Civil Construction in the US Chris Laughton, Fermilab

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Civil Construction in the US Chris Laughton,
Fermilab
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Outline

• Sites Under Consideration
• West Coast
• Midwest
• Scope
• Cost Schedule
• Contingency
• Next Steps

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Sites Under Consideration

• West Coast
• Diablo Canyon
• Midwest
• Braidwood
• Byron overburden requirements would place
  detector halls in weak sandstone. Dolomite and
  sandstone tunnels would be below the water table.
• LaSalle similar site conditions to Braidwood.
• Wolf Creek sited in shales and limestones.

Diablo Canyon-Type Portal Entrance
Scoped and Estimated
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Scope Underground Construction

• Braidwood
• 2 Vertical Shafts - 10m Ø 120m deep
• 1 Tunnel - 300m long 8m span horseshoe tunnel.
  Uniform 1 tunnel gradient to shaft.
• Firewall-Isolated Excavations accessed from the
  Running Tunnel/Shafts
• 3 Detector Rooms
• 1 x Near Detector Room - 32 m long 12 m span
• 2 x Far Detector Rooms with 8 m span access
  tunnels - 16 m long x 12 m span
• 1 Underground Emergency Refuge (at end of tunnel)
  
• 6 m long 4m span
• separately ventilation 2-hour fire rated wall
• Utility/Sump Room 4 m horseshoe
• nominal 8m length

• Diablo Canyon
• 1 Portal Entrance -10 m long
• 1 Tunnel - 850m long 6m span horseshoe tunnel.
  Uniform 1 tunnel gradient to portal.
• Firewall-Isolated Excavations accessed from the
  Running Tunnel
• 2 Detector Rooms
• 2 x 40m long 10m span chambers
• 1 Underground Emergency Refuge
• Nominal 6 m long 4m span
• Equipped with 2-hour fire rated wall and
  self-rescuers

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ScopeFinish-Out - Similar for Both Sites

• Single continuous concrete floor
• Hilman roller rails embedded (except in refuge)
• Cable Trays
• Pipe Stands
• Utilities in place at beneficial occupancy at
  both sites
• light string,
• ventilation ducting and fans
• refuge firewall
• At Braidwood
• Flood barrier at Far Detector site (1 m high
  concrete blocks)
• Pumps (Goodman quote)
• Elevators (Alimak quote)

Shotcrete Finish Walls Crown
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Scope Ground Conditions(assumptions pending
site investigation)

• Braidwood
• Soils
• 20 m of saturated soils
• Rock (Various Units)
• Coal measure strata
• Limestone with shale (NuMI - Fort Atkinson)
• Shale (NuMI - Scales)
• Galena Platteville (Dolomitic Limestone or
  Dolostone)
• Notable question marks relating to
• Deep water table elevation?
• In situ stress levels?
• Swelling potential of rock units containing clay
  minerals?
• Etc..

• Diablo Canyon
• Minimal Soil/Weathered Rock
• Rock (Mainly Dolomitic Sandstone)
• Heavily deformed geologic structure
  (folded/faulted)
• Inter/Intra-bedded volcanic sills (altered
  basalt, tuffs..)
• Surface rock samples have tested to high
  strength
• Thin chert stringers present (highly abrasive
  micro-silica)
• Notable question marks relating too
• Structure at depth- whats where?
• Abrasive cherts - roadheader impact
• Blocky rock behavior at depth
• Altered basalt behavior at depth
• Etc..

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ScopeExcavation Methods Means

• Braidwood
• Drill and Blast appears to be the preferred
  excavation method - short tunnels of varying
  cross-sections sited in relatively strong rock
  units
• Permanent Tunnel/Room Support
• Rock Bolts
• Reinforced Shotcrete
• Permanent Shaft Support provided by cast-in-place
  concrete lining

• Diablo Canyon
• Drill and Blast used for initial estimate - based
  on high strengths of surface-gathered samples
• (Viability of mechanical excavation will be
  reviewed after a modicum of site investigation
  has been performed)
• Permanent Tunnel/Room Support
• Rock Bolts,
• Lattice Girders
• Reinforced Shotcrete

Shotcrete
Scoop Tram
Drill Rig
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Cost ScheduleThe Estimating Process

• Proposal should be based on a reliable cost
  estimate.
• The only kind of estimate that is worth anything
  is the one that is clearly defined on paper and
  bears the signature of the author. J.S.Redpath,
  (1980). Theta 13 has underground estimates that
  are
• Well-documented and site-specific - developed
  from the bottom up
• Estimated independently by an experienced,
  tunneling professional.
• Reviewed independently by experienced, tunneling
  professionals.
• Underground estimate scopes include
• Underground Structural Shell and Utilities
• Utilities left in place (power, ventilation,
  water, air lines, communication..).
• Permanent facilities installed (groundwater
  pumps, elevators and refuge firewall, surface
  water treatment facilities).
• Estimates exclude
• Engineering, Design, Inspection and
  Administration (EDIA), Surface Buildings,
  Technical Installations, Life Cycle Costs

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Cost Schedule Aims of the Estimating Process

• Objectives
• Reduce uncertainty in cost/schedule data
  collected/reported in early work.
• Deliver a schedule and estimate by Mid-March.
• Outcome
• Consulted directly with tunnel estimators to
  obtain site-specific products, that met the
  deadlines at a relatively low unit cost
• 10k Tunnel Cost Estimating Consultants
  (Hilton, Sperry Wightman) vs.
• 15-20k Outside Tunnel Design Companies (CNA,
  HMM Jacobs Ass.)
• 40k In-House Engineering Group
• Established Solid Basis for Future Planning
• Experimental scoping and proposal development
• Reviews (Constructability, Value Engineering,
  Contract Strategies)
• Site investigation work
• Minimize potential for claims of low-balling -
  that may have surfaced if ball-park numbers had
  been used
• Cost better understood -gt Can plan with more
  confidence

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Cost Schedule Review of the Unit Cost Data Sets

• Sources tunnel contractors, designers and
  consultants
• Re-sorted for sub-horizontal, 4 - 8m span rock
  tunnels
• Mined in last ten years by TBM, DB or RH
  methodology
• Hard abrasive or very soft host rocks eliminated
• Cost as reported/quoted as a final cost per
  linear distance (auxiliary structures included)
• Wide Range of unit costs 3k to 12k/linear foot
• Average of 27 case histories 5k/linear foot
• Lowest unit costs in longer TBM tunnels (uniform
  mining/ground conditions/good TBM-systems, ref.
  Fermilab-Robbins RD)
• Highest unit costs in shorter drill and
  blast/roadheader tunnels (variable mining/ground
  conditions poor systems)

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Cost Schedule Need for a Site-Specific Estimate

• Wide range in unit prices underlines need for a
  site-specific estimate
• Costs ƒ(wage rates, craft skills, craft
  availability, infrastructure, support services,
  taxes, climate, local customs and methods, local
  support/opposition to the project, etc)
• Costs ƒ(ground conditions.)
• In tunneling a trend noted towards fewer
  bids/less competition
• Contractors are leaving the business -gt too risky
• Contractors are working at full capacity -gt too
  busy
• Contractors are joint venturing -gt too risky
• Nowadays expect fewer bids
• Unit prices are Site-Specific Time Specific -
  Braidwood Diablo Canyon unit pricing can be
  used for the sites but should not be used on
  other sites and should be checked periodically.

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Cost ScheduleBottoms-up Estimates Bottom-lines

• Braidwood
• Duration 39 months
• First detector site delivered in17 or 20 months
  (far or near)
• Cost 34.6M
• General Mobilization 3.3M
• Shafts 15.9M
• Tunnel 9.1M
• Detector Rooms 6.0M
• Refuge 0.3M
• 40 contingency.
• Initial comments equipment selection, crew
  sizing and productivity OK. Shorter shafts could
  use cranes.

• Diablo Canyon
• Duration 24 months
• Cost 23 M
• General Mobilization 2.9M
• Portal Cost 0.3M
• Tunnel 16.5M
• Detector Rooms 3.2M
• Refuge 0.1M
• 30 contingency.
• Initial comments equipment selection, crew
  sizing and productivity OK. Some relatively
  conservative production factors - mucking might
  be done more quickly.

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ContingencyUnderground Construction

• Many ways for a tunnel project to go wrong (not
  just a issues of differing conditions!)
• Make sure cost and schedule expectations are
  realistic at the outset and kept that way for the
  duration of the project.
• Risks needs to be identified, mitigated and
  properly documented/communicated.
• Even if the ground is expected to be perfect
  early construction contingencies need to be at
  least 25 range.

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ContingencyStatus of the US Proposals
Basis of Estimate. Guesswork based on limited
desk study of regional data sets.
We do not know for sure what is there because
we havent looked yet! Cant mitigate what has
not yet been identified! Contingency Allocated

• Rock mass characterization, alignment and
  estimate assumptions are subject to review after
  site-specific investigation work is performed
• Localized studies and site-specific investigation
  is a pre-requisite to support the advancement of
  the underground design

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Next Steps

• Site Investigation
• Engineering Tasking and Organization
• Reviews
• Making contact with design and contracting
  companies who can support the engineering,
  reviews - individual consultants will also be of
  value (notably where contracting rules are
  challenging!).

Natural Tunnels (Spooners Cove)
Man-Made Tunnels (Neutrinos _at_ Main Injector)
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Next StepsSite Investigation

• Braidwood (w/Exelon)
• Desk Studies
• ISGS support - others?
• Field Work
• _at_ Braidwood
• _at_ Other local rock/soil sites
• Initial Shaft Site Selection
• Avoid any surface and buried obstructions etc.
• Drilling Campaign
• Coreholes along shaft centerlines

• Diablo Canyon (w/PGE)
• Desk Studies
• LBL Earth Science Support complete
• Field Work
• _at_ Diablo Canyon site
• _at_ Other local rock sites
• Initial Tunnel Site Selection
• Portal Location,
• Tunnel Alignment
• Drilling Campaign
• Directional drilling
• Seismics _at_ Portal

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Next StepsEngineering Task Definition

• Initial Organizational Steps
• Site Investigation Work package(s)
• Plan Engineering Tasks (DisciplineTask Matrix)
• Outside Support Scope/Contractor
  Selection/Contracting
• What cant we do in-house?
• Who do we need to help? How do we find them?
• Develop some familiarity with Beavers, Groundhogs
  and Moles.
• Contracting Strategies (risks allocation/sharing)
  
• Design-Build (D-B)
• Engineer-Procure-Construct (E-P-C) etc..
• Schedule and WBS Development
• Availability of other Resources

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Next StepsReviews

• Requirements Definition (underground site visits)
• Make sure we are not asking for more than we need
• Define acceptable conditions e.g.
  moisture/floor movement (avoid over-design
  specification)
• Constructability Reviews
• Look for easier, practical ways of performing the
  work
• Value Engineering Reviews
• Once scope, costs and risks are well-defined
  investigate and estimate alternate ways of
  achieving the same end

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Next StepsFind Reviewers, Designers
Builders(Beavers, Groundhogs Moles)

• Tunnel Designers
• CNA
• Condor Earth Technologies
• Hatch Mott MacDonald
• Jacobs Associates
• Montgomery Watson Harza
• Parsons Brinckerhoff
• Parsons Engineering
• URS
• etc..

• National Tunnel Contractors
• Affholder, Atkinson, Frontier-Kemper Kenny
  Construction, Kiewit Construction, Obayashi,
  Traylor Brothers, etc..
• Local (Ca) Wine Cavers
• Alf Burtleson, California Wine Caves, Magorian,
  Nordby Wine Caves, Glen Ragsdale, etc.

Partial listings
SOQ Provided/Promised