Trenchless tunneling methods were key to the INDOT SR 37 project’s success by providing drainage for new depressed interchanges. Gravity outfall sewers were selected over pump stations, which eliminated long-term O&M costs. This presentation explains how trenchless methods were successful in difficult ground and groundwater conditions. Approximately 1.4 miles of 54-inch-diameter storm sewers were successfully installed using trenchless tunneling methods, including a record breaking 2,304-foot-long curved micro tunnel boring machine (MTBM) run

Farny, Eric

Flanagan, Michael

English

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Record-Breaking Trenchless IMPROVEMENT PROJECT Tunneling Success Demonstrates Value on SR 37 FISHERS EST. 1872 Purdue Road School March 16, 2022 ■•• ~ - STRUCTUREPOINT • • INC. ''' ) •Eric Farny, PE - Roadway Lead - American Structurepoint Michael Flanagan, PE - Lead Trenchless Designer, WSP USA Overview SR 37 Project Overview Design of Offsite Drainage Storm Sewers Geotechnical Conditions Trenchless Construction Lessons Learned m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I • • • • • SR37 - Hamilton County m ·~ ~ FIS..::RS \\'I) STRUCTUREPOl~I What Traffic Problem? m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I What Pedestrian Problem? m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I Mobility Study m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I Final Product m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I Depressing SR 37 - Maintain Sightlines m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I Pump Stations vs. Trunk and Offsite Drainage 126th St146th St. 141st St. 131st St. p q ~ r q ~ q m ·~ ~ FIS..::RS \\'I) STRUCTUREPOl~I Offsite Drainage Sewer Locations 6 Roadway and Bridge Improvements from 126th to 146th Streets 2 Depressed Interchanges Two Trenchless Gravity Outfall Storm Sewers Selected Over Stormwater Lift Stations m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I Storm Sewer Design WSP design selected reliable trenchless gravity outfall storm sewer Stormwater pump stations at each depressed interchange were rejected due to long term O&M costs Utilized existing Right-of-Way and existing drainage easements 3 s S. 126th . m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I • • • Design - South Offsite Drainage Sewer Location of alignment selected based on existing drainage easement. Upstream connection to mainline trunk storm sewer (STR 14) located at approximately 1,550 feet north of the proposed 126th street interchange 2,100-foot-long, 54-inch inside diameter pipe at 0.008% slope Outlets to new drainage detention pond then to Shoemaker Ditch m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I • • • • Design - North Offsite Drainage Sewer Location along 146th Street Right of Way Upstream manhole located approximately 500 feet west of the proposed 146th street interchange (STR 22) 4,620 feet long 54-inch inside diameter pipe at 0.040% slope Outlets into White River, just upstream of 146th Street bridge crossing. m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I • • • • --Geotechnical Conditions - South Drainage 1115 ,,,,-----,,,,,, I I I ...:.I ........ 1210$ _, -LITHOLOGY GRAPHICS Eff] :.,_ oor 1ZZJ 1-oor -,l -[II] [Jl)f l.affl m-J I.Jan 0(11' 0,,, II]] t:" DOT E:] I ~ INXJTSlrd! _.,. (:'B1 namin,..,sw Gll'--lot ~al~ 1110 790 785 780-775 Stal Road 37 l~ovements, Off-srte Drainage FIShers , H ·1 on C-ounty, Indiana m ·~ ~ FIS~~RS \\'I) STRUCTUREPOl~I Geotechnical Conditions - South Drainage Figure 8: Grain Size Distribution of Tested Samples for South Alignment in Primary Tunnel Zone '''11 100 ~ - ~ou• ... aT; 1----+------'..-----+J,,,------++-_____,,_________ - ou• .a1u .as - ~04~ .... . - --.004.. . LO 10 1---+------+----'"r'-,c----~...----",--~-~--.......-----+ - - "-LDOU --c -·· 90 80 70 60 30 20 10 0 100 10 0.1 0.01 0.001 Sieve SID (mm) Sand I CII C: 40 : ~ G SI I C yC<>ar$0 Sand Fine Sand m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I Geotechnical Conditions - North Drainage 800 f.. ui 700 740 SUiia 270S LITHOLOGY GRAPHICS on Em )0 no m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I Geotechnical Conditions - North Drainage Figure 15: Grain Size Distribution of Tested Samples for the North Alignment \\ 11 within Primary Tunnel Zone ----------- 100r-------i~~~~;;;;:::::--r-70 60 20 10 ~-- --------'---..,....;;:,,-=----4 0 100 10 0. 001 0.001 Coar'NSand $a,d m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I                       Design - Trenchless Tunneling Methods Open to various trenchless construction methods using modified INDOT Standard Specification 716 Project required Quality Control Plans (QCP) for Engineer review and acceptance via ITM 813. Non-pressurized face TBM with full face closure doors acceptable MTBM acceptable USP/ CIB Initial 4 hours of obstruction removal efforts included in trenchless pipe installation cost. Over 4 hours reimbursable to Contractor. m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I • Run lengths ranged from 577 to 1092 feet to accommodate range of trench less methods. • 4 Manhole Structure on South Drainage Line • 6 Manhole Structure on North Drainage Line • • • • • • • Begin STA End STA Slope (%) Length (ft) Offsite StormSewer Notes 16+85 (STR 11) 24+25 (STR 12) 0.08 731.5 South 24+25 (STR 12) 33+25 (STR 13) 0.08 891.5 South 33+25 (STR 13) 37+80 (STR 14) 0.08 451.0 South 206+35 (STR 15) 217+35 (STR 17) 0.40 1091.5 North STA 210+50 to 213+50, jet groutingrequired if using non-pressurized face TBM 217+35 (STR 17) 226+10 (STR 19) 0.40 866.5 North 226+10 (STR 19) 231+95 (STR 20) 0.40 576.5 North 231+95 (STR 20) 240+25 (STR 21) 0.40 821.5 North 240+25 (STR 21) 249+21 (STR 22) 0.40 891.5 North Design -Pipe Jacking Microtunneling Con rol Canta ner Sett/em n Tank •II• II t • Ground Wat r e I Launch Sha Plan Vi On d LineLaunch Shaft Recept10 Launch Seal ·ng P, Sal AV. Cutti H d m ·~ ~ FIS~~RS \\'I) STRUCTUREPOl~I Construction - Trenchless Tunneling Methods South Drainage Line Akkerman 720 TBM Two-Pass Tunneling Method 84-inch Diameter Primary Tunnel Liner Using W4x13 steel ribs and hardwood lagging 54-inch inside diameter fiberglass reinforced Hobas pipe m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I North Drainage Line Akkerman SLC MTBM Microtunneling One Pass Pipe Jacking Method AZ100 TGS 54-inch inside diameter Reinforced Concrete Jacking Pipe • • • • • • • • Construction - South Drainage Line m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I Construction - South Drainage Line m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I Construction - South Drainage Line m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I Construction - South Drainage Line Obstructions m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I Obstructions were frequently encountered on the South Drainage Line. 18 to 36-inch diameter granite boulders 37 obstructions encountered over 1,026 feet of tunnel Transitioned to MTBM half way through MTBM mined though at least 10 obstructions. Complete the second half with MTBM in about a month compared to 5 months for non-pressurized face TBM. • • • • • • Construction - North Drainage Line m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I Construction - North Drainage Line m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I Construction - North Drainage Line m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I Lessons Learned 1. The interim completion date for the South Drainage Line did not allow adequate time for mobilization of pipe and tunneling equipment. 2.The frequency of boulders encountered on the south drainage line (37 boulders over 1,026 feet) is important lesson from this case history. 3. Baseline estimated number of obstructions in a GBR. 4. Exclusion of the first 4 hours of obstruction removal time was successful in limited extra work cost. 5.ln difficult ground conditions with boulders and variable groundwater, microtunneling (MTBM) methods were more successful. The Contractor was able to complete the remaining run in about a month compared to 5 months for non-pressurized face TBM. 6. The flexibility of the as project sponsor and design engineers during construction, allowed for record breaking curved microtunneling success in Construction. m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I SR 37 Offsite Drainage Storm Sewer was successful despite encountering difficult ground conditions. First major trenchless project performed for the City of Fishers and Hamilton County. Trenchless runs included a record breaking 2,304-foot-long curved microtunnel run on the north drainage line. m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I • • • Team Project Sponsors City of Fishers, Indiana Hamilton County, Indiana City of Noblesville, Indiana Indiana Department of Transportation SR 37 Design Team RQAW - Program Management American Structurepoint - Lead Roadway and Bridge Designer United Consultants - Roadway and Bridges WSP USA - Trench less Drainage Designer DB Engineering - MOT & Erosion Control Atlas (ATC) - Geotechnical Investigation Construction Midwest Mole Inc. - General Contractor and South Drainage Line Super Excavators Inc. - Subcontractor North Drainage Line m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I • • • Thank You / Questions Publication Flanagan, M., Avila, L. & Brown, B. (2021). "Record-Breaking Trenchless Tunneling Success in Difficult Ground Demonstrates Value on Indiana SR 37." Proc. NASTT 2021 No-Dig Show, Orlando, FL. https://mem ber.nastt.org/prod ucts/product/2021-TA-T4-05 Contact Information Michael Flanagan, PE Michael.Flanagan@wsp.com Geotechnical & Tunneling Area Manager - WSP USA, Inc. Indianapolis, IN Eric Farny, PE EFarny@structurepoint.com Project Development Director - American Structurepoint Indianapolis, IN m ·~ ~ Fl~~;RS \\'I) STRUCTUREPOl~I 

Record-Breaking Trenchless Tunneling Success Demonstrates Value on SR-37

https://docs.lib.purdue.edu/cgi/viewcontent.cgi?article=4584&amp;context=roadschool

Record-Breaking Trenchless Tunneling Success Demonstrates Value on SR-37

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