Letter to the Editor

I was disappointed in the reporting of the record microtunneling drive on the City of Portland’s East Side CSO Tunnel Project (April 2008 Tunnel Business Magazine). My concern is that the story seems to suggest that the record microtunneling drive was the result of a three-way decision involving the contractor, designer, and MTBM manufacturer. This misses the mark. In the third paragraph under “The Drive”, the article states “...understanding the specific reasons for the specified length...is key to appreciating the record drive.” The article then fails to cite the specific reason for installing approximately 3,000 ft of pipe in one continuous drive, which was actually not specified.

The original 84-inch 3,000-ft connection of Outfall 46 to the Port Center Way Shaft was designed by Parsons Brinckerhoff to be microtunneled in two drives of 1,934 ft and 991 ft respectively, with an intermediate shaft. However, during construction, the contractor, Kiewit/Bilfinger Berger JV (KBB), proposed eliminating the intermediate shaft to the owner, the City’s Bureau of Environmental Services (BES). It should be noted that the construction contract is a cost-plus-fixed-fee contract, where labor, equipment, and materials are paid by the owner as reimbursable costs. Consequently, the “specific reason” for the long drive was a calculated risk taken solely by BES in accepting the higher risk of the long drive (in what we knew was difficult ground) against the potential cost savings in elimination of the intermediate shaft. The decision to take this risk was based on our previous experience with the microtunneling on the West Side CSO Project in similar ground conditions and with a similar machine. The advantage to KBB was the schedule savings with the elimination of the shaft in a difficult location of limited space.

KBB’s staff and the MTBM performed admirably through some very difficult mining conditions, including soft ground, wood debris, and rail spikes. However, during Mr. Hou Jin’s motorcycle stunt, the person pursuing the record was taking 100% of the risk himself, which is a slightly different case than what we had here. Under a hard bid contract or a risk-averse owner, the setting of a microtunneling record would have been unlikely.

Thanks for the opportunity to comment.

Paul T. Gribbon, P.E.
Chief Engineer
Willamette River CSO Tunnel Program
City of Portland, Bureau of Environmental Services

[Editor’s note: This project is featured this month in Trenchless Technology, our sister publication, as the 2008 New Installation Project of the Year. An updated version of the story appears in TT, including quotes from Mr. Gribbon.]

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U.S. Large Diameter Pipe Demand to Reach 203 Million Feet in 2012

Large diameter pipe demand in the US is forecast to increase 2.7 percent yearly to 203 million feet in 2012, valued at $10 billion. Growth stimulants include a rebounding construction sector and needs to expand and upgrade an aging pipe infrastructure. These and other trends are presented in Large Diameter Pipe, a new study from The Freedonia Group Inc., a Cleveland-based industry research firm.

Concrete will account for 54 percent of all linear pipe footage as a result of its structural integrity, durability, and high compression and pressure resistance. Demand for large diameter concrete pipe is projected to advance two percent annually to more than 109 million ft, paced by drainage and irrigation applications.

Best growth is anticipated for plastic pipe in light of resin and machinery improvements, as well as good joint integrity, excellent corrosion resistance and flow rates, and lower installation costs. Plastic pipe advances will be stimulated by resin advances (e.g., bimodal polyethylene and molecularly oriented PVC), which will extend the pressure resistance and other properties of large diameter plastic pipe. Best opportunities are expected for large diameter polyvinyl chloride (PVC) pipe.

Demand for large diameter steel pipe is projected to increase 1.8 percent per annum due to steel’s high strength, rigidity and pressure tolerance, especially in exploratory, distribution and transmission applications for the natural gas and petroleum industries. Cast iron pipe will remain the preferred choice in applications where high water pressure capabilities are required. Clay pipe demand will slowly diminish based on competition from higher performing and lower cost plastic pipe.

Storm sewers will remain the leading large diameter pipe market, although better growth is anticipated in natural gas and drainage/irrigation applications. Natural gas markets will be stimulated by high energy costs, increased exploration and drilling activity and the excellent performance of HDPE pipe in gas distribution uses. Good growth for drainage and irrigation pipe will result from rebounding construction activity and widespread drainage applications. Sanitary sewer growth will be based on needs to address problems with combined sewer overflows and the maintenance of clean water standards.
Large Diameter Pipe is available for $4,600 from The Freedonia Group, Inc., 767 Beta Drive, Cleveland, OH 44143-2326. For further details, please contact Corinne Gangloff by phone 440.684.9600, fax 440.646.0484 or e-mail pr@freedoniagroup.com.

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Jacobs Receives Contract for San Francisco Bay Tunnel Project

Jacobs Engineering Group received a contract from the San Francisco Public Utilities Commission to provide construction management (CM) services for the Bay Tunnel Project in California. The project will construct approximately five miles of 9-ft diameter soft ground tunnel below the San Francisco Bay, two vertical shafts in areas adjacent to the Bay, and a watertight final lining of welded steel pipe.

The total installed cost of the construction project is valued at approximately $270 million with a CM contract value of $18 million.

In making the announcement, Jacobs Group Vice President Bob Clement stated, “We are very pleased to be awarded this major tunneling project in the San Francisco Bay Area. The tunnel is one of the most critical elements of the Water System Improvement Program to ensure the delivery of reliable, high quality, and affordable water to 2.4 million customers in the four Bay Area counties of Alameda, Santa Clara, San Mateo, and San Francisco. Our selection is testament to our capabilities to manage tunneling in difficult ground conditions and we are privileged to have the opportunity to help enhance the quality of life for the residents of the region.”

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Atlas Copco Opens North American Distribution Center

Atlas Copco Compressors LLC recently opened a new distribution center in Rock Hill, S.C., as part of their commitment to work to ensure a 24-hour delivery of in-stock parts to customers across North America.

“Through our new distribution center in South Carolina we have the capability to deliver spare parts within 24 hours or less if that’s what the customer needs,” said Paul Hense, president of Atlas Copco Compressors LLC. “Our customers no longer have to worry about overseas shipping or potential delays in customs – they know they’ll get the parts they need the next morning, significantly reducing any downtime they may be experiencing.”

The distribution center is staffed by more than 30 full-time employees, who manage the shipping of an average of 1,000 order lines every day.
The opening of the new North American distribution center coincides with Atlas Copco’s North American headquarters relocation to Rock Hill from Westfield, Mass. The distribution center is part of an 187,000-sq ft facility, consisting of corporate offices, manufacturing and distribution space for Atlas Copco portable and stationary compressors. The facility is also used for the production of compressors for the many multi-brands within Atlas Copco.

Atlas Copco feels that this brand new manufacturing and distribution center ensures flexible manufacturing inline with customer needs. This flexibility allows for entire production lines to be changed from screw compressors to piston compressors within a matter of hours.

“Our new North American distribution center is another example of our continuing commitment to our customers, providing them with the best and most-accessible resources and services that complement our state-of-the-art compressor technology,” Hense added.

The company points to this new distribution center as part of Atlas Copco’s dedication to understanding, anticipating and satisfying every customer’s complete service requirements in order to provide maximum efficiency in productivity, while helping to significantly reduce energy consumption and costs.

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Friends and Family Gather for Akkerman’s 35th

Akkerman Inc. celebrated its 35-year anniversary and grand opening of its new manufacturing space on Sept. 25 and 26 in Brownsdale, Minn. The event was dubbed Akktoberfest and hosted approximately 150 Akkerman customers and vendors. Guests toured the newly expanded facility lead by staff guides who highlighted significant and historical elements throughout the tour. Next, guests enjoyed food, beverages and music from a polka band in Akkerman’s beer garden. The next day, about 60 guests self-selected their foursomes and played a full round of golf at the local country club. The “Micro-Masters Fivesome”, consisting of Robin Lorenzen of Akkerman Inc., Cal Terrasas of Nada Pacific Corporation, Jeff Weakly of Super Excavators Inc., Chris Knott of BT Construction and Neil Wither of Big Bertha Boring were the winning team with a score of 8 under par. Additional awards went to Ray Post of Michels for longest drive, Chris Knott and Jeff Weakly for closest to pin and Benjamin Media’s Dan Sisko won longest putt. Maynard Akkerman, CEO and owner, addressed the gathering, giving kudos to his mother Marlys Akkerman, for her long-time contributions to the business and his wife, Robin Akkerman, for making it possible for him to pursue his dreams. “I couldn’t be happier with the turnout at the event,” Maynard said. “I was humbled that so many customers took time out of their schedule to see what we’re all about. We maintain that heart of our business comes from the continued faith and loyalty from our customers.”

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A Lovat for Edmonton

Lovat recently announced the sale of a new Lovat MP159SE Series 25500 tunnel boring machine to the City of Edmonton, Department of Public Works and Asset Management. The 4.03-m diameter TBM is equipped with Lovat-type ripper teeth, scraper teeth and a 4-spoke cuttinghead design for soft ground excavation. The cuttinghead is powered by a hydraulic drive system (600 kW) with maximum torque of 3,000 kN·m at 1.9 rpm.

The TBM has been provisioned for the future installation of a screw conveyor to allow operation in Earth Pressure Balance mode. The TBM will be used to bore the Mill Woods Double Barrel Replacement Storm Trunk at a length of 1,750 m and a maximum slope of 0.10 percent. The entire tunnel alignment is below groundwater level in impermeable soils with a depth of cover varying from 30 to 37 m. The subsurface profile along the tunnel alignment consists of variable thicknesses of low strength clay shale and sandstone.

Edmonton will utilize financing from Caterpillar Financial Services for the purchase of the TBM. This facility is now available to all Lovat customers.
Lovat is also supplying technical assistance for TBM assembly, testing and the initial drive. The TBM is scheduled to be delivered mid-2009.

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Pipeline Project Moves Forward

San Mateo County Officials gave final approval for the Crystal Springs Bypass Tunnel project, which will construct an 8-ft wide, 3/4-mile long tunnel which will provide backup for an existing tunnel that has been threatened by landslides. Construction is expected to start near the end of 2008. The board of supervisors granted the necessary easements to allow drilling to install the pipe 80-ft below ground.

The $100 million project will be run by the San Francisco Public Utilities Commission. A bid is expected to be awarded in mid-October, 2008.

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Mexico City Tunneling for New Pipe

Officials announced plans to construct a 39-mile long, 21-ft diameter tunnel for a CSO to alleviate the centuries old drainage problem in Mexico City.

Reportedly, groundwater extraction has lowered the city overall, exacerbating its vulnerability to flooding. The city sits in a valley ringed by mountain ranges with no natural runoff route. Existing drainage tunnels are overwhelmed by heavy storms. Not only that, but since the city is sinking, the existing drain tunnels no longer move water by gravity.

The US$1.27 billion tunnel will be one of the largest and most expensive public works projects in recent memory.

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Breakthrough at Arrowhead

The last of the three major tunnels for the Inland Feeder project broke through in August, with the Herrenknecht TBM finding daylight for the first time in five years.

The $1.2 billion project is set to complete in 2010 with 44 miles of conveyance tunnels improving the overall water quality for more than 19 million Southern Californians. Notable in overall scope, the project is also impressive for boring through and near major fault lines.

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Detroit Sewer Tunnel Project Approved by Council

Pressured by state environmental officials to sign on or burden the city with financial consequences, Detroit City Council members approved a $314-million portion of the $1-billion CSO tunnel system. Reports indicate that the city could have faced an increase in cost of $100 million if they missed a state-imposed Sept. 28 deadline and were forced to sell construction bonds at higher rates to finance the project.

The Board of Water Commissioners approved the contract in May, though the contract was not put before the council until September.

The project is set to get under way before the end of the year and involves a seven-mile tunnel 160 ft under Rouge Park. When complete, the tunnel will store some 218 million gallons until it can be treated.

New state figures estimate the overall cost of the program will approach the $1 billion mark, with roughly 60 percent of that budget dedicated to tunnels and the remainder to an additional treatment facility and ancillary structures.

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In Memoriam

Donald Charles Rose, born March 3, 1933, passed away July 26, 2008. Don was a Tunnel and Dam Civil Engineer and Engineering Geologist who was an activist in the tunnel and dam industry and civil engineering and engineering geology professions. He was also a teacher -- as a visiting associate professor at Cornell, -- as in his lectures on Civil Engineering for Engineering Geologist for the U.S. Department of Agriculture and the Association of Engineering Geologist, -- as in his chapter contributions to tunnel textbooks, and -- as in his latest endeavor Tunnel Engineering and Cost Estimating at UCLA Extension course as part of the UCLA professional Construction Management certificate program. He made very notable contributions to the dam industry including reporting on Auburn Dam, Queen’s Dam, and his participation in the design and construction of dams in California, Washington, Oregon, Michigan, Thailand, Yemen, and East Pakistan (Bangladesh).

In the tunneling industry his contribution included consultant on the Superconducting Super Collider, Hai Van Pass Tunnel in Veitnam, tunnel geologist on the Trans-Koolau H-3 Pilot Tunnel and Honolulu Interceptor sewers on the University of Hawaii campus, editor for the Metropolitan Atlanta Regional Transit Authority Atlanta Research Chamber Monographs, principal author on revising Terzaghi Rock Loads, active subcommittee participant for the U.S. National Committee on Tunneling Technology Geotechnical Investigations, project manager for the largest application of steel fiber reinforced shotcrete in the world at the time for the Stanford Linear Collider, and tunnel cost estimator for major tunnel projects. He worked at many consulting firms and consulted on major dam and tunnel projects all over the world.

He is survived by his ex-wife and best friend Elizabeth Rose, daughter Victoria, and son Donald Jr., and three grandchildren.

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