Pages From Brochure_INLGESE

Microtunnel

1293 – Gasducto Tamazunchale - El Sauz Ixmiquilpan (Mexico)

Microtunneling at KP 94 Gasoducto Tamazunchale - El Sauz microtunel DI1800 - Ixmiquilpan (Mexico) Customer Transcanada Execution period April 2013 - December 2013 Work value € 6.920.680,00

Technical data

No. Microtunnel Machine Lenght ID OD Straight drive/slope

1 Ixmiquilpan AVN1800D 672 m 1800 mm 2120 mm 672 m / +8.5 %

Jobsite overview Jacking shaft (1773m asl) The Tamazunchale pipeline is a 130 km (81 mi) pipelines in east Central Mexico that connects facilities of Mexico’s state-owned petroleum company to natural gas power generation plants near Tamazunchale, Mexico. For the pipeline installation in the section included in KP 90 and KP 97+500, where unstable soil conditions have been identified, an alternative solution to open trench has been selected. The solution is the construction of a microtunnel with the installation of reinforced concrete pipe ID1800mm, total length approx. 670m. After the construction of the microtunnel and the pipeline pull in, the space between the pipeline and the concrete pipe had been filled with a cement bentonite mixture.

Jacking shaft area The drives passes a mountain with related problems regarding the inert level (up to 150 meters) and geostatic pressure with consequences on the slurry treatment management, lubrication effectiveness and jacking pressure. The Bauer slurry treatment plant linked to the filter press unit provided the required capacity to manage the huge excavated soil production, even though the unforeseen basalt layers found during tunnelling operations. Operating in a very rough mountainous area, quite distant from urban centres, represented on of the greatest challenge for I.Co.P S.p.A. The major suppliers were in the areas of Queretaro and Pachuca (respectively distant about 150 and 120 km from Ixmiquilpan).

Arrival of TBM (1827 asl) TBM breakthrough

Microtunnel

1262 - Muharraq Bahrain Micro Tunnelling work (D1800mm) for the Muharraq Sewage Treatment Plant (STP) and Sewer Conveyance System (SCS) Project – Deep Gravity Sewer (DGS) in Muharraq, Bahrain. Customer SAMSUNG ENGINEERING CO. LTD. (SECL) Execution period Completed Work value (Original) Total Length € 10.178.774,70 5,544.08 m Work value (Additional) Total Length € 2,045,746.81 1,134.79 m

Technical data (Original Scope of Works)

No. Microtunnel Machine Length ID OD Straight drive/slope Curve

Section Curve radius/slope

1* SH #21 – SH #22 AVN1800TB 955.10 m 1800 mm 2200 mm 250 m / - 0.1% 705.10 m 550 m Hor. Sx2 / -0.1 %

2 SH #21 – SH #20 AVN1800TB 586.92 m 1800 mm 2200 mm 210 m / + 0.1% 476.92 m 520 m Hor. / + 0.1 %

3* SH #47 – TLS AVN1800TB 891.25 m 1800mm 2200mm 891.25 m / -0.1%

4 SH #47 – SH #46 AVN1800TB 473.55 m 1800mm 2200mm 473.55 m / +0.1%

5 SH #29 – SH #28 AVN1800D 656.91 m 1800 mm 2200 mm 281 m / + 0.1% 374.91 m 660 m Hor. / + 0.1 %

6 SH #29 – SH #29B AVN1800D 244.58 m 1800mm 2200mm 244.58 m / -0.1%

7 SH #43 – SH #42 AVN1800D 344.10 m 1800mm 2200mm 344.10 m / +0.1%

8 SH #43 – SH #44 AVN1800D 328.75 m 1800mm 2200mm 328.75 m / -0.1%

9 SH #45 – SH #44 AVN1800D 319.64 m 1800mm 2200mm 319.64 m / +0.1%

10 SH #45 – SH #46 AVN1800D 323.28 m 1800mm 2200mm 323.28 m / -0.1%

11 SH #37A – SH #38 AVN1800D 420.00 m 1800mm 2200mm 420.00 m / -0.1%

1* - Longest Multiple Curvature Microtunnelling Drive in Middle East (3 sets of continuous S-Curves) 3* - Longest Sea Crossing Microtunnelling DN1800 Drive in the Middle East

Technical data (Additional Works)

No. Microtunnel Machine Length ID OD Straight drive/slope Curve

Section Curve radius/slope

12 SH #34 – SH #35 AVN1800D 317.73 m 1800 mm 2200 mm 40 m / + 0.1% 277.73 m 2000 m Hor. / +0.1 %

13* SH #12A – SH #11 AVN1500TC 483.06 m 1800 mm 2200 mm 318 m / + 0.1% 165.06 m 400 m Hor. / + 0.1 %

14* SH #10 – SH #11(2) AVN1800D 334.00 m 1800mm 2200mm 85 m / -0.1% 249.00m 500m Hoz. Sx1 / -0.1%

13* - Takeover TBM equipment from other tunnelling contractor 14* - Alternative drive due to other tunnelling contractor failed to complete the planned DN1400 drive. Tunneling pass (max clearance 7m) abandoned 237m DN1400 pipeline and a AVN1400TC Machine. Automatic Spoil Handling System (Bauer BE-500) Shaft Setup with Heat Process System (Cooling System )

With the exceptional growth of population and strategic plans and 2030 Vision to provide capacity to meet the needs of existing and future development in Muharraq Governorate, a BOOT Sewerage Treatment Plant and Conveyance system project was built in Kingdom of Bahrain. The project set out and covers the area of Muharraq, HIDD and Arad, consist of two parts, civil construction of the STP plant, and the other parts, sewer conveyance system. The Sewer conveyance system are constructed in two major section, main collection tunnel – Deep Gravity Sewer (DGS) and lateral connection to replace two major sewage pumping stations and 22 minor ones across the coverage area – Waste water collection network (WWCN). The WWCN pipeline collects the sewerage and directs it towards the DGS pipeline. The DGS conveys the sewerage through a gravity tunnel to the treatment plan through an intermediate lifting station (ILS). Concerning the environmental effects, disturbance to the population and neighbourhood and impact on the UNESCO Heritage Site (Fort Arad), the DGS route consist of 15.9 km of pipeline of DN1000, DN1400 & DN1800 was executed by Micro-tunnelling method. Whereas the WWCN route consist of 4.1km of DN300 to DN800 pipeline constructed mainly with trenchless technology. The success of the project contributed the reduction of energy use, reduced risk of odour, traffic disruption during maintenance, sewers backing up and associated sewage flooding. The sewage undergoes treatment process to produce Treated Sewage Effluent (TSE) suitable for re-use in industrial application, irrigation or landscaping. 47 nos. of shafts are constructed with Secant Pilling method to provide a watertight pit for the micro tunnelling activities. Upon completion of the pipeline installation works, the shafts are then converted to permanent manholes. Trenchless installation methods have less impact on the environment and the existing infrastructure than other methods applying open cut trenching. I.CO.P. had undertaken 5.5 km of the DN1800 pipeline. Two sets of Herrenknecht AVN1800 were utilized to tunnel the GRP Encased RC Jacking Pipe. The major challenges encountered during the execution of the works are the existing ground conditions (Layered of Anisotropic sequence of rock), high ground water table with influents of sea tidal, long and multiple curvature drives, historical and protected areas and tight construction tolerances. I.CO.P claims two major milestone records on the project by executing the longest DN1800 Sea Crossing (892m) and longest DN1800 Longest Multi Curvature Micro tunnelling Drive (955.10m with 2 sets of S-curves). Both records are not only valid in the Kingdom of Bahrain but throughout the Middle East Region. MICROTUNNEL no. 1 (Longest Multi Curvature Micro tunnelling Drive in the Middle East) During the project commencement and design phase, I.CO.P, EPC Contractor and the design consultant had been closely working on the tunnelling route, material optimization and value engineering to optimize the feasibility to construct the DGS pipeline considering the challenges and actual conditions on site. The table below compares the status of the pipe route/criteria based on the original pre engineering stage and post value engineering stage. Pre Engineering/Tender Pipeline Route along Fort Arad area (PS B2 to PS B3)

Microtunnel

Technical data of the pre and post value engineering stage (Fort Arad Section – PS B2 to PS B3)

Stage Pipe DN Total no.

of Shaft No. of Start

Shaft No. of Arrival

Shaft Distance

between Shafts Drive

Criteria Post/Tender 1400 5 3 2 Av. 280m Straight Pre/Construction 1800 2 1 1 942m S-Curves

Post Engineering/Optimization of Pipeline Route along Fort Arad area (PS B2 to PS B3) The optimization of the tunnelling route was finalized and approved by the project owner in the benefits of all parties. Shaft no. 21 that was originally 10A was designated as the launching shaft for the long DN1800 multi curvature drive towards the arrival shaft no. 22 that was originally 10E. The shafts (10B, 10C and 10D) allocated in between the drives were omitted. The drive was completed 25 days ahead of schedule. TBM Breakthrough at Shaft #22 Tunnel Auxiliaries along the drive

MICROTUNNEL no. 3 (Longest Sea Crossing Microtunnelling DN1800 Drive in the Middle East) This drive set out to be the longest sea crossing microtunnelling DN1800 drive that was executed within the project. The drive starts from Shaft #47 allocated at the Khalifa Bin Salman Causeway tunnelling under the wave break rocks then under the Gulf Sea into a man-made island into the Temporary Lifting Structure (TLS) shaft.

Multi Nationality Work Crew for the International Project TBM Breakthrough TBM Launching Site Setup with Gantry Crane

Microtunnel

1256 – Collalto (TV) Works for the construction of Edison gas pipeline (ID 600mm – 24”) connection of Collalto (Treviso). Jacking of 3 microtunnels: “Torrente Rujo”, “Castello S. Salvatore” and “Bosco Buricolat”. Customer Snam Rete Gas S.p.A. - San Donato Milanese – MI Execution period July 2011- March 2012 Work value € 1.550.000,00

Technical data

No. Microtunnel Machine Lenght ID OD Straight drive/slope Curved drive Curve radius/slope

1 Torrente Rujo AVN1600D 306 m 1600 mm 1940 mm 33 m / 7,32 % 270 m 600 m vert. / 7,32 – 45 %

2 Strada Comunale S. Salvatore

AVN1800D 726 m 1800 mm 2160 mm 381 m / -1,2 % 345 m 1500 m horiz. / -1,2 %

3 Bosco Buricolat AVN1600D 213 m 1600 mm 1940 mm 213 m / 0,25 %

Slurry and bentonite management operations Preparation of an interjack station. The 3 microtunnels driven by ICoP S.p.A. are part of the wide Snam Rete Gas project to develope the gas pipelines network by starting from the San Polo di Piave connection plant and passing through the municipality of Vazzola, Santa Lucia di Piave and Susegana (Treviso). The whole project develops under the Collalto hills, an high worthy area from the point of view of wine production, natural and cultural interest. ICoP S.p.A. pipe jacking technology was able to provide the most suitable tecnique to minimize the visual impact during and after the tunnelling operations and the installation of the gas pipeline (ID 600 mm – 24”) was possible. MICROTUNNEL 1 “TORRENTE RUJO” The large height gap between the jacking shaft (86 m above m.s.l.) and the receiving one (167 m above m.s.l.) and the relative short horizontal distance (289 meters) rappresented the greatest challenge for ICoP S.p.A.. After the first 33 meters long span with a 7,32% slope, the inclination of the tunnel axis increased constantly with a 600 m vertical radius and reached a final slope of 45%. These percentages requires the solution of many technical problems regarding jacking pressure, slurry pumping network, fluid losses, safe access to the tunnel by properly trained workers. A suitable ropes and breeching system was developed to ensure the safety and to continue the tunnelling works althought the high slope percentage. Despite the described problems the microtunnel was completed within the foreseen period of time.

MICROTUNNEL 2 “Attraversamento strada comunale San Sa lvatore” It is one of the so-called “Long Distance Microtunnel”, because of his lenght (more than 500 meters) and his inner diameter of1800 mm. The designed tunnel has a first straight 381 meters long section and a second 345 m long one with an horizontal radius of 1500 meters and -1,2% slope. The drives passes under 3 different hills with related problems regarding the inert level (over 50 meters) and geostatic pressure with consequences on the slurry treatment management, lubrication effectiveness and jacking pressure. The Bauer slurry treatment plant linked to 2 decanter units provided the required capacity to manage the huge excavated soil production, even though the unforeseen hard clayey and conglomerate layers found during tunnelling operations. MICROTUNNEL 3 “Attraversamento Bosco Buricolat” It’s a straight drive with a constant -0,25% inclination. The tunnel axis passes under the northern slope of one of the hills in the so-called “Madonna del Buricolat”. The ICoP S.p.A. pipe jacking trenchless technology allowed the main contractor to build his new pipeline even if placed in an environmentally sensitive area with grass fields, grass feed and woods with a minimal impact and, most of all, with a small working space requirement. The main geology made of conglomerate formations with rare clayey layers was easily managed by the slurry treatment plant by reducing the disposed materials and using part of them in the grouting of the tunnel after the 24” pipeline installation.

The castle of Collalto Pipe jacking operations

A view of MT2 job site. Final recovery of AVN1600D machine

Microtunnel

Designed microtunnel profile of “ Torrente Rujo” drive

Microtunnel

1255 - Shell Connect Project Double crossing of the river Rhine plus 1.5 km of pipeline in between to connect two Shell refineries with four different product pipes. Customer SHELL Deutschland Oil GmbH Execution period July 2011 – May 2013 Contract value 15.885.606,00 €

Technical data

No. Microtunnel Machine Length ID OD

1 Godorf-Tunnel AVN D 2000 AB 1300 m 2000 mm 2500 mm

2 Wesseling-Tunnel AVN D 2000 AB 1200 m 2000 mm 2500 mm

Pipeline description Starting shaft Shell Deutschland Oil GmbH planned the construction of an underground pipeline to connect the two Shell refineries in Wesseling and Cologne. The line is about 3,8 km and crosses the Rhine twice. The aim was to avoid the installation of the pipeline in the densely populated area on the left side of the Rhine. Both crossings, with a length of respectively 1.191 m and 1.299 m, were executed in microtunnelling process. The drilling was executed with reinforced concrete pipes DN 2000, which later acted as casing pipes for several product lines.

To perform the project river Rhine was crossed twice. Here you can see a map of the project, which required also the installation of 1.5 km of pipeline in between to connect the two Shell refineries.

Microtunnel

I.CO.P. was awarded both drilling projects thanks to its expertise based on the successful execution of many similar projects in the field of microtunnelling. The contract was concluded according to international / English contract law (EPCM Contract – Engineering / Procurement / Construction / Management), so that it can be spoken not only of construction performance but also of project success. Technical challenges: Crossing of several dikes in in homogenous ground conditions and work within a potential flooding-area. Several layers of brown coal had to be tunnelled through. Soil conditions : Launching pit: Gravel, sandy Gravel, clay Receiving pit: Gravel, sandy Gravel Drilling section: Gravel, sandy Gravel, clay, brown coal

(more than 750 m)

AVN D 2000 AB Cutting wheels

Launching Pit Break through

Microtunnel

No. MT / Direct Pipe Machine Length ID OD

1 Scolo Riolo (DP) AVN1000XC 360 m 1200mm -

2 Dosolo (DP) AVN1000XC 596 m 1200mm -

3 Fiumazzo (DP) AVN1000XC 371 m 1200mm -

4 Reno 1 (MT) AVN2000D 462 m 2000mm 2500mm

5 Reno 2 (DP) AVN1000XC 721 m 1200mm -

Technical Data

Execution of microtunneling and direct pipe works as part of the construction works for the pipeline Poggio Renatico – PIL 8 – Section of Poggio Renatico – PIL 8 (48) L = 36.656 km – 75 bar and secondary works.

Execution periodNovember 2010

1246 - Sala Bolognese (BO)

Work value€ 2.600.000,00

Customer

As part of the works for the construction of the pipeline SNAM Poggio Renatico – Sala Bolognese, I.CO.P. has been using a new trenchless technology – called Direct Pipe – to carry out three crossings.Patented by Herrenknecht AG, the Direct Pipe technology combines a typical microtunneling drilling system with a special thrusting unit called „Pipe Thruster“, enabling the laying of product pipelines without need of previously realized casings, as it is the case in microtunneling works.The Pipe Thruster consists in a clamping unit connected to a base structure by means of two hydraulic cylinders. By means of this system the steel pipeline is fastened and thrust into the soil, advancing as drilling takes place. In this way, long pipe strings are pulled in at a time, while considerably reducing both drilling and pull-in times, if compared to other trenchless technologies. The crossing of the channel “Scolo Riolo” - nearby Galliera (Bologna) - worked as pilot project for the launch of this technology in Italy.

Pipe string being pulled in through the launching pit Launching pit area

Straight sections / gradient Curved sections

83,13m + 36,10m 96,99m + 114,14m

209,57m+148,56 + 29,60m 211,13m

83,13m + 24,31m + 52,77m 97,00m + 114,14m

29,94m + 35,94m 396,08m

241,48m+149,34 329,93m

Snam Rete Gas S.p.A

Microtunnel

Installation of the clamping unit on the string to be pulled-in TBM receiving area DP Scolo

View of the starting shaft and the pipe string being pulled in Pipeline pull-in on guide rollers

The drilling consisted in the crossing of a river and a B-road. The drilling section, with bowing effect, had a total length of about 380 m, with a starting gradient of 7% and final gradient of 8% at the receiving pit. The drilling mainly took place in clay soils of medium consistency, with a few sections in clay sands. Two 48-inch pipe strings of 190 m each were pulled in and welded together after the first pull-in sequence. The crossing, including welding operations, was completed in about 10 days from the launch of the TBM. Maximum daily production amounted to 100m.

I.CO.P. S.p.a. Tel. +39 0432 838611Via S. Pellico, 233031 Basiliano

ISO 9001Fax +39 0432 [email protected]

C.F. e P.IVA 00298880303Reg. Impr. Udine 00298880303

ISO 14001OHSAS 18001

(UD) Italia www.icop.it R.E.A. 131947 Udine SA 8000

Microtunnel

Microtunnel Area L(m) ID(mm) ED(mm)

Offshore Livorno-Italy 750 2000 2500

Technical Data

Construction of a pipeline 2,500 mm in external diameter to be executed with microtunnelling techinque - OFFSHORE technology

Execution periodaugust 2010

1239 - Livorno Offshore

Work value€ 1.820.000,00

Customer

Construction of a 32" pipeline which, from the OLT LNG terminal, located off the Tuscan coast, reaches the mainland and joins the national transportation system in the municipality of Collesalvetti (Livorno). From the environmental point of view Livorno and its ecosystem are considered protected areas, but in the junction area have been found traces of contaminants that characterized the materials handled during the excavation as hazardous waste. For this reason, treatment and disposal of polluted materials would have constituted a significant burden in terms of cost and implementation time for the project. The alternative to digging an open trench was the trenchless technology, by means of a microtunnel able to pass under the polluted areas and to reduce the amount of material being handled. This technology implied an horizontally moving forward, towards the open sea, of a cutter head with ED of 2.5 m. The microtunnelling profile was determined by considering the maximum share of polluted sediments and the point closest to the coast with depth at least of -3.50 m (necessary in order to place a barge with a crane to recover the TBM). This resulted in a total length of microtunnel equal to 750m at a depth ranging from -8.80 m to - 6.00 m.

AVN 2000 Intermediate thrust station

Snam S.p.A.

Microtunnel

Detail of the Recovery Unit Starting shaft area

Backflling plant Starting shaft

The cutter head was placed in a 11.50 m deep shaft, dug in a "artificial temporary peninsula", previously constructed near the Canal Calambrone Bridge. Once, reached the final length of 741m, as provided in the project, the operations for the recovery commenced of TBM started following the listed steps: dredging around the cutting head, shaft and tunnel flooding with sea water, disconnection of the TBM from the first concrete ring, coupling and removal of the TBM by means of a suitable crane placed on the pontoon. The excavation of the tunnel reached peaks of 53 meter daily progress, respecting the timeframe of the program and without facing any technical problem. The drilling equipment installation was complicated by the small size of the thrust shaft and by the different structures necessary for its stability. After the necessary work to allow the TBM through the thrusting wall the installation of the microtunnel began. The need to pass through sediments with very small bearing capacity has made the implementation very difficult, requiring additional controls throughout the work activity in order to prevent mismatches with the quota and the directions of the project. The excavated material has been treated by means of filter presses that have allowed the transport to a waste recycling by reusing the water for the process of excavation and thus minimizing the use of resources.






Microtunnel

No. Crossings Length ID (mm) ED (mm)

1 Vacchelli Canal 374,29 m 2000 2400

2 Serio River 782,72 m 2400 3000

Technical Data

Microtunnel River Crossing: Vacchelli Canal and Serio River as part of the works for the construction of the Snam Rete Gas " Cremona -Sergnano" pipline. Lot no. 3.

Execution periodaugust 2010 - may 2011

1232 - Cremona

Work value€ 2.120.000,00

Customer

Snam Rete Gas has started laying the Poggio Renatico – Cremona gas pipeline, which will have a total length of about 150 Km, a nominal diameter of 1,200 mm (48”) and a working pressure of 75 bars. It will take the place of the existing, old ND 550 mm (22”) pipeline in operation since 1959, which runs from Minerbio to Cremona, thus increasing the capacity, flexibility and reliability of gas transport.

The gas pipeline runs through the Regions Emilia Romagna and Lombardy and the route of the new gas pipeline runs along many watercourses, such as the rivers Reno, Panaro, Secchia, Taro and Po, which will be crossed with trenchless technology to reduce the environmental impact of the work site to a minimum.The works we are referring to in this technical sheet are part of Lot no. 3 of the pipeline, belonging to the Cremona - Sergano increase.

Microtunnel Serio River starting shaft Job site area: separation plant

Machines

AVN 1500TI with extention kit and mixed boring machine

AVN 2000D with extention kit and mixed boring machine

Snam S.p.A.

Microtunnel

Mixed boring head for M591 used for the Vacchelli Canal crossing

Air quality monitoring while dismantling

The new pipeline - DN 1200 (48”) – starts near the existing Snam Rete Gas plant called “Cremona Junktion”; it then continues north-west ward, joining the existing pipeline DN 500 (20”) as far as the existing Snam Rete Gas plant called “Sergnano Junktion” where it ends.

The project involved the construction of two river crossings using the microtunnelling technique.The Vacchelli Canal crossing has a catenary layout: initial straight section with a gradient of -10,5%, then curving with radius R=1600m. Final straight section with a gradient of + 10,5%. The tunnel crosses sandy layers, with gravels quite small in size (2 – 3 cm), at the beginning and at the end, it also crosses larger gravels alternate with silty and clayey layers in its central part. Ground water level varies from – 2 to – 3 from ground surface.

The Serio River crossing has an initial straight section with a gradient of -10,5%, vertically curving with radius R=2000m up to a gradient of +0,5%; a straight section of about 295 m and another vertical curve with radius R=2000m follow in order to connect it with the breakthrough straight section with a gradient of 9,3%. The tunnel crosses sandy layers, with gravels (maximum size: 10 cm) at the beginning and at the end; there is a presence of alternate sandy and gravelly layers in the central part. Ground water level varies from – 1 to – 2 from ground surface.

In both cases the starting pit perimeter walls are made of sheet-piles. Inside that area it was then built the concrete box construction, including the thrusting and insertion walls.






Microtunnel

No. Microtunnel Length ID(mm) ED(mm)

1 PK0-PK13 1174 m 2000 2500

2 Pk53-V66 447 m 1600 2000

Technical Data

Connection to OLT Terminal in Livorno – Italy - Construction of no. 3 microtunnel and recover of the machine from the sea thanks to the OUTFALL technique.

Execution periodapril 2010 - may 2011

1231 - Livorno - OLT

Work value€ 3.034.202,00

Customer

The work consisted in the construction of 3 microtunnel with lengths of 1174 m, 884 m and 447 m and the relative starting and receiving pits.Peculiarity of the work was the recover of the AVN2000 M-583 machine from the sea ("OUTFALL" technique). The recovery was carried out and coordinated together with our client, the company SIDRA of Rome, as part of the work in Livorno for the regasification plant called OLT Offshore LNG Toscana. Special features of this work was the machine equipment, which was designed and built by I.CO.P. ‘s engineers and technicians in order to perform the recovery of the shield ensuring perfect water tightness of electromechanical equipment. After I.CO.P.'s work in Mira (Portugal) this is the first case in Italy of shore approach and its great success will help the use of the microtunnelling technique any time it is necessary to use trencheless technology to solve problems related to pipeline installation near the coastline.

Jacking station Job-site area on the bay

DENYS NV

Microtunnel

Injection plant

Starting Pit PK0-PK13 Starting Pit PK53-V66

TECHNICAL PARTICULARITIES OF THE CONSTRUCTION:• Pit constructed directly on the bay. • Machine recovered using platforms and swim cranes.• Special aim to sealing construction of the jacking pipes due to the ground conditions - quick sand, highly water sensitive ground. • Environmental protected area • Restricted access close to an harbor area• Complicated operation of the D-Mode system• Stabilization of the face of the ground using the telescopic unit• Permanent surveying • Under water recovering






Microtunnel

No. Microtunnel Area Length ID(mm) ED(mm)

1 Ems river Leer, Germany 1070 m 2000 2500

Technical Data

Microtunnel “Ems crossing at km 19.160” in Jemgum (Leer) – Germany

Execution periodnovember 2009 - november 2010

1224 - Leer - Germany

Work value€ 4.255.644,40

Customer

Works to construct the pipeline “Bunde - Etzel” with DN1200 (48’’):• Crossing under the Ems river with minimum distance between the bottom of the river and the tunnel of about 7m; maximal depth of the river: 12 m of with an average tide of 8 meters.• The starting pit is situated close to the Ems river; the pit is realized with bored piles, with vertical (in order to anchor the bottom of the pit against the water pressure beneath) and sub-horizontal (at the thrusting wall, in order to countervail the subsequent force due to the jacks) GEWI bars . Afterward it has been executed the excavation in water, the concrete cast and the drain of the fund. The structure is made of reinforced concrete. The arriving pit on the other side of the river has been constructed driving sheet piles in the ground as internal facing of the shaft and then casting not reinforced concrete on the arriving wall.• The tunnel is constructed with an AVN2000D with external diameter of 2500mm.

Inner area Strarting shaft with jacks

BEP Bunde-Etzel-Pipeline GmbH & Co KG

Microtunnel

Job site area Staff

Arrival of the machine in the exit pit Insertion of the gas line inside the tunnel

• Characteristics of the track: length L=1070m, initial descendent slope with a gradient of roughly 7%, Euler spiral for about 200m until the middle section (without gradient); final uphill part for about 150m with a gradient of about 4%. Level difference between the entrance and the exit of approximately 1m. Time of the drilling: 6 weeks• Drilling in clayey peat with presence of wood stumps at the beginning; then the material was mostly sandy loam, until the last part where it was again clayey peat.• Installation of the pipeline by pulling from the arrival shaft with a rig for HDI. Installation of sledges for the pulling phase in the tunnel.






Microtunnel

Nr. Microtunnel Area L(m) ID(mm) OD(mm)

1 Outlet tunnel V1 Mira, Protugal 1350 2600 3300

Technical Data

Projecto de Execucao Aquicola de Engorda de Pregado, em Mira, Coimbra, Portugal, Acuinova - Actividades Piscicolas, SA. Execution of a jacking 2,600/3,300 mm

Execution periodapril 2008 - september 2008

1185 - Mira, Portugal

Work value€ 3.375.000,00

Customer

In 2008 I.CO.P SpA was awarded a special project in a small town near Mira in Portugal. Pescanova Group had planned to execute this project in the expansion of the existing cultivation plant in Spain. The project consists of two parts: civil construction of buildings, structures, ponds for the cultivated fish and the construction of a pipeline connecting the cultivated area with the sea. The pipeline construction comes in 4 sections. Two sections (T1 & T2) are for pipeline for the intake of the sea water and the remaining two sections (V1 & V2) are for the ones for the discharge of the sea water. Concerning the environmental effects of the water used to grow the fish, a feasibility plan had been studied and microtunneling method had been seriously considered as the most effective method to construct the 4 sections of the pipeline. The tunnelled outfall constructions are often an effective and sustainable possibility to improve the quality of live in coastal areas. With the sea outfalls the water from the fish tanks can be transported away from the coastline and discharged at locations where diffusion, dispersion and decomposition are enhanced.

Eye bird view of the starting pit Tunnelling works in process

Machine Model Str../Curve

Herrenknecht AVND2000AB w/ ext.3300 - 1.1%

Pescanova Group

Microtunnel

Tunnel auxiliaries and piping running 1,35 km from the shaft to the TMB

Port of Averio, Portugal

TMB subsea recovery by BALLON BALLAST method Succesful recovery of TMB at Port of Averio, Portugal

The tunnel starts from a shaft (dia.18m, depth 12m - diaphragm wall method) and exist towards the sea (subsea recovery method).The project was successfully completed in 10 weeks, 4 weeks ahead of schedule with 1 week of standstill due to tunnel engulfment. 12 nos. Of Intermediate Jacking Station been installed along the tunnel but non had been utilized. The tunnel was completed and push through for subsea recovery with maximum force of 1100tons. The project was a trademark for the microtunnelling works with combination of best implementation results through proper engineering and planning, use of lubrication, controls and guidance including the team works in this project.






Microtunnel

N. Microtunnel Località L (m) DI (mm) DE (mm)

1 Leila Fusine 600 2000 2400

2 Valbruna Malborghetto 585 2000 2400

Dati tecnici

I microtunnel sono stati realizzati per superare dossi montuosi, evitando aree boschive di elevato pregio naturalistico (M.te Leila) e l’interessamento di versanti acclivi e potenzialmente instabili (Valbruna), nell’ambito della realizzazione del metanodotto Malborghetto-Tarvisio DN 900. Nel caso del microtunnel Valbruna lo scavo ha interessato la formazione geologica dei calcari di Bellerophon, nelle sue facies dolomitiche ed argillitiche. Per meglio determinare i rapporti tettonici-stratigrafici tra queste due formazioni sono stati realizzati 2 sondaggi a carotaggio continuo e 2 sondaggi a distruzione di nucleo (circa 120m di sondaggi complessivi): i risultati hanno evidenziato la presenza per buona parte del tracciato dei calcari in facies argillitica. Per evitare frequenti fermi macchina dovuti all’impastamento della testa nelle argille, è stato ottimizzato il tracciato (curvilineo con raggio di curvatura = 4250 m) riducendo al minimo l’attraversamento di quest’ultima formazione geologica a favore dei sovrastanti calcari dolomitici.

Microtunnel Leila: panoramica del cantiere Microtunnel Valbruna: installazione della stazione intermedia

Rett./Curvo

R/p.20%

C/ r.425

Metanodotto Snam Rete Gas Tarvisio-Malborghetto DN 1200 (48”) – lotto “B”-Minitunnel Leila e Valbruna

Periodo esecuzioneGiugno 2004 - Febbraio 2005

1090 - Valbruna - Tarvisio

Importo lavoro€ 3.000.000,00

CommittenteSnam S.p.A.

Microtunnel

Microtunnel Leila: particolare del freno ("pipe-brake") Microtunnel Leila: fresa a fine perforazione

Microtunnel Valbruna: posizionamento di un concio in c.a. Microtunnel Leila: uscita della fresa nella rincea di arrivo

L’accorgimento ha permesso di terminare la perforazione in circa 8 settimane, con produzioni fino a 115 metri settimanali senza fermi macchina. Il microtunnel Leila è stato invece scavato per i primi 450 metri all’interno della “Dolomia dello Schlern”, dolomie e calcari dolomitici con locali fratture (UCS da 50 a 120 MPa) e per gli ultimi 150 metri nella “Formazione di Buchenstein”, calcari e calcari marnosi (UCS=80 MPa). L’elevata pendenza del tracciato (20%) ha imposto l’adozione di un particolare accorgimento "pipe-brake" (freno condotta), posizionato nel pozzo di partenza, per evitare lo scivolamento della stessa durante le fasi di installazione di nuovi tubi in c.a. In entrambi i casi è stata utilizzata un’AVN 2000D, dotata di una testa chiusa e dischi da roccia, con fronte ispezionabile dall’interno della macchina nell’eventualità di sostituire gli utensili di perforazione durante lo scavo.






Microtunnel

Nr Microtunnel Area Straight L. (mt) ID (mm)

1 Backental Mettmenstetten grad. 1,4% 655 2000

Technical Data

Construction of microtunnel DN 2000 l = 825 mt in the Mettmenstetten area Zurich (CH)

Execution periodFebruary 2004 - July 2004

1070 - Mettmenstetten (CH)

Work value€ 2.806.413,18

Customer

The microtunnel is part of the project for the construction of a pipe for meteoric water collection connecting the national road nr. 4.1.6 and the Backental treatment plant. This 1460 mt long pipe has been constructed contemporary excavating on both sides of the tunnel with two different techniques, chosen according to their geological function. On one end of the tunnel an open TBM Robbins cut the rocky part of the excavation (762 mt), on the other end the Hydroshield AVN2000D drilled the glacial deposits (in presence of groundwater) with the microtunnel technique. In the preliminary phase two investigations were conducted in order to determine the limit between the rock basis and the upper morainal deposits. The results led to the definition of the exact route to be drilled with the AVN 2000D and the one to be drilled with the TBM Robbins. A further geognostic investigation revealed the geomechanic characteristics of the rock basis (constituted by sandstones, siltites and hard marles, with UCS 480-800 Kg/cm) and of the loose soil, constituted by fluvioglacial and full of water morainal deposits.

AVN2000D ready to start AVN 2000D at the end of the drilling

OD (mm)

2500

Arge Stollen Backental

Microtunnel

Recovery of AVN2000D at the end of the drilling Separation plant

Lowering of pipe ID 2000mm/OD2500mm Shield with rock cutting head

The AVN 2000 D was equipped with a closed rock cutting head, with a diameter of 2525 mm and 12" discs to drill both the cobbles and the final rocky part. Peculiar of the work was the recovery phase of AVN machine inside the tunnel drilled by TBM.






Microtunnel

Nr. Area Machine Model Drill.diam.

1 Genova Pegli Herrenknecht AVN2000D 3025 mm

Technical Data

Construction of the microtunnel connecting the Porto Petroli in Genova and the Praoil deposit in Genova Pegli

Execution periodFebruary 2003 - June 2003

1006 - Genova Pegli

Work value€ 3.617.328,00

Customer

In the project aiming to reorganize oil transportation, Praoil Oleodotti Italiani SpA, which is part of the Eni group, decided to use the microtunneling technique in order to directly connect the Porto Petroli in Genova Multedo and the Genova Pegli deposit.The microtunnel construction avoided to cross all morphological asperities and also all structures and infrastructures on the route. The use of an AVN2000D microtunneler allowed the crossing of the litotypes investigated by the geognostic report: clays, calcitic lime, ophiolites, flowage.The need to launch a pipeline made of nr. 4 pipes DN750mm and nr. 2 pipes DN300mm inside the microtunnel, imposed the total respect of the very small lying tolerances. The guide system usually employed was used adopting special devices, in order to reduce the tolerances typical of this kind of method. The area where the microtunnel was excavated is geologically characterized by Quaternary covering and reduced lenses of plyocenic deposits (“Argilliti di Ortovero”) laying on a cristallinic base, constituted by rocks related to oceanic crust (“Gruppo di Voltri”).

Work area at the starting shaft Breakthrough at the arriving shaft

Curved tunnel ID (mm) OD (mm) L. (mt)

r.2150mm 2600 3000 643

Praoil S.p.A.

Microtunnel

Internal view of the tunnel Pipe line installed inside the tunnel

Shield cutting head Launch of the pipe line (starting shaft)

The drilling involved the following litotypes:• from 0 to 140 mt "Argilliti di Ortovero": sands, siltites, sandstones and sandly marls; • from 140 a 590 mt, "Calcescisti del Monte Turchino": micaschists, calceschists and graphitic schists;• from 590 to 630 mt, "Ofioliti del Monte Beigua": "Ophyolitic breccias" and serpentinites;• from 630 mt to the end: alluvial deposits.During the drilling, due to the considerable mechanical properties of the drilled rocks, it was necessary to substitute the worn-out drilling equipment.In order to avoid settings in the Aurelia main road area, which was close to the arriving shaft and therefore with reduced cover, some consolidating injections were performed along the drilling axis. The injections, together with the guiding precision (maximum variations were comprehended in a range of ± 6 cm, considering both the vertical and the horizontal axis), allowed to end the drilling without surface setting.Once the microtunnel was ended, a pipe line made of four DN 750 pipes and two DN 300 pipes was launched inside it.






Microtunnel

tunnel hosting a conveyor belt length. 480 m

connecting shaft vol 1600 mC

depth of the shaft below s.l. 37,50 m

diam. of the shaft 14,20 m

Technical Data

Works to connect the deep ocean wharf of the Port of Savona to the city cable-car lines

Execution periodjanuary 2004 - 2010

9929 - Savona

Work value€ 35.472.374,28

Customer

Construction of civil works and systems for the transport of raw materials offloaded from ships, to replace the old cableway that crossed through the centre of Savona. The civil works involved a: sorting tower to gather the raw materials as they are unloaded from the ships; a 480 m long tunnel running just under wharf ground level to host a conveyor belt to carry the raw materials to the storage pit; connection well servig as storage for the materials (volume approx. 1600 m3, depth 37.50 m below sea level and diameter 14,20 m).

Intermediate shaft Box tunnel

DN microtunnel 2500

microtunnel leng 1077 m

microtunnel gradi 22%

FUNIVIE S.p.A.

Microtunnel

Connection well (microtunnel starting shaft) Microtunnel hosting conveyor belt

The connection well reaches nearly 40 meters below sea level The route along which the work has developed: from sea level - gradient: 22%

Inside the microtunnel DN 2500, lenght 1077 m, constructed onslope with a gradiente of 22%, there is a special conveyor belt to move the raw materials from the port to the overlying hillside. To the already mentioned civil works, an intermediate microtunnel aeration pit was added.






Microtunnel

Nr Microtunnel Crossing Curved/St. L. (mt) I.D. (mm)

1 Ceresone River Camisano (Vi) C/r.1800 159 2000

2 Rio Puina Camisano (Vi) C/r.1800 261 2000

3 Grimana Rd21 Camisano (Vi) C/r.2000 213 2000

4 Rio Tesinella M4 Grisignano (Vi) C/r.2000 216 2000

5 Main road 11 Grisignano (Vi) S/g.0.5% 90 2000

6 Rio Settimo Grisignano (Vi) S/g.0.4% 60 2000

7 Bacchiglione r. Montegalda (Vi) C/r.2000 738 2000

8 Main road 16 Montegaldella(Vi) S/g.0.5% 90 2000

Technical Data

Works for the construction of the pipeline Camisano Vicentino-Zimella DN 1400 (56”) of the by-pass line at the Zimella DN 1200 (48") junction and of the Guà and Bacchiglione river crossings along the pipeline Sergnano-Tarvisio DN 850 (34”)

Execution periodAugust 2005-December 2006

9937 - Camisano Vicentino -Vi

Work value€ 20.678.000,00

Customer

In the area of Vicenza and Verona I.CO.P constructed 18 microtunnels. 16 of them were constructed along the new pipeline Camisano Vicentino-Zimella DN 1400 (56”) and 2 of them on the Sergnano-Tarvisio DN 850 (34”) pipeline. The work also included the construction of all starting and arriving shafts.4.295 mt were drilled, in drilling sections going from the 738 mt of the Bacchiglione River microtunnel to the 60 mt of Scolo Ronego one. Underground channel and river (Guà and Bacchiglione rivers) crossings, motorway and main road crossings were constructed constantly checking the drilling pressure during the excavation, executed using two Herrencknecht machines (AVN2000D machine for microtunnels nr. 1, 2, 3, 4, 7, 9, 10, 16 and AVN 1600 machines for microtunnels nr 5, 6, 8, 11, 12, 13, 14, 15). The drilling involved alluvial river deposits, and more in general from medium to fine sands with loam; near the main rivers (Guà river and Bacchiglione river) there were peat and clay levels thick up to some meters; only locally there were gravellous strata.

Microtunnel nr 2: machine in the starting shaft. Microtunnel nr 7: view from the starting shaft

Nr Microtunnel Crossing Curved/St. L. (mt) I.D. (mm)

9 LEB channel Mossano (Vi) C/r.1800 306 2000

10 Bisatto channel Barbarano (Vi) C/r.2000 213 2000

11 Scolo Rion Villaga (Vi) C/r.1800 189 2000

12 Scolo Seonega Villaga (Vi) S/g.1.61% 93 2000

13 Scolo Liono Sossano (Vi) C/r.2000 273 2000

14 Scolo Ronego Orgiano (Vi) S/g.1.53% 60 2000

15 LEB channel Cologna V.ta (Vr) S/g.0.01% 72 1800

16 Guà river Cologna V.ta (Vr) C/r.2100 318 2000

Snam Rete Gas S.p.A.

Microtunnel

Microtunnel nr. 5: cutting head arrival of AVN 1600 Microtunnel nr.16: AVN 2000D breakthrough

Cutting head Microtunnel nr. 16: starting shaft

The drilling did not present any particular difficulty. Some problems of watertightness emerged in those shafts where the excavation was executed within fine sand with loam deposits. In this cases the difficulties were overcome both by the execution of well points and by using the jet grouting technique for the construction of reinforced concrete diaphragm walls and sheet piles.






Microtunnel

N. Microtunnel L(m) ID(mm) ED(mm)

1 Castelluccio 960 m 2400 3080

2 Piano di Comi 915 m 2400 3080

Technical Data

Works for the construction of the Montalbano Elicona - Messina DN 1200 (48") pipeline - 75 bar. Lots A and B.

Execution period2008 - 2009

9946 - Messina - Lots A & B

Work value€ 42.150.000,00

Customer

TECHNICAL DETAILS OF THE CONSTRUCTION of the microtunnel “Castelluccio” in Villafranca Tirrena (ME) – Italy:• The starting pit, situated inside the river shore, is constructed excavating and executing the concrete structure; the arrival is inside a trench. The maximum depth under the mountain is of about 200m. The tunnel is constructed by means of an AVN2500D with an external diameter of 3080mm.• Characteristics of the track: length L=960m, constant gradient of 5,6%, planimetric alignment with one curve of radius R=4000m. Level difference between the entrance and the exit of about +55m.• Drilling in metamorphic rock with high degree of alterations and cracks, presence of more than one area of fault with oblique direction compared to the alignment. Prolonged stop of the drilling process cause by the huge pressure and friction made by the rocks passed during the advancement in a fault area. Realization of works to remove the blockage and restart with the normal process of pipe jacking.• Insertions of sections with triple joint followed by pipeline installation from starting pit (thrust by a winch and pulleys).

Piano di Comi job site eye-bird view Installaton of one machine element - Piano di Comi

Snam Rete Gas S.p.A.

Microtunnel

View of the tunnel during the drilling phase - Castelluccio Machine breakthrough - Castelluccio

Machine breakthrough - Piano di Comi Insertion of the 42’’ pipeline

TECHNICAL DETAILS OF THE CONSTRUCTION of the microtunnel “Piano di Comi” in Villafranca Tirrena (ME) - Italy: • The starting pit, situated inside the river shore, is constructed excavating and executing the concrete structure; the arrival is inside a trench. • The maximum depth under the mountain is of about 120m;• The tunnel is constructed by means of an AVN2000D with an external diameter of 3080mm.• Characteristics of the track: length L=915m, first section without gradient followed by a vertical curve with radius R=2500m and a final slope with a gradient of about 22%. Level difference between the entrance and the exit of about +52m.• Drilling in metamorphic rock with high degree of alterations and cracks, crossing of a channel and an existing pipeline with a cover of 6m.• Installation of the pipeline from the starting pit through the thrust made by a winch and pulleys. Insertions of sections of line made with triple joint.






Microtunnel

9952 - Tarvisio - Malborghetto Works to construct “Tarvisio - Malborghetto” pipeline with DN1200 (48’’) and to change the existing pipeline DN900 (36’’). P 75 bar.

Customer Snam Rete Gas S.p.A. Execution Period january 2008 – december 2010 Work value € 40.960.000,00

Technical data

No.Microtunnel Machine Gradient ID (mm) ED (mm) 1 Bosco di Colma AVN2000D 11% 2000 3100 2 Coston Tedesco AVN2500D 5% 2500 3100 3 Lussari AVN2000D 1,8% 2000 3100

Lussari: starting pit with the locomotive for the Bosco di Colma: drilling rig used to pull the pipeline in the tunnel transport of materials Microtunnel "BOSCO DI COLMA" (crossing of a mountain with a maximum depth of about 250m) • The starting pit, situated near the mountainside entrance, is realized with excavation and execution of the concrete structure. The arrival point is realized in a open trench on the opposite side of the mountain. • The tunnel is realized with an AVN2500D with external diameter of 3100mm. • Characteristics of the track: length L=1320m, constant slope with a gradient of about 11%, absence of curve. Difference in level between the entrance and the exit about +150m. • Drilling in rock through different formations; presence of fault areas and rocks with variable consistence and rank of cracks. Huge quantities of water from the mountain with pressure over 2bar and flow about 15-20m3/hr. • Usage of the intermediate jacking stations to complete the drive. • Installation of the pipeline by pulling from the arrival shaft with a drilling rig for HDI. Installation of sledges for the pulling phase in the tunnel.

Microtunnel "COSTON TEDESCO" (crossing of a mountain with a maximum depth of about 100m) • The starting pit, situated near the mountainside entrance, is realized with excavation and execution of the concrete structure. The arrival point is inside an open trench in the riverbed of a mountain torrent. • The tunnel is made with an AVN2500D with external diameter of 3100mm. • Characteristics of the track: length L=1065m, constant slope of about 5%, absence of curve. Difference in level between the entrance and the exit about +50m. • Drilling in rock through different formation of lime; presence of rocks with variable consistence and rank of cracks, crossing two areas of fault. Presence of huge quantities of water with pressure over 2bar and flow about 20m3/hr. • Installation of the pipeline by pulling from the arrival shaft with a drilling rig for HDI. Installation of sledges for the pulling phase in the tunnel. Microtunnel "LUSSARI" (crossing of a mountain with a maximum depth of about 100m) • The starting pit is situated near the mountainside of entrance on the shore of the Lussari torrent; the pit is realized with excavation and execution of the concrete structure. • The arrival point is inside an open trench in the riverbed of the mountain torrent. • The tunnel is realized with an AVN2000D with external diameter of 3100mm. • Characteristics of the track: length L=1080m, constant slope of about 1,8%, absence of curve. Difference in level between the entrance and the exit of about +19m. • Drilling in rock through different formation of lime; stop of the advancement at the progressive of 570m because of the high lateral forces in a fault area. Change of the system from pipe jacking to segment lining and continue with the drilling. • Installation of the pipeline by pulling from the arrival shaft with a drilling rig for HDI. Installation of sledges for the pulling phase in the tunnel.

Lussari: construction of ring of segments Lussari: view of tunnel entrance for the segment lining system

Coston tedesco: installation of the sledges on the pipeline Coston tedesco: design of the sledge

Microtunnel

Geological section

Documents

Pages From Brochure_INLGESE