunnelling and 200+ Civil Employees

LLBJV Direct Labour

• 800+ (including M&E)Contractor

Partners

Lendlease Bouygues Joint Venture

What is NorthConnex?

• NorthConnex will provide the vital

link between Hills M2 Motorway

and the M1 Pacific Motorway.

• Two key components – Tunnel and

M2 Integration Works

• Australia’s longest and deepest road

tunnel – longer than the Eastern

Distributor, M5 East and Cross City

tunnels combined

Lendlease Bouygues Joint Venture

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Project scope

• Twin motorway tunnels - nine kilometres in

length / two lanes plus a breakdown lane in

each direction, and a speed limit of 80 km/h (or

90?)

• Each tunnel will be built with future capability to

provide three lanes in each direction at reduced

speed

• A northern interchange connecting with the M1,

the Pacific Highway & Pennant Hills Road

• A southern interchange connecting with the Hills

M2 Motorway and Pennant Hills Road

Lendlease Bouygues Joint Venture

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• A motorway control centre and ancillary

buildings, southern and northern ventilation

outlets and water treatment plant near the

southern interchange

• Ancillary facilities for operation, such as

electronic tolling facilities, ventilation

facilities as well as fire and life safety

systems

• Two additional smoke exhaust shafts in the

event of an underground fire

• Modifications to service utilities and

associated work at surface roads near the

two interchanges

Lendlease Bouygues Joint Venture

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Project scope cont.

Pioneer Avenue Construction Compound

M2 Integration Works

Project Map

Tunnelling – Basic schemeMain construction sites

Southern Interchange – M2 Portal

Wilson Road – Smoke Extraction Shaft

Trelawney Street – Smoke Extraction Shaft

Northern Interchange - M1 Portal

Southern InterchangeM2 Portal

WILSON SHAFT

TRELAWNEYSHAFT

M1 InterchangeNorth Portal

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Tunnelling – major quantities

Scope Quantity

Tunnel length - mainline tunnel 16,313 m

Tunnel length - cross passage only 1,375 m

Tunnel length - on and off ramp 3,177 m

Tunnel length - Y Junctions 1,050 m

Quantity - cross passages 75 pc

Quantity - substation underground 2 pc

Quantity - low point sumps underground 1 pc

Quantity - shafts 4 pc

Excavation total 2,250,000 m3

Project Design Features

Standard Cross Section Main Carriageway

2 lane tunnel designed for future 3 lane use

Dynamic envelope = 10.5m x 5.3m

Tunnel Concept :

- Mechanized excavation using road headers / rock boltings and shotcrete

- Drained tunnel: 1l/s/km allowable water inflow limit.

- Waterproof membrane to divert water away from tunnel crown

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Mechanical and Electrical Design

Electrical Systems• High voltage reticulation

• Low voltage reticulation

• Tunnel lighting

• Street lighting

• Emergency exit lighting

• Fire detection

Control Systems• Control room & video wall

• Plant management & control system

• Traffic management & control system

• Closed circuit television / Video incident detection

• Electronic signage

Mechanical Systems

• Tunnel ventilation

• Drainage

• Mechanical ventilation & air conditioning

• Tunnel air monitoring include air dispersion

• Fire and life safety strategy

• Fire suppression and tunnel fire doors Lendlease Bouygues Joint Venture

Communication systems

• Phones

• Public address

• Radio rebroadcast

• Mobile phone rebroadcast

Additional site investigation

Geology

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Geology

Competent geology / with localized features

Largely in Hawkesbury sandstone with some Ashfield shale

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Soil and extremely weathered

rock

Ashfield shale

Mittagong

Formation

Hawkesbury

sandstone

Permanent Lining - Cast in situ

Typical Cross Section – Shale only

Volume Kicker = 1.6m3/m

Volume Vault = 7.16m3/m

Perimeter = 22.7m

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Permanent Lining – Sprayed Shotcrete

Typical Cross Section – Hawkesbury Sandstone

Volume Vault = 2.72m3/m

Perimeter = 16.6m

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Tunnel Construction

Southern Portal and Ramps - Sequence of Excavation

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Typical Tunnel Sections

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Environmental Layout - Wilson Shaft

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Shaft depth

Shaft Depth (collar to invert)

Southern Interchange 12/30m

Wilson Road 81.3m

Trelawney 56.6m

M1 Interchange 43.7m

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Excavation Sequence – Wilson Shaft

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Typical Noise Shed arrangement / Conveyor

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Shaft access to tunnel

Lendlease Bouygues Joint Venture

Shaft access to tunnel

Lendlease Bouygues Joint Venture

Excavation Sequence – Shafts

Excavation Sequence – Tunnel Level

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Excavation Sequence – Tunnel Level

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Excavation Sequence – Tunnel Level

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Excavation Sequence Tunnel - Cut

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Different Excavation Activities in the tunnel

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Shotcrete Trials

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Plant (Shaft Jumbo)

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Tunnel Procurement - Plant

(Roadheader Fabrication in Japan)

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Tunnel Procurement - Plant (Road header Fabrication in

Austria)

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Tunnel Excavation

Lendlease Bouygues Joint Venture

Tunnel Procurement - Plant (Shotcrete Machines)

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Tunnel Procurement - Plant (Mobile Agitator and Bolter)

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Ventilation Fan

– Ventilation: Forced Overlap system chosen with 35and 50 M3/s de-Dusters

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Program of Works

Tunnelling – Basic scheme

General sequence of excavation:

1- RH excavation 1- XP Excavation 2- Benching 3- Lining / waterproofing

(1 activity in the program)

4- Drainage/Cable pit 5- Paving (no fine, asphalt, CRCP)

excavation ducts install backfill

Access to M&E Blue: Civil Activities

7- Cable Pulling Red: M&E Activities

7- M&E 1st Fix (cable trays, fans, cables)

6- Traffic Barriers fundation 7- Cladding frame support 8- Install Traffic Barriers

Access to M&E 11- Commissioning

9- Infill Concrete 10- M&E 2nd Fix (cable termination) 11- Cladding installation

11- Low noise diamond grind, pavement, line mark

together

Benching starts once excavation for full length of regular section is

completed by Road header

Enlarged section will be excavated once full length of regular section

is completed by road header

1- RH excavation 1- XP Excavation 2- Benching 3- Lining / waterproofing

(1 activity in the program)

4- Drainage/Cable pit 5- Paving (no fine, asphalt, CRCP)

excavation ducts install backfill

Access to M&E Blue: Civil Activities

7- Cable Pulling Red: M&E Activities

7- M&E 1st Fix (cable trays, fans, cables)

6- Traffic Barriers fundation 7- Cladding frame support 8- Install Traffic Barriers

Access to M&E 11- Commissioning

9- Infill Concrete 10- M&E 2nd Fix (cable termination) 11- Cladding installation

11- Low noise diamond grind, pavement, line mark

together

Benching starts once excavation for full length of regular section is

completed by Road header

Enlarged section will be excavated once full length of regular section

is completed by road header

M2 WILSON TRELAWNEY M1

NB Entry Ramp (M1C0)M1C0N1 M1C0N2

M2 ACCESS SHAFT FOR M110 & M120 S110N OUT M1C0N2 OUT T110N OUT T110N OUT

NB (M110) S110N M1C0N2 W110S W110N T110S T110N N110S N110N

M2W110S OUT T110S OUT N110S OUT

M1S120N OUT M1C0N1 OUT W120N OUT T120N OUT

SB (M120) M1D0N S120N M1C0N1 W120S W120N T120S T120N N120S N120NM1D0N OUT W120S OUT T120S OUT N120S OUT

N110N NB EXIT RAMP (M1P0)

SB Exit Ramp (M1D0) M1C0N1 M1D0N

N110N OUT

N120N SB ENTRY RAMP (M1Q0)N120N OUT

TEMPORARY

ACCESS TO SB &

M1D0 (XP13)

XP83 ACCESS

FOR ROAD

HEADER TO

M1DO

M1

C0

N1

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Overall program

Community Benefits

Hornsby Quarry (before)

Lendlease Bouygues Joint Venture

Hornsby Quarry (after)

Lendlease Bouygues Joint Venture

Local Engagement

Lendlease Bouygues Joint Venture

• Promote opportunities for local businesses

• Promote opportunities for local employees

Contact the NorthConnex team

Lendlease Bouygues Joint Venture

Project Information Line – 1800 997 057 (free call)

Questions?