Draft Detailed Project Report for Final Approved Alignment for Bypass Volume

543 Pages·2017·10.4 MB·English

Prepared for:
Project:
Consultancy Services for “Feasibility-Cum-Geo
Technical Study for the bypass to Shiradi Ghat
from Km 238.000 to 261.450 on NH-48 in the
State of Karnataka”

Subject:
KD-6- Draft Detailed Project Report for
Final Approved Alignment for Bypass

Volume -II: Design Report

Part II: Design of Tunnels
(A)-Proposed Tunnel Design, Standards
Prepared by:
473 Udyog Vihar
GEOCONSULT
Industrial Estate, Phase V
INDIA Pvt. Ltd.
Gurgaon 122016

Tel: [phone]
A company of the
Fax: [phone]
GEOCONSULT group
Email: [e-mail]

00 17.12.15 First Issue BRs FKr AKg
Rev. Date Description Originator Checked Approved
Document No: Revision:
I6060-REP-09-KD6-DDPR-Vo II-DR-Part II_A 00
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GCI File Path
DR-Part II_A\I6060-REP-09-KD6-DDPR-Vol II-DR-Part II_A.DOCX
Feasibility-Cum-Geo Technical Study for the bypass to Shiradi Ghat from Km 238.00 to 261.45 on NH-48 in
the State of Karnataka - KD6 - Draft Detailed Project Report Page 1

Disclaimer

This document has been prepared for the titled project or named part thereof and should not be
relied upon or used for any other project without an independent check being carried out as to its
suitability and prior written authority of GEOCONSULT being obtained. GEOCONSULT accepts no
responsibility or liability for the consequences of this document being used for a purpose other than
the purposes for which it was commissioned. Any person using or relying on the document for such
other purpose agrees, and will by such use or reliance be taken to confirm his agreement to in-
demnify GEOCONSULT for all loss or damage resulting there from. GEOCONSULT accepts no
responsibility or liability for this document to any party other than the person by whom it was com-
missioned.

GEOCONSULT INDIA Pvt. Ltd. I6060-REP-09-KD6-DDPR-Vol II-DR-Part II_A.DOCX 17.12.2015
Feasibility-Cum-Geo Technical Study for the bypass to Shiradi Ghat from Km 238.00 to 261.45 on NH-48 in
the State of Karnataka - KD6 - Draft Detailed Project Report Page 2

Revision History

Rev. Date Long Description

GEOCONSULT INDIA Pvt. Ltd. I6060-REP-09-KD6-DDPR-Vol II-DR-Part II_A.DOCX 17.12.2015
Feasibility-Cum-Geo Technical Study for the bypass to Shiradi Ghat from Km 238.00 to 261.45 on NH-48 in
the State of Karnataka - KD6 - Draft Detailed Project Report Page 3
TABLE OF CONTENTS
1 GENERAL ................................................................................................................ 9
2 PROPOSED DESIGN BASIS, STANDARDS & SPECIFICATIONS ........................ 10
2.1 Objectives of the study .................................................................................... 10
2.2 Condition Survey of Existing Railway Tunnel ................................................... 10
2.3 Proposal for New Tunnels ............................................................................... 10
2.4 Benefits of Tunnels Proposed in Shiradi Ghat ................................................. 12
2.5 Specification and Provisions ............................................................................ 13
2.6 Shape and Size of the Tunnel ......................................................................... 14
2.6.1 Twin Tube Solution – Introduction ...................................................... 14
2.6.2 Twin Tube Solution – Overall Safety Considerations.......................... 14
2.7 Tunnel design & construction .......................................................................... 16
2.8 Geology along Proposed Alignment ................................................................ 16
2.9 Tunnel system and safety issues ..................................................................... 17
2.10 General Principles of Design (as adopted in the present case) ................... 19
2.10.1 Length of Tunnels ............................................................................ 19
2.10.2 Horizontal Alignment of Tunnel ........................................................ 19
2.10.3 Vertical Alignment of Tunnel ............................................................ 19
2.10.4 Provision of Adequate Lighting System ............................................ 20
2.10.5 Ventilation Systems ......................................................................... 20
2.10.6 Signage within the Tunnel ................................................................ 20
2.10.7 Location of Exit Ramps .................................................................... 20
2.10.8 Provision of Edge Strip .................................................................... 20
2.10.9 Tunnel Dimensions .......................................................................... 20
2.10.10 Vertical Clearance .......................................................................... 21
2.10.11 Side-Walks..................................................................................... 21
2.10.12 Slot Gutters for Draining Waste Water ........................................... 21
2.10.13 Requirements for Fire fighting System ........................................... 21
2.10.14 Cable ducts / trenches ................................................................... 21
2.10.15 Cross Passages ............................................................................. 21
2.10.16 Fire Resistance of Structures ......................................................... 22
3 APPROACH AND METHODOLOGY TO MEET THE REQUIREMENT OF
DELIVERABLES AND SERVICES ......................................................................... 23
3.1 The Concerns of the Project ............................................................................ 23
3.2 General Consideration Regarding the Approach ............................................. 23
4 GENERAL PRINCIPLES: OBSERVATIONAL METHOD, NATM &
TUNNEL DESIGN .................................................................................................. 25
4.1 Observational method ..................................................................................... 25
4.2 NATM – main concepts ................................................................................... 26
4.3 Advantages of NATM ...................................................................................... 28
4.4 Tunnel Design Criteria ..................................................................................... 28
4.4.1 General .............................................................................................. 28
4.4.2 Design Approach as per Austrian Guideline ....................................... 29
4.4.3 Determination of Ground Types (GT) ................................................. 29
GEOCONSULT INDIA Pvt. Ltd. I6060-REP-09-KD6-DDPR-Vol II-DR-Part II_A.DOCX 17.12.2015
Feasibility-Cum-Geo Technical Study for the bypass to Shiradi Ghat from Km 238.00 to 261.45 on NH-48 in
the State of Karnataka - KD6 - Draft Detailed Project Report Page 4
4.4.4 Ground Behaviour Types (BT) ........................................................... 30
4.4.5 Selection of Construction Concept ..................................................... 30
4.4.6 Geological Interpretative Baseline Report .......................................... 31
4.4.7 Determination of Excavation Classes ................................................. 31
4.5 Portals ............................................................................................................. 32
4.5.1 Permanent portals ............................................................................. 33
5 TUNNEL DRAINAGE AND WATERPROOFING CONCEPT ................................... 34
5.1 General ........................................................................................................... 34
5.2 Water Proofing ................................................................................................ 34
5.3 Tunnel Drainage Concept ................................................................................ 34
6 DESIGN METHODOLOGY ..................................................................................... 36
6.1 Design of primary support measures ............................................................... 36
6.1.1 Sprayed concrete ............................................................................... 36
6.1.2 Lattice girders .................................................................................... 37
6.1.3 Rock bolts .......................................................................................... 37
6.1.4 Reinforcement steel ........................................................................... 38
6.1.5 Forepoling .......................................................................................... 38
6.1.6 Face stabilization measures ............................................................... 38
6.2 Design of inner concrete lining ........................................................................ 39
6.2.1 Design of Portal Slopes ..................................................................... 40
7 INSTRUMENTATION, MONITORING AND ITS EVALUATION –
OBSERVATION OF TUNNEL BEHAVIOUR ........................................................... 41
7.1 Monitoring Elements ........................................................................................ 41
7.1.1 3D-Targets / Monitoring points ........................................................... 42
7.1.2 Equipment / total station .................................................................... 42
7.1.3 Software ............................................................................................ 42
7.1.4 Extensometers ................................................................................... 42
7.1.5 Pressure Cells ................................................................................... 42
7.1.6 Radial Pressure Cells ........................................................................ 42
7.1.7 Tangential Pressure Cells .................................................................. 43
7.2 Principles and Procedures ............................................................................... 43
7.2.1 Installation and initial reading ............................................................. 43
7.2.2 Monitoring Frequency ........................................................................ 43
7.2.3 Monitoring Sections ........................................................................... 43
7.2.4 Evaluation and Interpretation of Monitoring Results ........................... 43
7.2.5 Risk management through Monitoring................................................ 45
8 TUNNEL CONSTRUCTION ................................................................................... 46
8.1 Excavation with conventional method (D&B) ................................................... 46
9 STANDARDS & REFERENCE DOCUMENTS ........................................................ 50
10 SPECIFICATIONS ................................................................................................. 53
10.1 Sprayed Concrete ....................................................................................... 53
10.2 Reinforcing steel ......................................................................................... 53
10.3 Steel Fibres ................................................................................................. 54
10.4 Rock bolts ................................................................................................... 54
GEOCONSULT INDIA Pvt. Ltd. I6060-REP-09-KD6-DDPR-Vol II-DR-Part II_A.DOCX 17.12.2015
Feasibility-Cum-Geo Technical Study for the bypass to Shiradi Ghat from Km 238.00 to 261.45 on NH-48 in
the State of Karnataka - KD6 - Draft Detailed Project Report Page 5
10.5 Lattice Girder .............................................................................................. 54
10.6 Forepoling ................................................................................................... 54
10.7 Final lining................................................................................................... 55
10.8 Waterproofing ............................................................................................. 55
10.9 Lean concrete ............................................................................................. 55
GEOCONSULT INDIA Pvt. Ltd. I6060-REP-09-KD6-DDPR-Vol II-DR-Part II_A.DOCX 17.12.2015
Feasibility-Cum-Geo Technical Study for the bypass to Shiradi Ghat from Km 238.00 to 261.45 on NH-48 in
the State of Karnataka - KD6 - Draft Detailed Project Report Page 6
Introduction
This report is prepared under Contract Agreement clause 2.8; “Key Date No: KD 6: Draft
Detailed Project Report for Final Approved Alignment for Bypass (DDPR)” after incorpora-
tion of Client’s observations on earlier submitted “KD5: Kucha Draft Detailed Project Report
(KDDPR)” vide letter no. NH/PIU-Tunnel/NH-48/KD-3/2015-16/383-386 dated 14.12.2015.

The present submission (10 Hard Bound Sets and 5 Soft Copies of each) is as detailed
below:

The present submission is as detailed below:
(i) Volume-I Main Report:
• Executive summary
• Project Description
• Socio Economic Profile
• Materials Surveys and Investigation
• Traffic Surveys and Analysis
• Design Standards and Specifications
• Alignment Proposals
• Summary of EIA/IEE and Action Plan
• Summary of Resettlement Plan
• Preliminary Cost Estimates
• Preliminary Economic Analysis
• Preliminary Financial Analysis
• Suggested Methods of procurement and packaging
• Conclusions and Recommendations
• Acknowledgement
• Compliance of the Observations
The basic data obtained from the field studies and investigations and input data used
for the detailed engineering design (if any) shall be submitted in a separate volume as
an Appendix to Main Report.
(ii) Volume – II : Design Report
Part- I Traffic Study, Analysis and Forecast :
• Description of Existing Road in Ghat Section
• Road and Bridge Inventory
• Traffic Surveys, analysis and forecast
• Proposed Pavement Design
Part-II Design of Tunnels:
• Proposed Tunnel Design and Standards
GEOCONSULT INDIA Pvt. Ltd. I6060-REP-09-KD6-DDPR-Vol II-DR-Part II_A.DOCX 17.12.2015
Feasibility-Cum-Geo Technical Study for the bypass to Shiradi Ghat from Km 238.00 to 261.45 on NH-48 in
the State of Karnataka - KD6 - Draft Detailed Project Report Page 7
• Technical Note on Tunnel Section and System
• Structural Analysis- Primary Lining
• Structural analysis of Inner lining and Design
Part-III Design of Bridges and Cross-Drainage Structures :
• Proposed Bridges and Structures Design Basis and
• Bridges Dimensioning
Part-IV Geological Design and Geotechnical Report:
• Geological Survey and Analysis
• Geotechnical Investigations Report
(iii) Volume-III Materials Report :
(iv) Volume - IV(a) Environmental Assessment Report including Environmen-
tal Management Plan (EMP) &
(v) Volume - IV(b) Resettlement Action Plan (RAP) :
(vi) Volume - V Technical Specifications :
(vii) Volume - VI Rate Analysis :
(viii) Volume - VII Cost Estimates :
(ix) Volume - VIII Bill of Quantities :
(x) Volume - IX Drawings (A3 Size) :
a. Location map
b. Layout plans
c. General Drawings
d. Plan and Profile of Refined Alignment ”A”
e. Typical Cross Sections showing Pavement details of Cut & Fill Section
f. Typical Cross Sections of Tunnel
g. Typical Cross Sections of Bridges
h. Tunnels- General Arrangement Plan and L-Sections (L&R)
i. Viaducts – General Arrangement Plan and L-Section
j. Cut & Fill and Viaducts – General Arrangement Plan and L-Section
k. GAD for proposed RoB at Railway km 54+650
l. Standard Drawings
m. Miscellaneous Drawings
n. Indicative Land Acquisition Plans
o. Detailed Cross Sections @ 100m interval
(xi) Volume - X Civil Work Contract Agreement :
(xii) Volume - XI Project Clearances :
GEOCONSULT INDIA Pvt. Ltd. I6060-REP-09-KD6-DDPR-Vol II-DR-Part II_A.DOCX 17.12.2015
Feasibility-Cum-Geo Technical Study for the bypass to Shiradi Ghat from Km 238.00 to 261.45 on NH-48 in
the State of Karnataka - KD6 - Draft Detailed Project Report Page 8

Volume - II: Design Report
Part- II: Design of Tunnels
(A): PROPOSED TUNNEL DESIGN AND STANDARDS

GEOCONSULT INDIA Pvt. Ltd. I6060-REP-09-KD6-DDPR-Vol II-DR-Part II_A.DOCX 17.12.2015
Feasibility-Cum-Geo Technical Study for the bypass to Shiradi Ghat from Km 238.00 to 261.45 on NH-48 in
the State of Karnataka - KD6 - Draft Detailed Project Report Page 9
1 GENERAL
This Volume - II: Design Report- Part II: Design of Tunnels, (A) Proposed Tunnel Design
and Standards, a part of “KD6: Draft Detailed Project Report for Final Approved alignment
for Bypass (DDPR)” is submitted in accordance with the Contract Agreement and as per
requirement specified in Terms of Reference (ToR) for preparation of Design Report -Part
II: Design of Tunnels, (A) Proposed Tunnel Design and Standards of “Feasibility-Cum-
Geo Technical Study for the bypass to Shiradi Ghat from Km 238.00 to 261.45 on NH-48
in the State of Karnataka”.
GEOCONSULT INDIA Pvt. Ltd. I6060-REP-09-KD6-DDPR-Vol II-DR-Part II_A.DOCX. 17.12.2015