Iain Simmons & David Taylor - Well Connected Alliance

Waterview Connection -The Final Drive to completion

Annual Australian Tunnelling Conference – Sydney 2016

Iain Simmons – Alliance Project Manager, Well-Connected Alliance

David Taylor – M&E Construction Manager, Well-Connected Alliance

11th October 2016

Waterview Connection –The Final Drive to Completion

1. (Re)Introduction to the project

2. Recap on tunnel facts

3. TBM final breakthrough

4. TBM de-mobilization

5. Status across the three distinct project zones

6. Cross passage completion

7. M&E fit-out to the tunnels and ventilation buildings

8. Timeline for completion

9. Community legacy

10. Questions

Contents

Key Auckland transport links- Less than 2km wide isthmus

- Traffic running through congested central corridor

- Overly dependent on central, single north-south spine

- Network “ladder” model adopted

Western Ring Route- One of the NZ Governments seven roads of

national significance (RONS)

- Waterview Connection is the missing link between SH 20 and SH 16

- Completes 48km motorway ring route for the NZ Transport Agency

- Links major population and industrial centres

Waterview Connection- 5km of new motorway

- 2.4km of which comprises two three lane tunnels

Project Costs- NZ $1.4 Billion – the country’s biggest roading

project

(Re)Introduction to the Project

Tunnel Section – Connecting State Highway 16 with State Highway 20

Tunnel Facts

• Southbound length 2398m

• Northbound length 2410m

• Internal dia. 13.1m

• 3 traffic lanes each direction

• Max. vertical grade 5%, curve min. radius 1,500m

• 18 Cross-passages linking both main tunnels together, spaced every 150m

Tunnel LayoutCross Section

M&E

Traffic Envelope

Lining

Pavement

Stage 2 Backfill

Stage 1 Backfill

Service Culvert

Tunnel during excavation

Completing the Northbound TunnelTBM Breakthrough

De-commissioning the TBM

Completing the Northbound Tunnel

Completing the Northbound TunnelDe-commissioning the TBM

Completing the Northbound TunnelDe-commissioning the TBM

Completing the Northbound TunnelDe-mobilisation of the TBM

Great North Road Interchange (GNRI)

• 4 new Highway Bridges linking with State Highway 16

GNRI Current Status

Southern SectionAerial view looking South

Finishing the Southern Approach PortalSouthern civils entering final stages

Cross PassagesLogistical challenge of 16 cross passages

Cross PassagesExcavation – monitoring load transfer

Cross PassagesShotcrete primary support

Cross PassagesWaterproof lining

Cross PassagesInvert Formwork

Cross PassagesCross PassagesCollar Reinforcement

Collar Formwork

Cross Passages

Completed cross passage ready to hand over to the M&E team

Cross Passages

Completing the paving

What’s happening underground right now?

Completing the M&E Installation

What’s happening underground right now?

M&E Fit-out

• Main challenges and lessons learnt

• Ngarara - The drilling gantry

• M&E fit-out Scope of works

Black roof 86,000m2

Tunnel Painting

White walls 48,000m2

• Tunnel Anchors (Approximately 36,000 post installed mechanical anchors in bored tunnel)

• Supports (Approximately 8,600 supports in bored tunnel)

• Typically support groups located (longitudinally) in the centre of every ring, skipping every third ring, e.g. 2m, 2m, 4m spacing

Tunnel Supports

• Tunnel lighting (4000)

• PA Speakers

• Radio Rebroadcast (RRB)

• Dynamic signage

Tunnel Systems

• Speed Cameras

• CCTV

• Overhead detection and barrier gates

• Fire deluge and hydrants (175 sprinkler zones, 109 double hydrant outlets)

• Jet Fans (62)

• Sliding egress doors (36)

• LHD Cable (10km)

Fire Life Safety

• Tunnel and culvert cable support system (50km cable tray)

• HV, LV, data and comms cabling (270T, 400km)

• 8 Transformers, 4 x 22kv Switchgear Panels, 8 x LV 690V/415V MSB, 4 x UPS Units, 500 Batteries, 64 x XP DB’s, 40 x RIO’s

Electrical Distribution

• Exhaust Fans (8)

• Maintenance Hoists (17)

• HVAC

• Fire alarm, gaseous suppression and foam suppression systems

• 3 drainage sumps (13 pumps)

• Fire water storage tanks (5)

• Fire water pumps (5)

Vent Building Systems

Challenges and Lessons Learnt

Design

• Subcontractor design

• Inter disciplinary coordination

Procurement

• Procurement packages

• Overseas supply and lead times

• Seismic compliance

Construction

• Planning & coordination amongst teams

• Storage & site facilities

Commissioning

• FAT

• Systems completion and handover

• Programme

Challenges and Lessons LearntDesign

• Subcontractor design

• Inter disciplinary coordination

• Construction and stakeholder review

Procurement

• Procurement packages

• Overseas supply and lead times

• Post award Subcontractor submittals

• Seismic compliance

Construction

• Resourcing

• Construction area handover

• Planning & coordination amongst teams

• Storage & site facilities

Commissioning

• FAT

• Systems completion and handover

• Programme

Ngarara – The Drilling Gantry

Ngarara – The Drilling Gantry

Ngarara – The Drilling Gantry

Overall Project Programme

October

2016

Waterview Playground

Community Benefits – already in use

Boardwalks, Shared paths, Skate parks, BMX tracks

Community Benefits – more to come

Thank you