An Overview of TBM Tunnelling in Turkey and Middle East Özgür Savaş Özüdoğru E-Berk Tunnelling...

An Overview of TBM Tunnelling in Turkey and Middle East

Özgür Savaş Özüdoğru

E-Berk Tunnelling & Foundation Tech.

21.08.2012

Colorado School of Mines

CONTENTS

• A quick overview of E-Berk• Project details in Turkey• Upcoming projects in Turkey• Project details in the Middle East• Selected planned major tunnelling projects in the

M.E.• Selected major tunnelling projects under way in

the M.E.• Conclusion

A Quick Overview of E-Berk• Founded in 2002 as subsidiary of Ozudogru Group of

Companies.

• Located in Ankara with 8000 m² manufacturing and heat treating closed facility.

• Offices are located in Istanbul, England and Qatar (from October 2012).

• All kind of TBM cutters has been producing such as cutter ring, single and double disc cutter, ripper, bucket, knife and any kind of cutter with tungsten carbide.

• Cutterhead modification, TBM overhaul and site assembly.

• 20 projects has been finished in Turkey and exports increased to 12 different countries such as Russia, Poland, India, Bulgaria, Saudi Arabia, Azerbaijan, Australia, Israel, and so on.

Metro transportation is an indispensible issue

for solving traffic problem for metropolitan

areas. Therefore, every year metropolitan

municipalities spend a lot of money for metro

tunnel construction from their budget. For

example, Istanbul Metropolitan Municipality

(IMM) has been spending approximately 45 %

of its investment budget for metro and

transportation projects in last year's.

Depending on the ratio of the population of

human beings, clean water supply and

waste water disposal projects is becoming

more importance. Within this scope, General

Directorate of State Hydraulic Works has

also been spending approximately 20 %

of its investment budget which is about 1

billion USD to clean and waste water tunnel

project.

PROJECT DETAILS IN TURKEY

ANADOLU RAY – Kadikoy Kartal Metro Project

Location: İstanbul, TURKEYContractor: YAPI MERKEZI-DOGUS-YUKSEL-YENIGUN Joint VentureLenght of Tunnel: 12331 mType of TBM: Herrenknecht EPBDiameter of TBM: 6,57 mNumber of Cutter Disc in Cutterhead:

26 single cutter disc 6 double cutter disc

Ground Condition: Clay, sand, gravel deposit, shale,limestone, fault

Single Disc Cutter Cutter Ring Hub Shaft Cutting KnifeTwin Disc Cutter

DSI Blue Tunnel Project (Turkish Republic Ministry of Environment and Forestry)

Location: Konya, TurkeyContractor: İLCİ Joint VentureLenght of Tunnel: 17034 mType of TBM: SELI Double ShieldDiameter of TBM: 4,2 m

Wedge Scraper Support Scraper Wedge TypeRemovableSingleDisc Twin Disc

ISKI Istanbul European Side 2nd Part Waste Water Tunnel Project

Location: Silivri- İstanbul, TurkeyContractor:NAS INS.Lenght of Tunnel: 8674 mType of TBM: Herrenknecht EPB Diameter of TBM: 3,82 m

Double Disc Cutter Scraper Knife HousingBucket Chisel

Single Disc Cutter

ISKI Istanbul European Side 3th Part Sea Water Tunnel Project

Location: Cayırbasi Ayazaga, Turkey

Contractor:DEPAR INS.

Lenght of Tunnel: 5000 m

Type of TBM: Herrenknecht Hardrock TBM

Diameter of TBM: 3120 m 

Over Cutter Scraper Bucket Disc Cutter Bucket

ISKI İstanbul European Side 4th Part Waste Water Tunnel Project

Location: Istanbul European SideİLCİ OZGUN Joint VentureLenght of Tunnel: 9254 mType of TBM: Herrenknecht EPBDiameter of TBM: 4,6 m

Twin RipperTwin Disc Cutter

Double Disc TBM Backup Equipments Knife

Istanbul BASAKSEHIR-IKITELLI Metro Project

Location: Istanbul GULERMAK-DOGUS Joint VentureLenght of Tunnel: 5350 mType of TBM: 2 LOVAT EPB, 1 Herrenknecht EPBDiameter of TBM: Each 6.5 m

Twin Ripper Twin Disc Cutter Single Disc TBM Backup Equipments Knife

General layout of ongoing metro projects in Istanbul

Istanbul OTOGAR-KIRAZLI Metro Project

Location: Istanbul GULERMAK-DOGUS Joint VentureLenght of Tunnel: 5500 mType of TBM: 1 Herrenknecht EPB 1 Lovat EPBDiameter of TBM: Each 6.5 m

Twin Ripper Twin Disc Cutter Single Disc TBM Backup Equipments Knife

Istanbul MARMARAY Project

Location: Istanbul TAISEI-GAMA-NUROL Joint VentureLenght of Tunnel: 9360 mType of TBM: 2 HITACHI ZOHEN, 1 JTSC EPBDiameter of TBM: Each 7.0 m

Single Disc Type 1 Single Disc Type 2

MELEN Project - Istanbul

Location: Istanbul,

Mosmetrostroy, Engeocom,

Alke and STFA Joint Venture

Lenght of Tunnel: 5500 m

Type of TBM:Herrenknecht EPB

Diameter of TBM: 6.15 m

Scraper BucketTwin Disc Cutter Single Disc

Istanbul-Ankara High Speed Rail Project, Kosekoy Tunnel

Location: Bilecik-Kosekoy,

Cengiz, Ictas, Belen Joint Venture

Lenght of Tunnel: 6100 m

Type of TBM:Herrenknecht

Single Shiled

Diameter of TBM: 13.77 m

Double Disc Cutter

Scraper Knife HousingBucket Single Disc Cutter

Twin Disc Cutter

ANKARA WATER II. MERHALE PROJECT-GEREDE

Location: Gerede, Kolin

Limak Joint Venture

Lenght of Tunnel: 31600 m

Type of TBM: 3 Herrenknecht

Double Shiled

Diameter of TBM: 5.40 m

Bucket Single Disc Cutter

Twin Disc Cutter

ISTANBUL METRO PROJECT, USKUDAR-UMRANIYE

Location: Istanbul, Dogus Const.

Lenght of Tunnel: 22100 m by

TBMs, 18700 m by NATM

Type of TBM: 3 Herrenknecht

Double Shiled

Diameter of TBM: 6.30 m

Double Disc Cutter

Scraper Knife HousingBucket Single Disc Cutter

Twin Disc Cutter

SURUC TUNNEL PROJECT

Location: Sanliurfa, Ilci Const.

Lenght of Tunnel: 17185 m

Type of TBM: SELI Double Shiled

Diameter of TBM: 7.80 m

Double Disc Cutter

Scraper Knife HousingBucket Single Disc Cutter

Twin Disc Cutter

ANKARA METRO PROJECTS

Under construction metro projects

• Ankara Metro (M2, Kizilay-Çayyolu)- 16.6 km total length, 3.7 km by TBM and 2.9km by NATM.

• Ankara Metro (M3, Batikent-Torekent)- 16 km total length, 2 km by TBM and 6.6 kmby cut and cover.

• Ankara Metro (M4, Tandoğan-Kecioren)- 9.2 km total length, 4.2 km by TBM and 3 km by

NATM.

KARGI HEP PROJECT

Location: Kargi-Corum, Gulermak

Heavy Ind.Co.

Lenght of Tunnel: 11800 m

Type of TBM: Robbins Double

Shiled

Diameter of TBM: 10.00 m

Single Disc Cutter

Twin Disc Cutter

Scrapper

YAMANLI HEPP PROJECT

Location: Adana, EnerjiSa-NTF

Const.

Lenght of Tunnel: 7900 m

Type of TBM: Robbins Double

Shiled

Diameter of TBM: 4.40 m

Double Disc Cutter

Single Disc Cutter

Twin Disc Cutter

Scrapper

DOGANCAY HEP PROJECT

Location: Adana, EnerjiSa

Atac,Hinteregger Joint Venture

Lenght of Tunnel: 6900 m

Type of TBM: Herrenknecht Double

Shiled

Diameter of TBM: 4.20 m

Double Disc Cutter

Bucket Single Disc Cutter

Twin Disc Cutter

KARAKUZ DAM and HEP PROJECT

Location: Adana, Alarko-Altek

Const.

Lenght of Tunnel: 11000 m

Type of TBM: 2 CAT Double

Shiled

Diameter of TBM: 3.00 m

Double Disc Cutter

Bucket Single Disc Cutter

Twin Disc Cutter

UPCOMING PROJECTS

• OVIT Tunnel Project;- City : Rize- Contractor : Makyol Const.- Length : 30 km (2 x 15 km)- Diameter : 12.50 m excavation- Machine Type : 2 Gripper TBM- 1850 m Raise Boring with 6 m diameter for

ventilation shafts

• Silvan Tunnel Project;- City : Diyarbakır- Contractor : Yertas, Kayaoglu Joint Venture- Length : 20.5 km (2 x 10.25 km)- Diameter : 7.9 m excavation- Machine Type : Double Shield TBM (Herrenknecht)

• Babakaya Tunnel Project;- City : Diyarbakır- Contractor : Unal Akpınar Const.- Length : 10.4 km (2 x 5.2 km) - Diameter : 7.9 m diameter- Machine Type : Double Shield TBM (CAT)

• Beylerbeyi Wastewater Tunnel Project,- City : Istanbul- Contractor : Unal Akpinar Const.- Length : 4680 m- Diameter : 3.2 m excavation- Machine Type : Single shiled

• Zeytinburnu Wastewater Tunnel Project,- City : Istanbul- Contractor : Unal Akpinar Const.- Length : 4500 m- Diameter : 3.2 m excavation- Machine Type : EPB

• Dogancay Tunnel Project (Ankara-Istanbul High Speed Rail Project);

- City : Bilecik (Vezirhan-Kosekoy)- Length : 7.4 km- Diameter : 13.80 m excavation- Machine Type : EPB (expected)

• Bagbası Tunnel Project;- City : Konya- Contractor : Ilci Constr.- Length : 18 km- Diameter : 5.2 m excavation- Machine Type : Double shiled TBM

• Bosphorus Crossing Tunnel Project;

- City : Istanbul, under the bosphorus- Contractor : Yapi Merkezi and SKEC-Samwhan-

Hansin-Namkwang-Kukdong Joint Venture- Length : 3.34 km- Diameter : 13.70 m excavation- Machine Type : Herrenknecht Slurry TBM

PROJECT DETAILS IN MIDDLE EAST

As it is know that the Middle East market has quite

big value of construction industry. About 80 per

cent of the projects involving tunnelling are in the

transport sector, including metro schemes in Cairo,

Abu Dhabi, Baku, Tehran,Tel Aviv, Doha, Riyadh

and Kuwait. Urban transport projects often for

tunnelling as underground lines minimise disruption to

the existing buildings and infrastructure of cities.

More than $279 bn-worth of projects with a tunnelling

element are currently planned or under way in the

Middle East.

With $76.2bn of new projects and extensions to

existing lines planned in the Gulf and North

Africa, the urban rail sector is set to offer

significant opportunities for contractors in the

region.

If we have a look at tunnelling industry, we have

seen that there are many projects which are under

way and planning to built.

Selected Planned Major Tunnelling Projects

• Kuwait Metro Project,Sector: RailCost : 7 billion USDScope : 160km metro networkClient : Partnerships Technical BureauCountry : Kuwait Expected Tunnelling : TBMTender Issue Date: Jul-12

• Inner Doha Resewerage Scheme,

Sector : Water Cost : 2,5 billion USDScope : Interceptor tunnelClient : Public Works Authority (Ashghal) Country : Qatar Expected Tunnelling : TBM Tender Issue Date : Dec-12

• King Faisal Tunnel,

Sector: Road Cost : 500 million USD Scope : 2.5km underpass beneath King

Faisal highwayClient : Ministry of Public Works Country: Bahrain Estimated Tunnelling : Cut and cover Tender Issue Date : Jan-13

• Etihad Rail Phase 3,

Sector : Rail Cost : 2,5 billion USDScope : Final section of 1,200km network to

Fujairah and Oman border Client: Etihad Rail Country: UAE Estimated Tunnelling: Drill and blast Tender Issue Date: Jan-13

• Oman National Railway,

Sector : Rail Cost: 2,5 billion USDScope : 1,370km network, starting with

230km line from Muscat to Sohar Client: Ministry of Transport Country: Oman Estimated Tunnelling : Drill and blast Tender Issue Date : Apr-13

• Mecca-Taif Road Tunnel,

Sector : Road Cost : 533 million USD Scope : 11km road tunnel Client : Al-Tareek Investment & Development

Company Country : Saudi Arabia Estimated Tunnelling : Cut and cover Tender Issue Date : Apr-13

• Abu Dhabi Metro,

Sector : Rail Cost : 7 billion USDScope : 131km network under Abu Dhabi,

mainly tunnelled Client : Ministry of Transport Country : UAE Estimated Tunnelling : TBM Tender Issue Date : Jun-13

• Cairo Metro Line 4 ,

Sector : Rail Cost : 2,6 billion USDScope : 24km metro linking Giza and Grand

Museum to city centre Client : National Authority for Tunnelling Country : Egypt Estimated Tunnelling : TBM Tender Issue Date : Aug-13

• Cairo Metro Line 3 Phase 3 ,

Sector : Rail Cost : 1 billion USD Scope : 16.6km, mainly underground,

extending current Line 3 Client : National Authority for Tunnelling Country : Egypt Estimated Tunnelling : TBM Tender Issue Date : Third quarter 2012

• Baghdad Metro Project,

Sector : Rail Cost : 3 billion USDScope : 39km city centre metro network Client : Baghdad Municipality Country : Iraq Estimated Tunnelling : TBM Tender Issue Date : Dec-13

• Tehran Metro Lines 8,9 and Express Lines,

Sector : Rail Cost : 10 billion USD Scope : 179km expansion of existing system

by 2025Client : Tehran Metro Company Country : Iran Estimated Tunnelling : TBM Tender Issue Date : First quarter 2018

• Al-Hayer Wastewater Project,

Sector : Water Cost : 100 million USD Scope : Two 37km 3,000mm wastewater

tunnelsClient : National Water Company Country : Saudi Arabia Estimated Tunnelling : TBM Tender Issue Date : Bids under evaluation

Selected Major Tunnelling Projects Under Way

• Abu Dhabi Road Tunnels Project, Sector : Road Cost : 817 million USDScope : Three road tunnels and two flyovers

improving road access to Port Zayed Status : Under construction Country : UAE Client : Abu Dhabi Municipality Proposed Completion Date : May-12

• Qatar Education City Utilities Tunnel,

Sector : Water Cost : 184 million USDScope : 9km utility tunnel for Education City

services Status: Under construction County : Qatar Client :Qatar Foundation Proposed Completion Date : May-12

• Dammam University Tunnel Project,

Sector : Road Cost : 66 million USD Scope : 30km connection between university

and hospital Status : Under construction Country : Saudi Arabia Client : Ministry of Higher Education Proposed Completion Date : Oct-13

• Riyadh Road Tunnels,

Sector : Road Cost : 55 million USD Scope : Two road tunnels in Riyadh Status : Under construction Country : Saudi Arabia Client : Riyadh Municipality Proposed Completion Date : Apr-14

• Muharraq Wastewater Treatment Project,

Sector : Water Cost : 250 million USD Scope : New facility including 20.9km gravity

sewerStatus : Under construction Country : Bahrain Client : Muharraq STP Company Proposed Completion Date : Oct-14

• Abu Dhabi Step,

Sector : Water Cost : 1,6 billion USDScope : 41km water storage tunnel Status: Under construction under three

tunnelling packages Country : UAE Client : Abu Dhabi Sewerage Services Co. Proposed Completion Date : Dec 2014

• Etihad Rail Project,

Sector : Rail Cost : 11 billion USD Scope : 1,200km network including six

tunnels Status : Phase 1 under construction Country : UAE Client : Etihad Rail Proposed Completion Date : Jan-18

• Azer Korpu Baku Metro Project,

Sector : Rail Cost : 600 million USD Scope : Under Construction, 12200 m length in

total with 6.5 m 2 EPB (1 Herrenknecht, 1 Robbins)

Country : Azerbaijan Proposed Completion Date : 2015

• Tel Aviv – Jeruselam High Speed Rail Project,

Sector : RailScope : Under construction, 21000 m length in

total, 1 Herrenknecht EPB and 2 double shiled with 10.3 m diameter.

City : Tel AvivProposed Completion Date : 2015

• Tel Aviv Metro Project,

Sector : Rail Cost : 12 billion USD Scope : Under construction, 23 km Red Line with

6.5 m diameter, 35 km Green Line with 6.5 m diameter

Country : Israel Client : Metropolitan Mass Transit System Ltd. Proposed Completion Date : 2017

CONCLUSIONAccording to growing population and increasing economic

opportunities in rapidly developing countries, especially

infrastructure investments in are gaining more and more

importance.

In this context, local administrations have been planing to

invest more for metro, rail, road, clean and waste water

tunnel projects as it is seens in this presentation.

As one of the companies that related in TBM industry , we

would like to be also one of the solution partners for each

single project.

ANY QUESTION ???

THANK YOU