Delivering the North West Rail Link Colin Rudd, Deputy Project Director, NWRL David Polkinghorne, Design Team Leader, TJHD November 26, 2013
The starting point
Project overview $8.3 billion budget Open by late 2019 First stage of rapid transit
Bigger than the Harbour Bridge Artist s impression: Kellyville Station street view Eight new railway stations 4,000 car parking spaces A train at least every five minutes in the peak 15km twin tunnels 4km skytrain viaduct 20,000 more tonnes of steel than the Sydney Harbour Bridge.
Artist s impression: an underground station More trains, more choice Australia s first fully-automated rapid transit rail system Fast, safe and reliable single deck trains Conversion and upgrade of Epping to Chatswood line The longest rail tunnels built in Australia.
Bringing the project to life Widespread community engagement since June 2011 Project aligned with key Government plans, Transport Master Plan Major scope improvements made since June 2011 Fully funded from State budget $806m FY2013-14, $4 billion over next 4 Property acquisitions well advanced >85% of transactions completed EIS 1 approved September 2012 ; EIS 2 approved May 2013 Early construction works managing contractor appointed August 2012 Tunnelling contract (TSC) awarded June 2013 Surface viaduct and civils contract (SVC) tenders received August 2013 Shortlist of two consortia for operations (OTS) PPP announced May 2013 On program for the first of the TBMs in ground in 2014
Aligned with State strategies State Infrastructure Strategy State Plan Budget Planning Transport Rail
The plan: Sydney s Rail Future
The plan: delivered in five stages Stage 1 Operational efficiencies Stage 2 Network efficiencies Stage 3 Rapid transit: North West Rail Link Stage 4 Rapid transit: New harbour crossing Stage 5 Rapid transit: Southern sector conversion
Artist s impression: Kellyville Station, aerial view Sydney s Rail Future & North West Rail Link
Heating and cooling in underground stations. Artist s impression: Castle Hill Station The stations Bus interchanges, taxi ranks, bicycle storage Easy access, kiss-and-ride Safe, well-lit environments, constant CCTV monitoring Passenger screen doors
No timetable just turn up and go. Artist s impression The trains Single deck, no internal stairs, three doors per carriage 1,300 capacity Automated, modern technology
Clear and constant communications with customers. Artist s impression Automation Safety No. 1 priority Platform screen doors: train operations faster and safer Constant live monitoring by expert train controllers
Australia s first fully-automated rapid transit system. Artist s impression: Cherrybrook station aerial view Automation Clear communications Multiple cameras and help points, inside trains and out Staff moving through the system during the day
Automation 30 years of operations 588km, 41 lines, 25 cities, 585 stations, 4 continents Impressive safety record Source: International Association of Public Transport, 2011 report.
Potential western extension Contract packages and interfaces Cudgegong Bella Vista Epping Chatswood Operations, Trains & Systems (OTS) Partially privately financed (with substantial State contribution) subject to VfM Train & station operations Mechanical, electrical, signalling, train control & other systems (new and upgraded) Supply & maintain rolling stock, including maintenance facilities and control centre, New stations construction & fit-out, civil works (including stabling and track) Overall infrastructure maintenance Surface & Viaduct Civils (SVC) Design & construct Surface civil infrastructure (including viaduct), Bella Vista to Cudgegong Tunnels & Station Civils (TSC) Design & construct Driven tunnels, station excavation, ground support Early Works Managing Contractor Managing Contractor ECRL existing infrastructure interface Sydney Trains operational interface at Epping & Chatswood Sydney s Rail Future Cudgegong Bella Vista Epping Chatswood
Project phase and timing Artist s impression: Rouse Hill Station, street view
Delivery scope major civil works
Tunnelling product requirements Geometry to suit rapid transit operations Convenient locations for access Shallow stations
Tunnelling constraints CHERRYBROOK CASTLE HILL SHALE NORWEST BELLA VISTA SANDSTONE CUDGEGONG ROAD ROUSEHILL KELLYVILLE SHALE SHOWGROUND Topography Hills District Creeks, no major watercourse Geology 60% sandstone, 40% shale Existing rail crossing ECRL dive with 5m rock cover Highways M2, Castle Hill Rd Buildings Castle Towers, Norwest Business Park
Tunnelling strategy Configuration twin tunnels Fire and life safety Groundwater Space proofing Cross passages Crossover cavern
TBMs to be manufactured by NFM, headquartered in France Tunnelling contract $1.15 billion contract Thiess John Holland Dragados joint venture Three portions to provide early access for OTS Contractor Completion date 2017
Thiess John Holland Dragados Awarded $1.15 Billion contract in June 2013 Australia s most experienced tunnelling contractors 70% of Australia s major underground infrastructure in last decade 1,200 km of tunnels world wide Delivery of tunnelling and rail projects in metropolitan cities across the world
TJHD: Key objective We will deliver a safe, high quality and value for money rail asset, in partnership with TfNSW, on time and on budget.
Tunnels and Station Civil scope 15 km TBM tunnels Mined tunnels and rail crossover cavern Cross passages Five stations: civil excavations Two service facilities: shaft excavations
TBM tunnels
The design team
Design process and roles TJHD integrated design verification TJHD internal independent verification TfNSW technical review Independent certifier Agency review - RMS for arterial roads - Council for local roads - Sydney Trains for rail connection
Design Priorities
Critical equipment ordering Day 1 TBM Carousels, moulds & Ancillary Equipment 24 th June 12 th July 13 th September Segment Carriers (TSPs) 9 th September Order dates Segment Gaskets Batch Plant Yard factory sheds & Gantry Cranes 24 th September September September
Early design/construction assessments Rapid mobilisation of D & C Team Segment ring build - Type and features - Casting methodology - Handling methodology TBM Capability and Features
Concrete segment manufacture Six segments form one ring for tunnelling Each segment ~ 3.75 tonnes Total segments for TBM tunnels ~ 100,000 Total rings for TBM tunnels ~ 16,500 145,000 m3 of concrete
Segment geometry
Site planning 3 x TBM Sites (Bella Vista, Showground & Cherrybrook) 1 x Station site to support mined tunnel operations (Castle Hill) 1 x Also includes a bridge (Norwest) 2 x Shaft excavations with one supporting mined tunnel (Epping & Cheltenham)
Bella Vista
Precast segment carousel plant
Demoulding / Vacuum lifter Segment being demoulded using vacuum lifter
Segment handling in the yard
Precast segment transport Bella Vista Segments transported to tunnel Supplied to other tunnelling sites at Showground and Cherrybrook
Tunnel Boring Machine (TBM) Tunnel and Station Civil Works Scope TBM shield, with grippers
TBM tunnel cross sections
TBM facts and figures NFM Technologies Double Shielded TBM (x4) Internal tunnel diameter ~ 6m TBM shield length ~ 12.5m 9 backup trailers on bogies running on segments Cutterhead with 40 disk cutters TBM total installed power ~ 3500kW Total weight of each TBM ~ 1000T
Ring erection, within the tailshield
Mined tunnel - Castle Hill
Mined tunnels - Epping
Castle Hill site
Cherrybrook site