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OptimizationOpportunitiesinthe
Design&ConstructionofUndergroundSpace
ChrisLaughtonPhD,PE,C.Eng.
ProjectManagerforUndergroundDesign&
ConstructionFermiNationalAcceleratorLaboratory.
DraftLayout
OptimizationPotential
Someprojectarerigid>corefunctionsoverride
engineeringpreferencesformoststable&mostpractical
PointConnectingorCorridorsutility,transit,accelerators,
beamlinedetectors(LongBaselines?)..
Miningorecentriclayouts,shorttermaccess,lowFOS
Someprojectsaremoreflexible.
Hydropower,storage(drygoodandfluids),publicspaces
engineerscanpickhostrock,orientations,shapes,dimensions..
DUSELopeningsmayhavesomeflexibilitypotentialto
optimizekeyengineeringaspectsofthedesigntoenhance
selfsupportingabilityofrockandimprovepracticalityand
safetyofconstructionwhilerespectingcorefunctions
DraftLayout
Space
EndUserRequirements
Alignment,crosssection,volume(detectors),connections..
Structures(enduserdriven)
Soffit:Anchors,partitions,rails,cranes,trays,racks,shields..
Invert:stabilityagainstvibrations,destress,overstress,swell..
Services(ideallysomereuseofconstructionutilities)
HVAC,Water,Power,Communication,DataAcquisition..
ES&H(onsiteandoffsite)
Egress,access,airquality,noise,groundwater,lightingetc..
DocumentNeeds>beforedevelopingsolutions(datafirst)
Integratedesignandconstructionengineerspreferencesintothe
Baseline.
EarlyIntegrationfewerchanges,time/costsavings.
DraftLayout
Geology,Geology,Geology
Explorebeforeyoudraw..pickthebesthostrockmass..
Modicumofdata/rationalanalysesneededatstartsimpleisOK
RMCsguidanceonly~questionableapplicationinhighstress?
Modelingisapowerful,butgoodinputiscritical..garbagein..
LikelyStabilityIssuesatDUSEL:
StressDrivenYieldand/orBurst(overstress)
GravityDrivenFallOut(blocks,wedges,soillikefill)
Waterpressureandinflow(erosion,shearstrengthreduction)
Combinationsoftheabove
EarlySiteInvestigationObjectives(reduceuncertainties):
RockIntactrockstrengths
StressInSituStresslevels/orientations
FractureDiscontinuities
Waterhead,permeability,estimatesflowlocationsandrates)
DraftLayout
DUSELRockMassAssumptions..
BasisofConceptualDesign~data+assumptions
RepresentativeBehaviors(routinevariability)
LocalAdversities~frequency/severity
PreSIBaselineDocumentationofbothKnowns&Unknowns
>nomoresophisticatedthanthedatacansupport!!(KIS,S)
Moreassumptions=morecontingency
Rule#1avoidancepreferredtomitigation(e.g.SIfirst)
PendingSIassumeahard&blockyrockmass
Relativelystrongandabrasiveintactrocks100MPa+
Containingfracturesandfracturezones,somewithwater
Subjecttosignificantstressatdepth
DraftLayout
StabilityofUndergroundOpenings
Underground,twoformsofinstabilityoftenobserved:
1) Geostructurallycontrolled,gravitydriven
processesleadingtoblock/wedgefallout
2) Stressdrivenfailureoryield,leadingtorockburst
orconvergence
(afterMartinetal.IJRM&MS,2003)
Note:structureandstresscanactincombinationto
producefailureandaddingwatercanexacerbate
failureorreducetheFOSagainstfailurethrough
theactionofflowand/orpressure
DraftLayout
OrientationofMajorExcavations
ConsiderOrientationwithrespecttoStressFieldandGeo
Structure(discontinuityboundblocks/wedges)
1)Ifthereisamajorfaultorfracturezoneinthevolumeofa
majorexcavationfindanewsite!(e.gdatabeforedesign!)
2)Ifasingledominantdiscontinuitysetispresent
Minimizegravitydrivenfalloutbyplacingthelongaxisoftheexcavation
subperpendiculartothestrikeofthediscontinuityset.
3)Ifmultiplesetsarepresentavoidplacingthelongaxisparallel
toanygivemoreweighttosetsmostlikelytocauseinstability.
4)Ifhighstressesareunavoidableatasite
Destabilizingforces..gravityalways..rockstress/waterpressuresometimes
Alittlestressandfracturecanaidstability
Minimizeyield,slabbing,rockburstactivityavoidplacingthelongaxisof
theperpendiculartotheprincipalstress(~1530degreesfromparallel,after
Broch,E.1979).
DraftLayout
RockFractureOrientation
SingleSetofplanesofweakness.
StabilityisafunctionofExcavation
Axis:
ExcavationAxisPerpendiculartoDiscontinuityStrike
MaximizeStrikePerpendicular
MinimizeStrikeParallel
Moretypicallymultiplesetsof
planesofweaknesses..
Maximizebyavoidinghavingany
strikeclosetoparalleltoaxis.
DraftLayout
ExcavationParalleltoDiscontinuityStrike
RockFractureSize/ScaleEffects
LargerExcavation>increasedpotentialforblockyfallout
BoredDiameter
8meters
4meters
RockMass
Structureonan
AbsoluteScale
8meters
RockMass
Structureonthe
"TunnelScale"
Tunnel
Diameter
DraftLayout
2meters
High&LowStress
Excavationresultsinstress
redistributionatperimeter:
LowStressorTension:
mobilizedshearstrengthwillbe
lowFailure!
HighStress:locally,tangential
stressesmayexceedrock
strengthFailure!
Aboveconditionscanresultin
fallout(walls,crown)
Geometryoffalloutmateriala
keyconsideration
Ideallyeliminateorlimitthe
zonesofbothhighandlowstress
aroundtheperimeter
DraftLayout
Low Stress
Conditions
High Stress
Conditions
MitigatingStressSectionShape
MinimumBoundary
stressesoccurwhenthe
axisratiosofellipticalor
ovaloidopeningsare
matchedtotheinsitu
stressratioafterHoek+Brown
Nicetokeepthebottom
flat.However,some
designersgothewhole
hog(counterarch..),
Sauer..
DraftLayout
2
2
1
2
HighStressFailureZones
Notalwayspracticaltohave
circular/ellipticalsections..
Stressconcentrationwilloccurasa
functionofstressfield/orientationand
excavationshape
Shadedareasshowwhererockburstor
yieldismostlikelytooccurarounda
horseshoeopeningunderthreetypesof
principalstressorientation..
Vertical
Horizontal
Inclined
DraftLayout
VerticalPrincipalStress
HorizontalPrincipalStress
InclinedPrincipalStress
AfterSelmerOlsen+Broch
StressDrivenInstabilitycanbeSevere
SeverityPrediction?
relativetoVirginStressvs.
IntactStrengthRatio
OverstressFailures
UniaxialCompressiveStrength
UCS,MPa
200
150
Undermoderatestress
regimeaimtoevenoutthe
distributionofstressesto
100
avoidlocalstability
problems,asdiscussed
50
Underhigherstresslocalize
stressconcentrationsto
0
0
reduceunstableareaand
costsofsupport
DraftLayout
0.1
0.2
VAS/UCS
0.3
0.4
50
VerticalAppliedStress,VAS,MPa
AfterHoek+Brown
0.5
100
Section&SupportMitigation
StrategyforMinimizingImpactof
Overstress
VerticalPrincipalStress
Reducepotentialforbuckling/slabbingby
avoidinglongperimeterssubparallelto
principalstresslowexcavations
HorizontalandInclinedPrincipalStresses
Focusandsupporthighlystressedvolumeat
discretelocationsaroundthesectionby
increasingradiiofcurvatureofsectionto
concentrateloading
boltsupportcanbeusedtostabilizeareas
ofconcentratedloading
DraftLayout
afterSelmerOlsen+Broch
MitigationStep:OpeningSeparation
Virginstressconditionsare
modifiedwhenopeningsaremade,
attheperimeter(hydrostaticstress)
stress
Radialstresszero
Tangentialstress2xvirgin
tangential
radial
2circularopenings
Shareddiameter,a
Inhydrostaticstressfield
MinimalInteractionifdistance
betweenopeningscentersisgreater
than6a
Inhighstresssituations,ensure
openingsdonotoverlyencroach
onzonesofinfluence
DraftLayout
distancefromtunnelwall
DI,II 6a
II
AfterBrady&Brown
Methods&MeansAssumptions
DrillandBlastpreferred
FlexibleHeadingOperationscanAccommodate
AlignmentandSectionChanges
SupportandTreatmentChanges
PreConditioning/CautiousBlastingOptions
TBMscapableofhigherproductivity,but
RigidHeadingOperations
Changes>MajorUtilizationdrops(~5090%)
PotentialR&Dtoolexploratorylong,straighttunnels+uniform,goodrock
RoadheadersHardRockChallenged
PotentialR&Dtollref.ICUTROCinitiative
Raise/BlindBoreEquipment
Inclined/VerticalShaftDrilling
StabilizationMeasures
BoltsandCables(prepostreinforcement..)
SuperSkins/Liners(sprayon,cip..)
FinalLiners(Paint,shotcrete,Gunite,.waterproofing..)
DraftLayout
DesigningPracticalSolutions
UndergroundConstructionEngineersoften
complainthatthedesignofastructureisnot
alwaysmadewithduerespecttomodern
construction.(Brannsfor&Nord,Skanska)
Toimprovetheconstructabilityofunderground
structuresitisworthwhileincludingactive
constructionengineersinthedevelopmentofthe
designconcepts..(Laughton,01)
Someexamplesonimprovingconstructability..
DraftLayout
LayoutforOptimizedConstruction
Ingeneralcapitalcostsundergroundareproductivitydriven
InTunnels..MinimizeLayoutGymnasticsAvoid
Steepramps(>810%)=significantproductivityreductions(haulageetc.)
Longcurveslongstraightsections/shortswitchbackspreferred
Miningincloseproximitytoexistingstructurescautiousblastingisslower
Multipasssections>uselargestmechanizedequipmentthatcangetdown!
RoutineChanges>standardizeexcavation/supportprocedureswhenpossible
Incompatibilitiesbetweenequipment/materialssystems>matchcapacities/sizes
Impracticalsectiontransitions>design/drawasitwillbebuilt
Additionally...inMultiPassOperations/CavernsAvoid
BottomsupMining>prefertopdownworkunderasupportedcrown
Wide,shortexcavationswithhighspan:depthratios>benchedvolumesgivehigher
productivity/requirelessreinforcementcomparedtoheadings
InWetGroundAvoid
Downhillminingachievegravitydrainage
DraftLayout
Practicalities..SectionsTransitions
Rightangledintersectionscanbeproblematic
Drill/blastwilltypicallyproducebellshaped
transitionswhynotdrawitlikethat(endusermight
beabletobetteradaptinstallationstoreality!)?
Difficulttominetolineandgrade
Liabletobeunderlowstress/tension
Chamber
Tunnel
SelmerOlsen&Broch
Chamber
Tunnel
DraftLayout
LongSection
Practicalities..AccessTunnels
Excavationmethodsoftodaymakeitpossibletouselong
inclineddrifts..providedthatthedriftsarecorrectlyshaped,
sothatmaximumtransportcapacityisobtained.Thiscannot
beachievedbyconstructingthedriftsasspirals:curves
shouldbekepttoaminimumandbeasshortaspossible.
Straightreachespromotehighspeedandconsequently
greatercapacity(alsoyieldsimprovedvisibility/safety,ideal
passingplacesetc..).
DraftLayout
Plan
Practicalities..ShaftAccess
Rockfallsareoftenaproblemiftheshaftopens
outdirectlyintotherockcavernwhereworkisin
progress.Itisthereforebettertopositionthe
shaftsomewhattoonesideandmakea
horizontalconnection.
DraftLayout
CrossSection
Practicalities..CavernAccess
Itisnotalwaysselfevidentwhereanaditshould
enterinarockcavern.
Generalagreementthatiftherockcavernisshort,
<150m,theaditshouldcomeinattheend.
Wherethecavernislonger,itmaybemorecost
effectivetostartinthemiddleandworktwofaces.
DraftLayout
PlanView
PracticalitiesCavernAccess
Thecavernlongsectionshownbelowissuitable
forrockcavernswherevolumeisafunctional
demand.Noextratunneltunnelisconstructedfor
excvatingthebenches:itissufficienttohavean
inclineddriftintherockcavern.
DraftLayout
LongSection
CavernCostStudyLayout
Economyinrockcavernconstructionoilstorage..
Lookingforthecheapestunitvolume
Norwegianexperienceinhardrockatrelatively
shallowdepth(stressanoccasionalaproblem)
afterE.DJohansen,79.
Access Tunnel
LongSection
CrossSection
Top Headings
Bench 1
Bench 2
Bench 3
HardRockCavernCostModelGeometry
DraftLayout
CavernCostStudyFindings
ExcavationCosts
Unitcost(Nk/m3)reducedas
spanincreased
Reductionmostmarkedinthe
1020mspanrange
ReinforcementCosts
80
BadRock
60
Ingoodrockslightdropin
unitcost(Nk/m3)calculated
withincreasedspan(1020m
range)
Whenrockconditionsareless
favorable,thecostsof
reinforcementcanincrease
rapidlywithincreasingspan.
Excavation&ReinforcementCostsNk/m3
GoodRock
40
Excavation
20
DraftLayout
15
20
25
Span,m(TopHeading&3Benchesseemodelconfiguration)
CavernCostStudyConclusions
RockCavernswithSpans>20m
Reductionsinexcavationcost~
relativelysmallcomparedtopotential
forincreaseinreinforcementcost
Many20m+cavernshavebeenbuilt,but
Reinforcementneedscanincreaserapidly
Designersandbuildersperceptionofrisk
willbecriticaltoaffordability>how
goodistheground?,howwellareits
characteristicsknown?
Reservedetaileddesignuntiltheground
isadequatelycharacterizedconduct
tradeoffdesign/coststudiesbefore
committingtoalargespandesign
ApproximateCavernSpan,m
20
40
60
LEP
LHC
(CERN) (CERN)
KoreaInvisibleMassSearch
(YangYangHEPPS)
SuperKamikande
GranSasso (KamiokaMine)
(RoadTunnel)
SNOLab
(CreightonMine)
Choosingaspangreaterthantherock
WesternDeep
(CrusherRoom)
masscanreasonablyallowisthegreatest 3
erroradesignercanmake,after
ApproximateDepth,km
Johansen
DraftLayout
Gjovik
(IceRink)
DomedCavern
PrismaticCavern
OnePossibleGenericLabLayout
DominantRockStructure
CleanLaboratorySpace
Services(HVAC,Power,Comm.,SharedSpaceetc..)
AirFlow
DirtyLaboratorySpace
ExcavationAxes
AirFlow
strike
ShaftorRamp
ExcavationAxes
People..................................
PrincipalInSituStress
Machines/Materials...........
ServiceCavern..................
ExperimentCavern..........
DraftLayout
ContractOptimization
ClearDefinitions
Scopeincludinggroundbehaviors
AcceptabilityofAlternates
Allowbiddertomatchfacilitytohis/herspecificskillse/tools/materials
Riskregister/allocate/address
Riskallocatedtopartybestabletoaddressit
Prequalify
Streamlinedrolesandresponsibilities
Authorityandresponsibilitiesaligned
Realtime,onsitedecisionmaking
Variableconditions=variableresponse(inmanycontractssomevariability
maybepotentiallyunexpected..DSC)
Agreementonrangeoftreatment,excavationandsupportoptions(Design
asyougo!)
DraftLayout
ConceptDevelopmentSteps
1)FindaVolumeofRockMassSuitabletoHousetheRequired
UndergroundOpening(s)
Tieintoexistingexcavationsetc..
2)OrientationofLongAxis
3)CrosssectionalSizeandShape
4)InterSpacingBetweenExcavations
Ensurethatthecostsandcontingenciesthataredevelopedtrulyreflect
theuncertaintiesintherockmassconditionsandtheconstruction
process
afterSelmerOlsen&Broch
DraftLayout
SummaryConceptOptimization
Notrocketsciencebutamodicumofengineeringinputduringthe
conceptdevelopmentmayreducecostandrisk..
Notonly..EndUserNeeds
Butalso..(ifyouneeditwecanbuildit,butwedprefer..)
DesignEngineerPreferred(Stability)
Characterizepotentialadversegroundbehavior(s)toincluderealisticworstcase
scenarios(forewarnedforearmed)
Identifythebestrockcompatibleengineeringsolution(s)
ConstructionEngineerPreferred(Practical,CostEffective)
Meetenduseddemandsmoresafelyandatlowercostandrisk
accommodatedesignersrangeofadversegroundconditions/behaviors
Assumeschangeisacceptable(Constructability,VEReviewframework)
Earlyintegrationofneedsandpreferencesiskey
Explorebeforeyoudraw>whenpossibleletgeologyguidedesign
(easiertochangethedesignthantherock!)
DraftLayout
OtherOpportunities..
Proposal#99:WineStorage?
LargeElectronPositron
CentralCaliforniaWineCave
ThanksforYourAttention
DraftLayout