1. Civil Construction in the US Chris Laughton, Fermilab
Theta 13 San Luis Obispo Workshop

2. Theta 13 San Luis Obispo Workshop
Outline
Sites Under Consideration
West Coast
Midwest
Scope
Cost & Schedule
Contingency
Next Steps
Theta 13 San Luis Obispo Workshop

3. 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
Theta 13 San Luis Obispo Workshop

4. 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
Theta 13 San Luis Obispo Workshop

5. Scope “Finish-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
Theta 13 San Luis Obispo Workshop

6. 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- what’s where?
Abrasive cherts - roadheader impact
Blocky rock behavior at depth
Altered basalt behavior at depth
Etc..
Theta 13 San Luis Obispo Workshop

7. Scope Excavation 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
Theta 13 San Luis Obispo Workshop

8. Cost & Schedule The 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
Theta 13 San Luis Obispo Workshop

9. 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 -> Can plan with more confidence
Theta 13 San Luis Obispo Workshop

10. 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, D&B 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 R&D)
Highest unit costs in shorter drill and blast/roadheader tunnels (variable mining/ground conditions poor systems)
Theta 13 San Luis Obispo Workshop

11. 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 -> too risky
Contractors are working at full capacity -> too busy
Contractors are joint venturing -> 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.
Theta 13 San Luis Obispo Workshop

12. Cost & Schedule Bottoms-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.
Theta 13 San Luis Obispo Workshop

13. Contingency Underground 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.
Theta 13 San Luis Obispo Workshop

14. Contingency Status 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 haven’t looked yet!
• Can’t 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
Theta 13 San Luis Obispo Workshop

15. 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
(Spooner’s Cove)
“Man-Made” Tunnels
Main Injector)
Theta 13 San Luis Obispo Workshop

16. Next Steps Site Investigation
Braidwood (w/Exelon)
Desk Studies
ISGS support - others?
Field Work
@ Braidwood
@ 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/PG&E)
Desk Studies
LBL Earth Science Support ~ complete
Field Work
@ Diablo Canyon site
@ Other local rock sites
Initial Tunnel Site Selection
Portal Location,
Tunnel Alignment
Drilling Campaign
~ Directional drilling
~ Portal
Theta 13 San Luis Obispo Workshop

17. Next Steps Engineering Task Definition
Initial Organizational Steps
Site Investigation Work package(s)
Plan Engineering Tasks (Discipline:Task Matrix)
Outside Support Scope/Contractor Selection/Contracting
What can’t 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
Theta 13 San Luis Obispo Workshop

18. Theta 13 San Luis Obispo Workshop
Next Steps Reviews
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
Theta 13 San Luis Obispo Workshop

19. Theta 13 San Luis Obispo Workshop
Next Steps Find 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
Theta 13 San Luis Obispo Workshop