Ph. Lebrun & J. Osborne 5 th FCC Infrastructure & Operation meeting CERN, 28 May 2014

1. Progress on tunnel cross-section options2. A simplified model for the cost of a “smooth” tunnel excavated by TBM in sedimentary rock

Ph. Lebrun & J. Osborne

5th FCC Infrastructure & Operation meetingCERN, 28 May 2014

http://doc.cern.ch/archive/electronic/cern/others/PHO/photo-bul/bul-pho-2007-046_01.jpg

FCC I&O meeting 140528 2

Single tunnel, longitudinal ventilationRevised

Ph. Lebrun



Double tunnelRevised

Ph. Lebrun


FCC I&O meeting, 140326 4

Single tunnel, transverse ventilationTo be revised with ventilation duct cross-

sections

Lebrun, Osborne, Collier



Tunnel cost model: a word of caution

• The simplified cost model presented here is based on the study performed by Amberg Engineering for the CLIC CDR cost estimate

• Strictly valid for hard-rock TBM tunnelling in the molasse of the Geneva basin, it is based on a set of unit costs applicable to geology, depth below ground, tunnel size and configuration, excavation equipment, rock support, lining and sealing techniques, progress rates, personnel, materials, transport and handling

• Consequently, the model should not be used for estimating tunnel costs outside its range of validity

• It is recommended to use output results for relative cost comparison rather than absolute cost assessment

Ph. Lebrun



CLIC 3 TeV tunnel profile

Ph. Lebrun



CLIC tunnel cross-section

Ph. Lebrun



Shafts, caverns and other singularities

Ph. Lebrun



Methodology of Amberg studyfor CLIC underground works [1/2]

• Standard profiles were developed for each underground structure, including details on the excavated cross sections as well as the inner lining. For each of these standard profiles, the following main items are evaluated in quantity and price: Labour for workmanship like workers and foremen (below senior level)

(shift work system: 3 shifts working 24 h/day, 7 days/week, 320 days/year , rest: official holidays and maintenance)

Tunnel excavation with shielded TBM and single-pass pre-cast concrete lining, mucking and disposal

Rock support for caverns by means of rock bolts with steel-fibre shotcrete Full sealing of the caverns and halls, as well as collecting and diverting of

dropping water in the remaining structures Inner lining considered with reinforced concrete Implementation of an invert with sufficient bearing capacity to withstand

the probable swelling pressure of the present Molasse Connection works to the neighbouring contracts

Ph. Lebrun



Methodology of Amberg studyfor CLIC underground works [2/2]

• The previously listed main items cover basically 55 – 65 % of the final costs. Given the preliminary phase of the study, some further costing positions were added to the main items as percentage surcharge of the subtotal: Drainage including the pumping stations at the shaft bases (4%) Quality control (2%) Auxiliary measures (15%) such as pre-investigations, pre-injections,

ground improvement Installations and equipment for construction works (e.g.: TBM, excavators,

cranes, lorries) (30-40%) Overhead (15.9%) (according to the calculation scheme of Swiss

Contractor Ass.) including:- surcharges on hourly wages e.g. for shift works 24 h/day and 7 days/week, workmen’s equipment, recruiting and training, - maintenance and operation of the workshops and site installations,- senior personnel for management and surveillance, - administration costs and interest rates,- insurance and contributions

Ph. Lebrun



Amberg study for CLIC underground works

Ph. Lebrun

CLIC undergreound structures

250.0

1,795,895,622 5.6

657,052,054 4.25

1,138,843,568

m m m m m m m2 m m m/AT Stk h/AT h/m CHF/h CHF/m 2.00% CHF m3 CHF/ entity

CHF CHF/ entity

CHF/ entity

CHF m CHF/ entity

CHF m3 CHF/ entity

m3 CHF/ entity

CHF/ entity

CHF m2 CHF/ entity

CHF m3 CHF/ entity

CHF/ entity

CHF m2 CHF/ entity

CHF to CHF/ entity

CHF/ entity

CHF m3 CHF/ entity

CHF/ entity

CHF m2 CHF/ entity

CHF to CHF/ entity

CHF/ entity

CHF CHF m2/m' m3 CHF/ entity

CHF/ entity

CHF CHF/ entity

CHF CHF CHF 4.0% 2.0% 15.0% CHF 15.9% 3.9% CHF CHF/ m' TBM-G

G-TBM dewatering tunnel 3.70 6,543.00 1.00 0.10 3.90 11.95 0.85 9.88 9.88 20.00 6 8 7 80 576 75,375 3,844,143 78,162 110 8,597,827 0 12 937,945 51,035 17.5 893,120 8,404 550 0 300 0 4,622,251 64,647 60 3,878,812 0 275 0 0 0 20 0 0 1,600 0 0 0 275 0 0 0 75 0 0 1,600 0 0 0 0.75 4,907 300 0 1,472,175 24,246,272 24,246,272 969,851 484,925 3,636,941 9,698,509 3,843,034 1,682,511 44,562,043 6,811 570 44,562,043

G-TBM main beam turn around 3.00 1,949.00 2.40 0.10 0.05 0.20 3.70 10.75 0.70 7.92 7.04 20.00 6 8 7 80 576 22,452 1,145,076 20,956 135 2,829,039 0 12 251,470 11,538 17.5 201,916 1,003 550 0 300 0 551,618 15,430 60 925,792 2,057 275 0 565,762 13,715 28 389,800 0 1,600 0 0 0 275 0 0 0 75 0 0 1,600 0 0 0 2.00 3,898 300 0 1,169,400 8,029,874 8,029,874 321,195 160,597 1,204,481 3,211,950 1,272,735 557,214 14,758,046 7,572 704

conv. BC2 cavern 100.00 10.00 5.50 0.20 0.15 0.25 0.00 61.58 0.00 19.79 16.71 2.92 6 8 49 80 3,945 7,890 402,411 6,158 50 307,901 0 12 73,896 10,080 17.5 176,400 534 550 0 300 0 293,925 1,979 75 148,447 468 275 0 128,719 1,671 75 125,310 0 1,600 0 0 137 275 0 37,567 1,120 75 84,000 15 1,600 0 24,118 145,685 10.72 1,072 300 0 321,600 2,124,293 2,124,293 84,972 42,486 318,644 637,288 336,700 139,075 3,683,458 36,835 598

firewall with door 33.50 wall and door 10,000.0 335,000.0 335,000 335,000 13,145 348,145

conv. main beam tunnel 120.00 5.60 4.23 0.15 0.10 0.20 0.00 28.78 0.00 13.96 11.65 6.00 6 8 24 80 1,920 4,608 235,008 3,453 55 189,942 0 12 41,442 3,900 17.5 68,250 302 550 0 300 0 165,847 1,675 60 100,513 327 275 0 90,026 1,398 43 60,000 23 1,600 0 36,665 92 275 0 25,245 753 75 56,448 10 1,600 0 16,232 97,925 6.01 721 300 0 216,180 1,301,798 1,301,798 52,072 26,036 195,270 390,539 206,335 85,227 2,257,277 18,811 654

conv. drive beam turn around 42.00 2.40 3.00 0.10 0.05 0.20 0.00 10.44 0.00 9.17 7.37 6.00 6 8 24 80 1,920 1,613 82,253 438 55 24,114 0 12 5,261 326 17.5 5,696 35 550 0 300 0 19,063 385 75 28,884 74 275 0 20,261 310 75 23,215 0 1,600 0 0 0 275 0 0 0 75 0 0 1,600 0 0 0 2.65 111 300 0 33,327 242,075 242,075 9,683 4,841 36,311 72,622 38,369 15,848 419,750 9,994 957

conv. drive beam turn around enlargement1 14.00 8.70 5.35 1.00 14.00 0.20 0.15 0.25 0.00 54.33 0.00 18.75 15.67 6.00 6 8 24 80 1,920 538 27,418 761 55 41,833 0 12 9,127 1,109 17.5 19,404 71 550 0 300 0 38,983 263 75 19,688 61 275 0 16,697 219 75 16,449 4 1,600 0 6,800 17 275 0 4,576 136 75 10,231 2 1,600 0 3,003 17,810 9 132 300 0 39,564 253,774 253,774 10,151 5,075 38,066 76,132 40,223 16,614 440,035 31,431 579

conv. drive beam turn around enlargement2 9.00 8.70 5.35 1.00 9.00 0.20 0.15 0.25 0.00 54.33 0.00 18.75 15.67 6.00 6 8 24 80 1,920 346 17,626 489 55 26,893 0 12 5,867 713 17.5 12,474 46 550 0 300 0 25,061 169 75 12,657 39 275 0 10,734 141 75 10,575 3 1,600 0 4,372 11 275 0 2,941 88 75 6,577 1 1,600 0 1,958 11,476 9 85 300 0 25,434 163,167 163,167 6,527 3,263 24,475 48,950 25,862 10,682 282,926 31,436 579

conv. drive beam turn around enlargement3 15.00 8.00 5.00 1.00 15.00 0.20 0.15 0.25 0.00 47.96 0.00 17.65 14.57 6.00 6 8 24 80 1,920 576 29,376 719 55 39,565 0 12 8,632 966 17.5 16,905 71 550 0 300 0 39,318 265 75 19,858 60 275 0 16,393 218 75 16,387 4 1,600 0 6,676 16 275 0 4,508 134 75 10,080 2 1,600 0 2,960 17,548 9 131 300 0 39,240 249,899 249,899 9,996 4,998 37,485 74,970 39,609 16,361 433,317 28,888 602

conv. main beam tunnel TBM-start/end 31.00 5.80 5.80 0.15 0.10 0.20 0.00 40.07 0.00 17.22 14.91 6.00 6 8 24 80 1,920 1,190 60,710 1,242 55 68,325 0 12 14,907 1,142 17.5 19,991 96 550 0 300 0 52,861 534 60 32,037 112 275 0 30,770 462 75 34,667 8 1,600 0 12,532 25 275 0 6,755 201 75 15,103 3 1,600 0 4,398 26,256 6.21 192 300 0 57,707 410,764 410,764 16,431 8,215 61,615 123,229 65,106 26,892 712,251 22,976 573

conv. drive beam dump tunnel 6.00 3.00 3.00 0.10 0.05 0.20 0.00 12.22 0.00 9.51 7.71 6.00 6 8 24 80 1,920 230 11,750 73 55 4,033 0 12 880 67 17.5 1,166 5 550 0 300 0 2,825 57 75 4,280 11 275 0 3,041 46 75 3,471 0 1,600 0 0 0 275 0 0 0 75 0 0 1,600 0 0 0 3.25 19 300 0 5,841 37,287 37,287 1,491 746 5,593 11,186 5,910 2,441 64,655 10,776 882

conv. containment pit 6.00 3.00 2.00 0.10 0.05 0.20 0.00 8.52 0.00 7.51 5.71 6.00 6 8 24 80 1,920 230 11,750 51 55 2,812 0 12 614 67 17.5 1,166 4 550 0 300 0 2,231 45 75 3,380 8 275 0 2,183 34 75 2,571 0 1,600 0 0 0 275 0 0 0 75 0 0 1,600 0 0 0 3.25 19 300 0 5,841 32,548 32,548 1,302 651 4,882 9,764 5,159 2,131 56,437 9,406 1,104

conv. drive beam dump enlargement 11.00 8.70 5.35 1.00 11.00 0.20 0.15 0.25 0.00 54.33 0.00 18.75 15.67 6.00 6 8 24 80 1,920 422 21,542 598 55 32,869 0 12 7,171 871 17.5 15,246 56 550 0 300 0 30,630 206 75 15,469 48 275 0 13,119 172 75 12,924 3 1,600 0 5,343 13 275 0 3,595 107 75 8,039 1 1,600 0 2,376 14,010 9 104 300 0 31,086 199,410 199,410 7,976 3,988 29,911 59,823 31,606 13,055 345,770 31,434 579conv. drive beam dump cavern 6.50 9.00 5.00 0.20 0.15 0.25 0.00 52.08 0.00 18.22 15.14 6.00 6 8 24 80 1,920 250 12,730 338 55 18,617 0 12 4,062 530 17.5 9,282 32 550 0 300 0 17,589 118 75 8,883 27 275 0 7,440 98 75 7,379 2 1,600 0 3,030 8 275 0 2,198 66 75 4,914 1 1,600 0 1,482 8,593 10 63 300 0 18,954 116,560 116,560 4,662 2,331 17,484 34,968 18,475 7,631 202,111 31,094 597

conv. shielding wall 8.95 2.00 7.50 0 0 0 0 134 275 0 36,919 200 75 15,004 9 1,600 0 15,036 0 275 0 0 0 75 0 0 1,600 0 0 0 0 0 66,959 66,959 1,339 16,740 10,613 3,753 99,403 740

conv. cavern access 12.00 1.50 2.08 0.10 0.15 0.00 0.00 4.72 0.00 6.29 5.01 6.00 6 8 24 80 1,920 461 23,501 57 55 3,118 0 12 680 36 17.5 630 20 550 0 300 0 11,217 0 75 0 0 275 0 0 0 75 0 0 1,600 0 0 0 275 0 0 0 75 0 0 1,600 0 0 0 1.63 20 300 0 5,850 44,996 44,996 1,800 900 6,749 13,499 7,132 2,946 78,022 6,502 1,376conv. access Tunnel 11 1,089.00 6.00 5.30 0.20 0.10 0.25 0.00 40.05 0.00 16.86 14.03 6.00 6 8 24 80 1,920 41,818 2,132,698 43,615 50 2,180,759 0 12 523,382 42,525 17.5 744,195 3,305 550 0 300 0 1,817,500 18,359 75 1,376,894 5,099 275 0 1,402,203 15,279 14 217,800 0 1,600 0 0 0 275 0 0 7,318 75 0 0 1,600 0 0 0 6.61 7,193 300 0 2,157,854 12,553,284 12,553,284 502,131 251,066 1,882,993 3,765,985 1,989,696 821,848 21,767,003 19,988 499

conv. shaft base cavern 11 and UTR-C 59.00 17.00 18.00 0.20 0.30 0.85 0.00 366.15 0.00 52.64 45.70 0.49 6 8 294 80 23,510 27,742 1,414,844 21,603 50 1,080,135 0 12 259,232 18,016 17.5 315,274 1,677 550 0 300 0 922,493 3,106 75 232,953 1,963 275 0 539,832 2,697 75 202,238 0 1,600 0 0 0 275 0 0 0 75 0 0 1,600 0 0 0 20.65 1,218 300 0 365,417 5,332,419 5,332,419 213,297 106,648 799,863 1,599,726 845,188 349,107 9,246,247 156,716 428

conv. connecting tunnel diagonal 50.00 4.50 4.00 0.15 0.10 0.20 0.00 23.33 0.00 12.88 10.57 6.00 6 8 24 80 1,920 1,920 97,920 1,167 55 64,161 0 12 13,999 1,080 17.5 18,900 116 550 0 300 0 63,767 644 75 48,309 122 275 0 33,509 528 75 39,632 0 1,600 0 0 0 275 0 0 0 75 0 0 1,600 0 0 0 4.91 245 300 0 73,575 453,772 453,772 18,151 9,075 68,066 136,132 71,923 29,708 786,826 15,737 674

conv. cavern access 35.00 2.00 3.00 0.10 0.15 0.00 0.00 8.08 0.00 8.43 7.14 6.00 6 8 24 80 1,920 1,344 68,544 283 55 15,553 0 12 3,393 175 17.5 3,063 80 550 0 300 0 43,799 0 75 0 0 275 0 0 0 75 0 0 1,600 0 0 0 275 0 0 0 75 0 0 1,600 0 0 0 2.13 74 300 0 22,313 156,664 156,664 6,267 3,133 23,500 46,999 24,831 10,257 271,651 7,761 961

conv. shielding door cavern 33.50 12.50 7.40 0.20 0.20 0.35 0.00 103.57 0.00 25.79 21.93 1.74 6 8 83 80 6,621 4,436 226,229 3,470 50 173,478 0 12 41,635 5,159 17.5 90,283 311 550 0 300 0 171,073 864 75 64,800 240 275 0 66,020 735 75 55,112 0 1,600 0 0 0 275 0 0 0 75 0 0 1,600 0 0 0 13.63 456 300 0 136,931 1,025,561 1,025,561 41,022 20,511 153,834 307,668 162,551 67,142 1,778,290 53,083 513

conv. shielding door 11.00 10.50 7.40 0 0 0 855 275 0 235,043 549 75 41,190 60 1,600 0 95,726 0 275 0 0 0 75 0 0 1,600 0 0 0 0 0 371,959 371,959 7,439 92,990 58,955 20,849 552,192 646

conv. main beam tunnel TBM-start/end 40.00 5.80 5.80 0.15 0.10 0.20 0.00 40.07 0.00 17.22 14.91 6.00 6 8 24 80 1,920 1,536 78,336 1,603 55 88,161 0 12 19,235 1,474 17.5 25,795 124 550 0 300 0 68,208 689 60 41,338 144 275 0 39,703 596 75 44,732 10 1,600 0 16,170 32 275 0 8,716 260 75 19,488 4 1,600 0 5,653 33,856 6.21 248 300 0 74,460 529,996 529,996 21,200 10,600 79,499 158,999 84,004 34,698 918,996 22,975 573

conv. main beam turn around enlargement1 46.00 9.35 5.68 1.00 46.00 0.20 0.15 0.25 0.00 32.38 0.00 19.77 16.69 6.00 6 8 24 80 1,920 1,766 90,086 1,490 55 81,928 18 12 44,688 4,125 17.5 72,188 246 550 0 300 18 139,482 910 75 68,213 215 275 18 62,993 768 75 57,570 15 1,600 18 24,350 59 275 18 17,215 482 75 36,128 7 1,600 18 10,533 63,877 10.07 463 300 18 147,304 852,680 852,680 34,107 17,054 127,902 255,804 135,150 55,824 1,478,520 32,142 993

TBM-S main beam tunnel 5.60 838.23 4.80 0.10 0.10 0.25 6.50 33.18 0.65 20.11 19.01 25.00 8 8 8 80 614 10,300 525,309 27,815 60 1,668,903 18 12 834,451 0 17.5 0 0 0 1,685 300 18 535,945 0 0 0 3,983 400 18 1,664,887 0 0 0 438 1,600 18 708,891 0 275 18 0 16,625 75 ####### 0 1,600 18 0 1,246,867 5.30 4,443 300 18 1,412,753 remove lining 1,361 114,354 8,712,360 8,712,360 348,494 174,247 1,306,854 3,484,944 1,380,909 604,573 16,012,382 19,103 576

conv. drive beam turn around 42.00 2.40 3.00 0.10 0.05 0.20 0.00 10.44 0.00 9.17 7.37 6.00 6 8 24 80 1,920 1,613 82,253 438 55 24,114 18 12 13,153 326 17.5 5,696 35 550 0 300 18 19,687 385 75 28,884 74 275 18 21,587 310 75 23,215 0 1,600 18 0 0 275 18 0 0 75 0 0 1,600 18 0 0 2.65 111 300 18 35,327 253,916 253,916 10,157 5,078 38,087 76,175 40,246 16,624 440,282 10,483 1,004

conv. drive beam turn around enlargement1 14.00 8.70 5.35 1.00 14.00 0.20 0.15 0.25 0.00 26.12 0.00 18.75 15.67 6.00 6 8 24 80 1,920 538 27,418 366 55 20,115 18 12 10,972 1,109 17.5 19,404 71 550 0 300 18 40,259 263 75 19,688 61 275 18 17,790 219 75 16,449 4 1,600 18 6,877 17 275 18 4,875 136 75 10,231 2 1,600 18 3,037 18,144 9 132 300 18 41,938 239,052 239,052 9,562 4,781 35,858 71,716 37,890 15,650 414,509 29,608 1,133conv. drive beam turn around enlargement2 9.00 8.70 5.35 1.00 9.00 0.20 0.15 0.25 0.00 26.12 0.00 18.75 15.67 6.00 6 8 24 80 1,920 346 17,626 235 55 12,931 18 12 7,053 713 17.5 12,474 46 550 0 300 18 25,881 169 75 12,657 39 275 18 11,436 141 75 10,575 3 1,600 18 4,421 11 275 18 3,134 88 75 6,577 1 1,600 18 1,980 11,691 9 85 300 18 26,960 153,703 153,703 6,148 3,074 23,056 46,111 24,362 10,063 266,517 29,613 1,134

conv. drive beam turn around enlargement3 15.00 8.00 5.00 1.00 15.00 0.20 0.15 0.25 0.00 19.75 0.00 17.65 14.57 6.00 6 8 24 80 1,920 576 29,376 296 55 16,296 18 12 8,889 966 17.5 16,905 71 550 0 300 18 40,605 265 75 19,858 60 275 18 17,466 218 75 16,387 0 1,600 18 0 16 275 18 4,803 134 75 10,080 2 1,600 18 2,993 17,877 9 131 300 18 41,594 225,252 225,252 9,010 4,505 33,788 67,576 35,702 14,747 390,580 26,039 1,318

conv. UTR-A 67.50 10.50 7.20 1.00 11.00 0.20 0.20 0.35 0.00 88.95 0.00 24.25 20.39 2.02 6 8 71 80 5,703 7,699 392,650 6,004 50 300,202 18 12 180,121 7,695 18 134,663 589 550 0 300 18 334,702 1,637 75 122,763 443 275 18 129,843 1,377 75 103,241 0 1,600 18 0 0 275 18 0 0 75 0 0 1,600 18 0 0 12 785 300 18 249,531 1,947,715 1,947,715 77,909 38,954 292,157 584,315 308,713 127,514 3,377,277 50,034 563


conv. drive beam dump tunnel 6.00 3.00 3.00 0.10 0.05 0.20 0.00 12.22 0.00 9.51 7.71 6.00 6 8 24 80 1,920 230 11,750 73 55 4,033 18 12 2,200 67 17.5 1,166 5 550 0 300 18 2,918 57 75 4,280 11 275 18 3,240 46 75 3,471 0 1,600 18 0 0 275 18 0 0 75 0 0 1,600 18 0 0 3.25 19 300 18 6,191 39,249 39,249 1,570 785 5,887 11,775 6,221 2,570 68,057 11,343 928

conv. containment pit 6.00 3.00 2.00 0.10 0.05 0.20 0.00 8.52 0.00 7.51 5.71 6.00 6 8 24 80 1,920 230 11,750 51 55 2,812 18 12 1,534 67 17.5 1,166 4 550 0 300 18 2,304 45 75 3,380 8 275 18 2,326 34 75 2,571 0 1,600 18 0 0 275 18 0 0 75 0 0 1,600 18 0 0 3.25 19 300 18 6,191 34,034 34,034 1,361 681 5,105 10,210 5,394 2,228 59,015 9,836 1,154conv. drive beam dump enlargement 11.00 8.70 5.35 1.00 11.00 0.20 0.15 0.25 0.00 26.12 0.00 18.75 15.67 6.00 6 8 24 80 1,920 422 21,542 287 55 15,804 18 12 8,621 871 17.5 15,246 56 550 0 300 18 31,632 206 75 15,469 48 275 18 13,978 172 75 12,924 3 1,600 18 5,403 13 275 18 3,830 107 75 8,039 1 1,600 18 2,403 14,272 9 104 300 18 32,951 187,843 187,843 7,514 3,757 28,176 56,353 29,773 12,298 325,714 29,610 1,134

conv. drive beam dump cavern 6.50 9.00 5.00 0.20 0.15 0.25 0.00 52.08 0.00 18.22 15.14 6.00 6 8 24 80 1,920 250 12,730 338 55 18,617 18 12 10,155 530 17.5 9,282 32 550 0 300 18 18,165 118 75 8,883 27 275 18 7,927 98 75 7,379 2 1,600 18 3,064 8 275 18 2,342 66 75 4,914 1 1,600 18 1,498 8,754 10 63 300 18 20,091 125,047 125,047 5,002 2,501 18,757 37,514 19,820 8,187 216,828 33,358 641


conv. cavern access 12.00 1.50 2.08 0.10 0.15 0.00 0.00 4.72 0.00 6.29 5.01 6.00 6 8 24 80 1,920 461 23,501 57 55 3,118 18 12 1,701 36 17.5 630 20 550 0 300 18 11,585 0 75 0 0 275 18 0 0 75 0 0 1,600 18 0 0 275 18 0 0 75 0 0 1,600 18 0 0 1.63 20 300 18 6,201 46,735 46,735 1,869 935 7,010 14,020 7,407 3,060 81,037 6,753 1,430



conv. drive beam turn around enlargement1 14.00 8.70 5.35 1.00 14.00 0.20 0.15 0.25 0.00 26.12 0.00 18.75 15.67 6.00 6 8 24 80 1,920 538 27,418 366 55 20,115 18 12 10,972 1,109 17.5 19,404 71 550 0 300 18 40,259 263 75 19,688 61 275 18 17,790 219 75 16,449 4 1,600 18 6,877 17 275 18 4,875 136 75 10,231 2 1,600 18 3,037 18,144 9 132 300 18 41,938 239,052 239,052 9,562 4,781 35,858 71,716 37,890 15,650 414,509 29,608 1,133

conv. drive beam turn around enlargement2 9.00 8.70 5.35 1.00 9.00 0.20 0.15 0.25 0.00 26.12 0.00 18.75 15.67 6.00 6 8 24 80 1,920 346 17,626 235 55 12,931 18 12 7,053 713 17.5 12,474 46 550 0 300 18 25,881 169 75 12,657 39 275 18 11,436 141 75 10,575 3 1,600 18 4,421 11 275 18 3,134 88 75 6,577 1 1,600 18 1,980 11,691 9 85 300 18 26,960 153,703 153,703 6,148 3,074 23,056 46,111 24,362 10,063 266,517 29,613 1,134


conv. UTR-A 67.50 10.50 7.20 1.00 11.00 0.20 0.20 0.35 0.00 88.95 0.00 24.25 20.39 2.02 6 8 71 80 5,703 7,699 392,650 6,004 50 300,202 18 12 180,121 7,695 18 134,663 589 550 0 300 18 334,702 1,637 75 122,763 443 275 18 129,843 1,377 75 103,241 0 1,600 18 0 0 275 18 0 0 75 0 0 1,600 18 0 0 12 785 300 18 249,531 1,947,715 1,947,715 77,909 38,954 292,157 584,315 308,713 127,514 3,377,277 50,034 563



conv. containment pit 6.00 3.00 2.00 0.10 0.05 0.20 0.00 8.52 0.00 7.51 5.71 6.00 6 8 24 80 1,920 230 11,750 51 55 2,812 18 12 1,534 67 17.5 1,166 4 550 0 300 18 2,304 45 75 3,380 8 275 18 2,326 34 75 2,571 0 1,600 18 0 0 275 18 0 0 75 0 0 1,600 18 0 0 3.25 19 300 18 6,191 34,034 34,034 1,361 681 5,105 10,210 5,394 2,228 59,015 9,836 1,154

conv. drive beam dump enlargement 11.00 8.70 5.35 1.00 11.00 0.20 0.15 0.25 0.00 26.12 0.00 18.75 15.67 6.00 6 8 24 80 1,920 422 21,542 287 55 15,804 18 12 8,621 871 17.5 15,246 56 550 0 300 18 31,632 206 75 15,469 48 275 18 13,978 172 75 12,924 3 1,600 18 5,403 13 275 18 3,830 107 75 8,039 1 1,600 18 2,403 14,272 9 104 300 18 32,951 187,843 187,843 7,514 3,757 28,176 56,353 29,773 12,298 325,714 29,610 1,134conv. drive beam dump cavern 6.50 9.00 5.00 0.20 0.15 0.25 0.00 52.08 0.00 18.22 15.14 6.00 6 8 24 80 1,920 250 12,730 338 55 18,617 18 12 10,155 530 17.5 9,282 32 550 0 300 18 18,165 118 75 8,883 27 275 18 7,927 98 75 7,379 2 1,600 18 3,064 8 275 18 2,342 66 75 4,914 1 1,600 18 1,498 8,754 10 63 300 18 20,091 125,047 125,047 5,002 2,501 18,757 37,514 19,820 8,187 216,828 33,358 641


conv. cavern access 12.00 1.50 2.08 0.10 0.15 0.00 0.00 4.72 0.00 6.29 5.01 6.00 6 8 24 80 1,920 461 23,501 57 55 3,118 18 12 1,701 36 17.5 630 20 550 0 300 18 11,585 0 75 0 0 275 18 0 0 75 0 0 1,600 18 0 0 275 18 0 0 75 0 0 1,600 18 0 0 1.63 20 300 18 6,201 46,735 46,735 1,869 935 7,010 14,020 7,407 3,060 81,037 6,753 1,430TBM-S main beam tunnel 5.60 878.23 4.80 0.10 0.10 0.25 6.50 33.18 0.65 20.11 19.01 25.00 8 8 8 80 614 10,792 550,376 29,142 60 1,748,542 18 12 874,271 0 17.5 0 0 0 1,766 300 18 561,520 0 0 0 4,173 400 18 1,744,335 0 0 0 459 1,600 18 742,719 0 275 18 0 17,418 75 ####### 0 1,600 18 0 1,306,367 5.30 4,655 300 18 1,480,169 remove lining 1,361 91,211 9,099,510 9,099,510 363,980 181,990 1,364,927 3,639,804 1,442,272 631,438 16,723,922 19,043 574

raise survey boring 11.1 1.50 280.00 350.00 630.00 0.00 0.10 0.00 1.70 2.27 1.00 5.03 0.00 25.00 2,500 0 700,000 636 35 22,244 18 12 19,066 0 18 0 141 1,300 0 300 18 185,500 0 0 0 0 400 18 0 0 0 0 0 1,600 18 0 0 275 18 0 0 75 0 0 1,600 18 0 0 5 1,484 300 18 471,912 1,398,722 1,398,722 55,949 27,974 209,808 559,489 221,697 97,061 2,570,701 9,181 4,045

conv. survey boring cavern 11.1 7.00 7.00 6.00 1.00 7.00 0.25 0.25 0.00 49.13 0.00 18.57 16.00 3.66 6 8 39 80 3,148 441 22,473 344 50 17,196 18 12 10,318 364 18 6,370 58 550 0 300 18 33,219 0 75 0 0 275 18 0 0 75 0 0 1,600 18 0 7 275 18 1,961 55 75 4,116 1 1,600 18 1,267 7,344 8 53 300 18 16,695 113,616 113,616 4,545 2,272 17,042 34,085 18,008 7,438 197,007 28,144 573





conv. UTR-A 67.50 10.50 7.20 1.00 11.00 0.20 0.20 0.35 0.00 88.95 0.00 24.25 20.39 2.02 6 8 71 80 5,703 7,699 392,650 6,004 50 300,202 18 12 180,121 7,695 18 134,663 589 550 0 300 18 334,702 1,637 75 122,763 443 275 18 129,843 1,377 75 103,241 0 1,600 18 0 0 275 18 0 0 75 0 0 1,600 18 0 0 12 785 300 18 249,531 1,947,715 1,947,715 77,909 38,954 292,157 584,315 308,713 127,514 3,377,277 50,034 563




conv. drive beam dump enlargement 11.00 8.70 5.35 1.00 11.00 0.20 0.15 0.25 0.00 26.12 0.00 18.75 15.67 6.00 6 8 24 80 1,920 422 21,542 287 55 15,804 18 12 8,621 871 17.5 15,246 56 550 0 300 18 31,632 206 75 15,469 48 275 18 13,978 172 75 12,924 3 1,600 18 5,403 13 275 18 3,830 107 75 8,039 1 1,600 18 2,403 14,272 9 104 300 18 32,951 187,843 187,843 7,514 3,757 28,176 56,353 29,773 12,298 325,714 29,610 1,134

conv. drive beam dump cavern 6.50 9.00 5.00 0.20 0.15 0.25 0.00 52.08 0.00 18.22 15.14 6.00 6 8 24 80 1,920 250 12,730 338 55 18,617 18 12 10,155 530 17.5 9,282 32 550 0 300 18 18,165 118 75 8,883 27 275 18 7,927 98 75 7,379 2 1,600 18 3,064 8 275 18 2,342 66 75 4,914 1 1,600 18 1,498 8,754 10 63 300 18 20,091 125,047 125,047 5,002 2,501 18,757 37,514 19,820 8,187 216,828 33,358 641conv. shielding wall 8.95 2.00 7.50 18 0 18 0 134 275 18 39,335 200 75 15,004 9 1,600 18 15,205 0 275 18 0 0 75 0 0 1,600 18 0 0 18 0 69,544 69,544 1,391 17,386 11,023 3,898 103,242 769


TBM-S main beam tunnel 5.60 878.23 4.80 0.10 0.10 0.25 6.50 33.18 0.65 20.11 19.01 25.00 8 8 8 80 614 10,792 550,376 29,142 60 1,748,542 18 12 874,271 0 17.5 0 0 0 1,766 300 18 561,520 0 0 0 4,173 400 18 1,744,335 0 0 0 459 1,600 18 742,719 0 275 18 0 17,418 75 ####### 0 1,600 18 0 1,306,367 5.30 4,655 300 18 1,480,169 remove lining 1,361 81,681 9,089,981 9,089,981 363,599 181,800 1,363,497 3,635,992 1,440,762 630,777 16,706,408 19,023 573conv. drive beam turn around 42.00 2.40 3.00 0.10 0.05 0.20 0.00 10.44 0.00 9.17 7.37 6.00 6 8 24 80 1,920 1,613 82,253 438 55 24,114 18 12 13,153 326 17.5 5,696 35 550 0 300 18 19,687 385 75 28,884 74 275 18 21,587 310 75 23,215 0 1,600 18 0 0 275 18 0 0 75 0 0 1,600 18 0 0 2.65 111 300 18 35,327 253,916 253,916 10,157 5,078 38,087 76,175 40,246 16,624 440,282 10,483 1,004




conv. UTR-A 67.50 10.50 7.20 1.00 11.00 0.20 0.20 0.35 0.00 88.95 0.00 24.25 20.39 2.02 6 8 71 80 5,703 7,699 392,650 6,004 50 300,202 18 12 180,121 7,695 18 134,663 589 550 0 300 18 334,702 1,637 75 122,763 443 275 18 129,843 1,377 75 103,241 0 1,600 18 0 0 275 18 0 0 75 0 0 1,600 18 0 0 12 785 300 18 249,531 1,947,715 1,947,715 77,909 38,954 292,157 584,315 308,713 127,514 3,377,277 50,034 563




conv. drive beam dump enlargement 11.00 8.70 5.35 1.00 11.00 0.20 0.15 0.25 0.00 26.12 0.00 18.75 15.67 6.00 6 8 24 80 1,920 422 21,542 287 55 15,804 18 12 8,621 871 17.5 15,246 56 550 0 300 18 31,632 206 75 15,469 48 275 18 13,978 172 75 12,924 3 1,600 18 5,403 13 275 18 3,830 107 75 8,039 1 1,600 18 2,403 14,272 9 104 300 18 32,951 187,843 187,843 7,514 3,757 28,176 56,353 29,773 12,298 325,714 29,610 1,134

conv. drive beam dump cavern 6.50 9.00 5.00 0.20 0.15 0.25 0.00 52.08 0.00 18.22 15.14 6.00 6 8 24 80 1,920 250 12,730 338 55 18,617 18 12 10,155 530 17.5 9,282 32 550 0 300 18 18,165 118 75 8,883 27 275 18 7,927 98 75 7,379 2 1,600 18 3,064 8 275 18 2,342 66 75 4,914 1 1,600 18 1,498 8,754 10 63 300 18 20,091 125,047 125,047 5,002 2,501 18,757 37,514 19,820 8,187 216,828 33,358 641




Rat

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Simplified cost model of TBM excavated tunnel

• Specified free diameter D• Excavated diameter Dexc = D + 2 (tolerance + lining thickness+ grouting

thickness)• Cost per meter C = C1 + C2 + C3 + C4 + C5• C1 fixed cost per meter (e.g. TBM personnel for given progress rate)• C2 proportional to excavated volume ~ Dexc

2

• C3 proportional to lining & grouting volumes ~ Dexc• C4 proportional to invert (floor) volume• C5 cost per meter of additional construction elements (partitions, firewall)

Cost per meter of finished tunnel is expected to scale between D and D2Ph. Lebrun



EXCEL tableAll dimensions and unit costs adjustable

Ph. Lebrun

GEOMETRYFinal diameter [m] 4.00 5.00 6.00 7.00 8.00 9.00 10.00 11.00 12.00Tolerance [m] 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10Lining thickness [m] 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25Grouting thickness [m] 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10Excavated diameter [m] 4.90 5.90 6.90 7.90 8.90 9.90 10.90 11.90 12.90Floor width [m] 3.00 3.75 4.50 5.25 6.00 6.75 7.50 8.25 9.00PERSONNELTBM speed [m/day] 25.00 25.00 25.00 25.00 25.00 25.00 25.00 25.00 25.00TBM personnel 8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00TBM shift duration [h] 8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00TBM shifts/day 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00Personnel hourly cost [CHF/h] 80.00 80.00 80.00 80.00 80.00 80.00 80.00 80.00 80.00TBM personnel cost [CHF/h] 640.00 640.00 640.00 640.00 640.00 640.00 640.00 640.00 640.00TBM raw personnel cost [CHF/m] 614.40 614.40 614.40 614.40 614.40 614.40 614.40 614.40 614.40add 2% without excavation 12.29 12.29 12.29 12.29 12.29 12.29 12.29 12.29 12.29Tunnel personnel cost [CHF/m] 626.69 626.69 626.69 626.69 626.69 626.69 626.69 626.69 626.69EXCAVATIONExcavated volume [m3/m] 18.86 27.34 37.39 49.02 62.21 76.98 93.31 111.22 130.70Excavation raw cost [CHF/m3] 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00Spoil up shaft cost [CHF/m3] 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00Spoil deposit cost [CHF/m3] 12.00 12.00 12.00 12.00 12.00 12.00 12.00 12.00 12.00Excavation full cost [CHF/m3] 90.00 90.00 90.00 90.00 90.00 90.00 90.00 90.00 90.00Tunnel excavation cost [CHF/m] 1697.17 2460.58 3365.36 4411.51 5599.04 6927.93 8398.20 10009.84 11762.86LININGLining inner diameter [m] 4.20 5.20 6.20 7.20 8.20 9.20 10.20 11.20 12.20Lining outer diameter [m] 4.70 5.70 6.70 7.70 8.70 9.70 10.70 11.70 12.70Lining volume [m3/m] 3.50 4.28 5.07 5.85 6.64 7.42 8.21 8.99 9.78Lining concrete raw cost [CHF/m3] 400.00 400.00 400.00 400.00 400.00 400.00 400.00 400.00 400.00Concrete down shaft cost [CHF/m3] 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00Concrete full cost [CHF/m3] 418.00 418.00 418.00 418.00 418.00 418.00 418.00 418.00 418.00Lining steel reinforcement [kg/m3] 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00Lining steel mass [kg/m] 384.45 470.85 557.24 643.64 730.03 816.42 902.82 989.21 1075.61Steel raw cost [CHF/kg] 1.60 1.60 1.60 1.60 1.60 1.60 1.60 1.60 1.60Steel down shaft cost [CHF/kg] 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02Steel full cost [CHF/kg] 1.62 1.62 1.62 1.62 1.62 1.62 1.62 1.62 1.62Tunnel lining cost [CHF/m] 2082.97 2551.05 3019.13 3487.22 3955.30 4423.38 4891.46 5359.55 5827.63GROUTINGGrouting inner diameter [m] 4.70 5.70 6.70 7.70 8.70 9.70 10.70 11.70 12.70Grouting outer diameter [m] 4.90 5.90 6.90 7.90 8.90 9.90 10.90 11.90 12.90Grouting volume [m3/m] 1.51 1.82 2.14 2.45 2.76 3.08 3.39 3.71 4.02Grouting concrete raw cost [CHF/m3] 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00Concrete down shaft cost [CHF/m3] 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00Concrete full cost [CHF/m3] 318.00 318.00 318.00 318.00 318.00 318.00 318.00 318.00 318.00Tunnel grouting cost [CHF/m] 479.53 579.44 679.34 779.24 879.15 979.05 1078.95 1178.85 1278.76FLOORAlpha [rad] 1.59 1.61 1.62 1.63 1.64 1.65 1.65 1.66 1.66Floor volume [m3/m] 1.30 2.07 3.01 4.12 5.41 6.88 8.52 10.34 12.34Concrete raw cost [CHF/m3] 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00Concrete down shaft cost [CHF/m3] 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00 18.00Concrete full cost [CHF/m3] 318.00 318.00 318.00 318.00 318.00 318.00 318.00 318.00 318.00Tunnel floor cost [CHF/m] 414.69 657.52 956.29 1311.01 1721.69 2188.33 2710.93 3289.49 3924.02

SUBTOTAL 1 [CHF/m] 5301.05 6875.28 8646.81 10615.67 12781.86 15145.38 17706.24 20464.43 23419.95add 4% drainage/dewatering [CHF/m] 212.04 275.01 345.87 424.63 511.27 605.82 708.25 818.58 936.80add 2% probes 106.02 137.51 172.94 212.31 255.64 302.91 354.12 409.29 468.40add 15% auxiliary measures 795.16 1031.29 1297.02 1592.35 1917.28 2271.81 2655.94 3069.66 3512.99add 40% installation 2120.42 2750.11 3458.72 4246.27 5112.75 6058.15 7082.50 8185.77 9367.98add 15.9% overhead 842.87 1093.17 1374.84 1687.89 2032.32 2408.12 2815.29 3253.84 3723.77SUBTOTAL 2 [CHF/m] 9377.57 12162.36 15296.21 18779.13 22611.12 26792.18 31322.34 36201.57 41429.89add 3.9% metallic frame/prefab 365.73 474.33 596.55 732.39 881.83 1044.90 1221.57 1411.86 1615.77TOTAL [CHF/m] 9743.29 12636.69 15892.76 19511.51 23492.95 27837.08 32543.91 37613.43 43045.66



Cost of tunnel vs finished diameter(TBM in sedimentary rock, no additional

construction)

Ph. Lebrun



Cost structure of tunnel(TBM in sedimentary rock, no additional

construction)

Ph. Lebrun


http://www.affccs.org/

Documents

Ph. Lebrun & J. Osborne 5 th FCC Infrastructure & Operation meeting CERN, 28 May 2014