Tunnel Operations Practices Featuring the Hampton Roads

Bridge-Tunnel

Wednesday, October 16, 20192:00-3:30 PM ET

TRANSPORTATION RESEARCH BOARD

The Transportation Research Board has met the standards and

requirements of the Registered Continuing Education Providers Program.

Credit earned on completion of this program will be reported to RCEP. A

certificate of completion will be issued to participants that have registered

and attended the entire session. As such, it does not include content that

may be deemed or construed to be an approval or endorsement by RCEP.

Purpose

To discuss recent developments in tunnel management practices and provide announcements from tunnel-related organizations.

Learning ObjectivesAt the end of this webinar, you will be able to:

• Describe how to structure design-build procurement to maximize value-generating innovation

PDH Certificate Information• This webinar is valued at 1.5 Professional Development

Hours (PDH)• Instructions on retrieving your certificate will be found in

your webinar reminder and follow-up emails• You must register and attend as an individual to receive a

PDH certificate• Certificates of Completion will be issued only to

individuals who register for and attend the entire webinar session

• Q&A counts as part of the session• TRB will report your hours within one week• Questions? Contact Reggie Gillum at RGillum@nas.edu.

4

Louis J Ruzzi, PE PennDOT, AASHTO COBS T 20 Tunnel

Committee ChairOctober 16,2019

Thank you/Purpose of Webinar

• Thank you to Bill Bergeson at FHWA for coming up with the tunnel webinar idea and Elaine Ferrell at TRB for helping us put together and run this webinar series

• Purpose of the Webinar-to help build/ develop the Tunnel Community. A strong tunnel community is important for raising awareness and integrating the diverse roles of our stakeholders to include planners, decision makers, regulators, tunnel owners, designers, contractors, inspectors, operators, suppliers, public sector users, and industry trade organizations.

• The tunnel community needs to be more than just work being done by AASHTO COBS T 20 Tunnel Committee , TRB AFF6O Underground Structures Committees the states and FHWA and their research projects. But should include transit, other agencies like PIARC-the World Road Association, IRF-International Road Federation, Dept of Energy, TSA, COE and Colleges /Universities, etc.

T 20 Purpose/current make up

• T20 was created back in 2006 because Tunnels never had a home at AASHTO. Mal Kerley, the Chairman of SCOBS( Subcommittee on Bridges and Structures -now called COBS) , thought is was best for Tunnels to be under Bridge, because bridge engineers typically got calls to handle structural problems at Tunnels anyway.

• T20 meets as a group( 10 members from different states, 2 toll agencies and FHWA Liaison) twice a year. Once at the COBS Annual meeting in June and at TRB in mid-January of each year

• T 20’s Mid -Year meeting is tentatively scheduled for January 14, 2020 at Marriott Marquis next to Washington DC convention center. Current research submissions and new research ideas, Alternate Fuel vehicles, Pittsburgh’s tunnel emergency exercise, tunnel rehab/new projects and robotic inspections will be discussed.

T 20 Continued

• It is at this meeting that T20’s chair and AFF60’s Chair give each group an update on each group’s work and generate new prioritized research ideas with input from members of both groups

• Over the last 14 years, the committee has completed an International Tunnel Scan in 2005, a Domestic Tunnel Scan in 2009, completed research which resulted in a new LRFD Design spec for tunnels, methods for rehabbing tunnels and guidelines for Emergency Exit signs and Marking Systems to name a few .Other projects can be found on AASHTOs website at https://bridges.transportation.org/technical-committees/t-20-tunnels/.

• This website also lists our current research for LED lighting and potential future research tunnel linings and calibration of load factors for tunnels and FHWA s research Fixed Fire Suppression Systems

T 20 Continued

• T20 also partners with FHWA and other industry stakeholders to develop products that benefit the tunneling community, a sampling, of current technical products, includes:

• Load rating guidelines• TBM tunnel liner design guidelines• Integrated FFFS-EVS design guidelines

T 20 Continued

• As part of our effort to engage industry stakeholders in the development process, workshops are being planned for each of these guidelines.

• Please note that you’re always welcome to learn more about these technical products and the things that the T20 committee does at the public portion of the T20 Midyear and AASHTO COBS Annual meetings.

• If you are interested in becoming a friend of the committee, or else simply contributing your research ideas, please feel free to send your contact information to me at: Ruzzi, Louis <LRUZZI@pa.gov>, and I’ll add you to our T20 Friend’s list; I hope to see you in January or next June.

Welcome to TRB

Conrad W. Felice, PhD. P.E., F. ASCEChair, AFF60 – Tunnels and Underground Structures

About TRB

• Part of the National Academies of Sciences, Engineering, and Medicine

• Private, non-profit institution

• Independent, non-partisan, objective

Research – Convene – Advise

Strategic Issues

• Resilience

• Transformational technology

• Public health and transportation

ResearchGoal: Ensure that competitive research programs address the most pressing transportation needs of the sponsors

Multidisciplinary topics: Make connections with stakeholders in other disciplines

Transformative Resiliency Public Safety

AFF60

Committee Scope

This committee is concernedwith the planning, design,construction, inspection,operations/systems, andmaintenance of undergroundstructures and theircomponents.

AFF60: Research NeedsAFF60 - RNS

TunnelInducedDeformationusingModernTunnelingEquipment

Connect with Us• Theme for 2020: A Century of Progress: Foundation

for the Future

Volunteer for TRB

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Thank You

For More InformationVisit: www.TRB.orgconrad.felice@cwfelicellc.com

VIRGINIA TUNNEL PROGRAM VDOT

Prasad Nallapaneni, PE; Vice Chair - T20 Tunnels, AASHTO

Tunnels in Virginia1

2

3

3

4

5

6

7

Big Walker Mountain Tunnel

East River Mountain Tunnel

Hampton Roads Bridge Tunnel (2 tunnels)

Monitor Merrimac Memorial Bridge Tunnel

Downtown Tunnel (2 tunnels) – ERC Maintained

Midtown Tunnel (2 tunnels) – ERC Maintained

Rosslyn Tunnel

8

89

Thimble Shoal Tunnel – Entity Owned

Chesapeake Channel Tunnel – Entity Owned9

Roanoke Airport Tunnel – Entity Owned

I-564 Runway Tunnel

10

11 21 34

56

7

89

11

10

Bluff Mountain Tunnel – Federally Owned12

12

Williamsburg Tunnel – Federally Owned13

14 Mary’s Rock Tunnel – Federally Owned

13

14

Name Type Length Year BuiltBig Walker Mountain Tunnel Twin Rock Bore (NATM) 4228’ 1972

East River Mountain Tunnel Twin Rock Bore (NATM) 5661’ 1974

Hampton Roads Bridge TunnelImmersed Tube

Immersed Tube

7479’

7315’

1957

1976

Monitor Merrimac Memorial Bridge Tunnel Immersed Tube 4860’ 1992

Elizabeth River Downtown TunnelImmersed Tube

Immersed Tube

3350’

3814’

1952

1987

Elizabeth River Midtown TunnelImmersed Tube

Immersed Tube

4192’

4198’

1962

2016

I-564 Runway Tunnel Cut and Cover 662’ 1972

Thimble Shoal Tunnel Immersed Tube 5738’ 1964

Chesapeake Channel Tunnel Immersed Tube 5424’ 1964

Rosslyn Tunnel Cut and Cover 900’ 1983

Roanoke Airport Tunnel Cut and Cover 951’ 1985

Tunnels in Virginia (excluding Federally Owned)

• Multi-Billion Dollar Investment

• Used by over 400,000 Vehicles per Day

• Limited Detour Routes

• Over 20,000 events logged each year that require operator response

Tunnel Criticality

• Formed in 2010 to provide direction and guidance for all of the tunnels across the state• Executive Leadership• Regional Operations Managers• Operations Division• Tunnel Managers

• Recently VDOT designated all tunnels, movable bridges and few large fixed span bridges as Special structures• Currently working on the needs of these structures • Will lead to special funding – General Assembly

established fund in 2019

Statewide Tunnels Oversight Committee (STOC)

• Midtown Tunnel • Opened in 2016 – Immersed tube

• Parallel Thimble Shoal Tunnel Chesapeake Bay Bridge Authority (CBBT)• 2023 - Construction Completion

• New Hampton Roads Bridge Tunnel (HRBT) • 2025 - Construction Completion

Tunnel Activity

CBBT – Statistics 2018 – Existing Tunnels• 3,999,228 vehicles crossed the facility

• ADT approx. 11,000• Peak Weekend Days traffic exceeds 25,000• 9% Heavy Trucks• 67% use EZ Pass

• Tunnel Lane Closures – over 900 hours of lane closures• Nighttime Work Details• Oversized loads• Disabled vehicles

Parallel Thimble Shoal Tunnel

• D-B contract value: $756m• Length of Tunnel: 6,525-ft Portal-to-Portal• Diameter of Tunnel: 43-ft Outside Diameter• TBM: Herrenknecht EPB machine• Segment Ring: 9+1 universal ring• Roadway Depth: 134-ft below MLLW• Contractor: Chesapeake Tunnel JV

(Dragados USA andSchiavone Construction Co.)

• Engineer of Record: Mott MacDonald• Owner’s Engineer: Jacobs• Construction Manager: HNTB

Project Overview

Sources of Funding

Project Priorities • To provide mobility enhancements and travel-time

reliability along the project corridor • To minimize project impacts on adjacent communities • To improve transportation operations and safety

throughout the project corridor• To develop public infrastructure in a financially

responsible manner

New Hampton Roads Bridge Tunnel (HRBT)

Design-Build procured under PPTA• Unique Funding• Hampton Roads Transportation

Accountability Commission (HRTAC) is primary funding agent

• HRTAC funds to be provided through the Hampton Roads Transportation Fund (HRTF) from regional sales and gas taxes

HRBT - Public-Private Partnerships

Initial bidders during RFQ• Hampton Roads Capacity Constructors, • Hampton Roads Connector Partners• Skanska Kiewit

Best Value Proposer• Contract awarded to Hampton Roads

Connector Partners (HRCP)• A consortium of Dragados, Vinci, Flatiron,

and Dodin Campenon Bernard.

HRBT – Design Build Selection Process

Benefits• Direct Impact within Hampton Roads - ~$3 B• Direct cumulative jobs – ~16,000 (through

construction)• Indirect impact within Hampton Roads - ~$900 M• Indirect cumulative jobs – ~5,700

• Architecture, engineering services, maintenance, truck transportation

HRBT – Benefits to Commonwealth

Since the roll out of the SNTI and NTIS• Completed initial inspections of all 11 VDOT

owned tunnels• Reviewed initial inspections performed by agency

entities• Chesapeake Bay Bridge Tunnel (CBBT)• Elizabeth River Crossings (ERC)• Roanoke Airport Authority (ROA)

• Second cycle of inspections has been completed

NTIS – National Tunnel Inspection StandardsSNTI – Specifications for National Tunnel Inventory

NTIS – Inspections

Tunnel Inspection Manuals

Inspections Manauls are developed for each tunnel • Description of element configuration and components

• Pre-inspection preparation and review

• Tools and Equipment

• Personal Protective Equipment

• Field Inspection Procedures

• Reporting and Rating Procedures

Developing two Instructional and Informational Memorandums (IIM) • Draft IIM for Inventory and Inspection Requirements

for Tunnels• Contains definitions, roles and responsibilities, frequencies,

level of inspections, report requirements, inspection forms, critical findings and recommendations, Load rating analysis and posting/restriction guidelines (per CFR 23- Part 650).

• Draft IIM for QA/QC for Tunnels• Contains definitions, training and certification requirements for

team leaders, procedures for office and field reviews and QA/QC forms (per CFR 23- Part 650.513(i)).

Inspection Updates - Improvements

Review of initial inspections resulted in• Requiring all VDOT tunnel inspections and reports use a uniform

stationing system for easy referencing• Noting deficiencies in notes and sketches with the stationing• Maintaining cross references between the sketches, notes and

element ratings • Ensuring correlation between element quantities, condition state

and notes/sketches• Inspection annual updates include comments/observations from

current inspections, inventory and element data updates

Inspection Updates - Improvements

Tunnel Owner Operator Key Operation ActivitiesI-77 Big Walker VDOT VDOT Lighting, Fire life safety, Ventilation, Incident

management, ERPI-77 East River VDOT VDOT Lighting, Fire life safety, Ventilation, Incident

management, ERPUS 460 Christiansburg

VDOT VDOT Lighting, Fire life safety, ERP

I-664 MonitorMerrimac

VDOT VDOT Lighting, Fire life safety, Ventilation, Incident management, ERP, Vehicle inspection

I-64 Hampton Roads

VDOT VDOT Lighting, Fire life safety, Ventilation, Incident management, ERP, Vehicle inspection

US 58 Midtown VDOT Contractor Lighting, Fire life safety, Ventilation, Incident management, ERP, Vehicle inspection

I-264 Downtown

VDOT Contractor Lighting, Fire life safety, Ventilation, Incident management, ERP, Vehicle inspection

I-564 VDOT VDOT Lighting, Fire life safety, Incident management, ERP

I-66 Rosslyn VDOT VDOT Lighting, Fire life safety, Ventilation, Incident management, ERP

Key Operations Activities

Tunnel Operations – Incident History at Major Facilities

Tunnel All Incidents Crashes FiresI-77 Big Walker 61 23 0I-77 East River 105 19 6I-664 Monitor Merrimac 1592 613 12I-64 Hampton Roads 1996 755 10US 58 Midtown 267 45 0I-264 Downtown 872 209 1

Tunnel Operations – Exercise Program Overview

FY # Exercises PlanningMeetings

Participants Recommendations

2014 1 5 49 232015 2 10 103 442016 6 19 320 862017 6 13 229 532018 2 10 85 32

Initiated in 2012 by STOC

Emergency Response Plans (ERPs) • For each tunnel and bridge facility • Implemented in 2013

• In accordance with NFPA

Tunnels - Exercise Program

After Action Reviews (AARs)For each tunnel and bridge facility Implemented in 2013

• In accordance Homeland Security Exercise and Evaluation Program (HSEEP)

• Identify areas of response that may be improvedupon for future accidents.

Tunnels - Exercise Program

Yearly communication drills• At each tunnel• Involve local and statewide partners

• Local Police and Fire Departments• City and Town Officials• State Police• Virginia Dept. of Emergency Management• Towing Facilities• United States Coast Guard

Tunnels – Communication Drills

Remote Location of Mountain Tunnel

Response Time

Need of Emergency Response Team• Started in June, 2015• Very effective in fire response

Mountain Tunnels – Emergency Response Team

Robust Tunnel Preservation Program• Cyclic

• Schedules - Bimonthly, monthly, biweekly, weekly and daily• Tunnel washing• Underground tank inspections• Fire extinguishers • Cleaning

Tunnel Preservation

Robust Tunnel Preservation Program

• Condition Based• Sidewalk Hand-hole Cover Replacement with stainless steel

cover• Egress signage added to the tunnels for Fire, Life, Safety

improvements• Drainage Improvements

Tunnel Preservation

Design‐Build Procurement of the Hampton Roads Bridge‐Tunnel (HRBT)

Martha E. Gross, PhD, PEVirginia Department of TransportationOctober 16, 2019

Overview

■ Context Tunneling in Hampton Roads  Challenges and solutions

■ Design‐build procurement decisions Procurement of new HRBT Scope of design‐build contract

■ Tools for generating value Cost estimate and risk review Assigning value to innovation

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Hampton Roads

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■ Virginia’s second‐largest metropolitan area

■ Many river crossings

■ Heavy traffic    congestion

Hampton Roads and Its Crossings

Thimble Shoal Tunnel (1964)

Chesapeake ChannelTunnel (1964)

Monitor-MerrimacMemorial Bridge-

Tunnel (1992)

Hampton RoadsBridge-Tunnel(1957 & 1976)

MidtownTunnel

(1962 & 2016)Downtown

Tunnel(1952 & 1987)

10/16/2019 4

Downtow

n Tunn

el #1

Hampton

 Roads #1

Midtown Tunn

el #1

Thim

ble Shoal #1                                        

& Che

sape

ake #1

Hampton

 Roads #2

Downtow

n Tunn

el #2

Mon

itor‐Merrim

ac

Midtown Tunn

el #2

1950

1955

1960

1965

1970

1975

1980

1985

1990

1995

2000

2005

2010

2015

2020

■ Two observations:

Today’s tunnel‐builders have less firsthand experience to draw from

Much has changed in tunnel‐building technology over six decades

10/16/2019 5

65 Years of Tunneling in Hampton Roads

HRBT Facts and Figures

■ Existing: 2‐lane immersed‐tube tunnel on artificial islands

■ Superlatives when completed in November 1957:

Longest immersed‐tube tunnel in the world

First marine tunnel between artificial islands

■ Lowest point of roadway is 105’ below water

■ Tunnel length = approx. 7500’  

■ Total crossing length = approx. 3.5 miles

■ Second immersed‐tube tunnel opened in 1976

■ Third crossing (twin 2‐lane bored tunnels) planned for 2025

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Design‐Build Procurement

■ Industry outreach in early 2017 to explore optimal procurement method for new HRBT crossing Technical aspects Financial aspects

■ Considerations for design‐build procurement of underground projects

■ Balance of prescriptive and performance‐based specifications

■ Value of proposer feedback and alternative technical concepts (ATCs)

10/16/2019 7

Procurement of Third HRBT Crossing

10/16/2019 8

ACTIVITY DATE

RFQ Issued  December 15, 2017

Shortlist Announced April 26, 2018

Draft RFP Issued May 22, 2018

Selection of Tunnel Construction Method July 31, 2018

Final RFP Issued September 27, 2018

Technical Proposal Submission January 15, 2019

Price Proposal Submission February 8, 2019

Contract Award April 3, 2019

Design‐Builder LNTP 1 April 12, 2019

Project Complete  November 2025

Project Overview

10/16/2019 9

I‐64 improvements from Settlers Landing interchange in Hampton to       I‐564 in Norfolk (10 miles)

Highway widening and construction of new harbor crossing = four‐lane bridge‐tunnel

2 existing HRBT tunnels will serve westbound traffic 

New HRBT tunnels (twin 2‐lane tubes) will serve eastbound traffic

Design‐build contract: $3.3 billion Total project cost: $3.8 billion Scheduled completion date: 

November 2025

Project Scope

10/16/2019 10

North Trestles2 x 3,400 ft

South Trestle1 x 5,900 ft

TunnelsMarine TrestlesOther TrestlesStandard BridgesRoadway Works

Tunnels2 x 7,900 ft

City of Hampton

City of Norfolk

Project Scope

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Tunnels• Length 7,900 ft• Inner Diameter 41.5 ft• Excavation 950,000 CY• Segmental Lining   120,000 CY• Ground Improv. 500,000 CY

Structures• Bridges to Demo    5 • Bridges to Build 4• Bridges to Widen    23• Total Length 39,000 ft• Total Surface 2,000,000 SF

Islands Expansion• Footprint 860,000 SF• Fill 170,000 CY• Dike 190,000 CY• Armor Stone 350,000 tons• Splash Wall 6,000 CY

Roadway• Excavation 130,000 CY• Embankment 90,000 CY• Noise Walls 730,000 SF• Retaining Walls 100,000 SF

By the numbers:

12

2019 2020 2025

Contract Execution + LNTP1April 2019

Anticipated Permit Approval Date = NTP540 days (18 months) after LNTP1

= October 2020

LNTP 1 Design and Investigation Works for Environmental Permitting

LNTP 3 LNTP3 : Launching Pit Construction to Start

LNTP2 + LNTP3September 2019

Substantial Completion Target06/30/25

Permanent Works over 55 months

6 Months of Scope Validation

Substantial  Completion Deadline  09/01/25Final  CompletionDeadline  11/01/25

Interior Works Tunnels

Launch & Receiving Pit Ready for TBM

202320222021 2024

LNTP 2 LNTP2 : Authorization for TBM Procurement

TBM Assembly andMining

Commissioning and Testing

North & South Marine Trestles

Land Work I‐64 Widening

10/16/2019

Project Schedule

Assigning Value to Innovation

■ During procurement, owner’s team refined project risk register as project scope developed

■ 37 key risks (34 threats, 3 opportunities) were distilled from risk register and quantified for FHWA risk model

■ FHWA cost estimate review (CER) used Monte Carlo analysis of risk model to identify range of impacts

■ Impact at 70% confidence interval was calculated for both DB contract costs and owner’s oversight costs

■ Innovation generated tangible value by mitigating risks and enhancing opportunities

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Verify

• Major cost elements• Allowances/contingencies• Adjust estimate as necessary

Model

• Base variability• Market conditions and inflation• Risk events (cost, schedule, probability, impact, relationships)• Monte Carlo simulation

Communicate

• Closeout presentation• Final report• Approval of financial plan

FHWA’s Cost Estimate Review Methodology

14

Design‐Build Contract

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Owner’s Oversight

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Total Project Cost

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Total Project Cost in Year of Expenditure ($YOE)

■ Pre‐review estimate: $3.9 billion

■ Post‐review estimate at 70% confidence interval: $3.8 billion

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■ Soil variations at north and south islands HRBT has the geotechnical feature of 

one “good island” and one “bad island”

■ Mitigation of soft material at HRBT south island 1957: material was excavated and 

replaced with sand fill

1976: up to 25’ surcharge and wick drains were used to consolidate compressible layers

Maximum settlement: 13 feet

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Sample Risk in CER: Geotechnical Risk at Island

Expansion of HRBT South Island in 1970’s

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Proposed Work at South Island

■ Expansion of island footprint

■ Excavation for tunnel entrance

■ Buildings and related utilities

■ Protection/monitoring of existing facilities

10/16/2019 21

Ground Improvement at South Island

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Value‐Generating Innovation vs. Risk‐Taking

■ Issues: Constructing launch shaft for tunnel boring machine Limiting ground movement for adjacent structures Maintaining tunnel alignment in soft soil

■ Approach:  Prescriptive vs. performance‐based geotechnical 

design requirements Monte Carlo risk review helped evaluate maximum, 

minimum, and probable impact outcomes

10/16/2019 23

Closing Thoughts

Today’s Participants• Bill Bergeson, FHWA,

william.bergeson@dot.gov• Lou Ruzzi, Pennsylvania DOT,

LRuzzi@pa.gov• Conrad Felice, CW Felice LLC,

conrad.felice@cwfelicellc.com• Prasad Nallapaneni, Virginia DOT,

prasad.nallapaneni@vdot.virginia.gov• Martha Gross, Virginia DOT,

martha.gross@vdot.virginia.gov

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