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Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013 Copenhagen Cityringen Metro Project

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Page 1: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Infrastrutture:Qualità sotto controllo

Il Valore delle Verifiche Indipendenti

Ing. Matteo BuzzettiCopenhagen Metro TeamCMT Design Coordinator

31-01-2013

Copenhagen Cityringen Metro Project

Page 2: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Agenda

1. Introduction to Cityringen Project

2. Design Process – Check, Validation & Approval

3. Design Structure

4. Conteco Review Process

5. Special Stations

6. Optimized Construction Sequence

Page 3: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

1. Introduction to Cityringen Project

Page 4: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Contract- Copenhagen Cityringen Project Civil Works (signed on 7 January 2011)- Design & Build Contract- Value: approx. 1.500 mln Euro

Joint Venture:- Salini S.p.A.- Tecnimont Civil Construction S.p.A.- Seli

Client: Metroselskabet I/S

Metroselskabet I/S is owned by:•Municipality of Copenhagen (approx. 50%)

•Danish State (approx. 42%)

•Municipality of Frederiksberg (approx. 8%)

Cityringen shall operate 24 hours/7 days a week with a planned operational headway of approximately 100 sec. during rush hours, in the first years of operation

Cityringen is expected to serve up to 240.000 passengers per day or 72 million passengers per year

Page 5: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

The tunnel construction will be done by means of three methods: • Approximately 16 km of twin tunnel using TBM (tunnel boring

machines) EPB type (Earth Pressure Balance) Type Diameter 5.78 m to ensure an internal minimum diameter of 4.9 m.

• Variable diameter twin tunnel and caverns using sprayed concrete lining and steel ribs temporary supports (SCL)

• Cut and Cover Tunnel

Description of the works

•Two single track tunnels each approximately 16 km in length

•17 underground Stations

•3 Construction and Ventilation Shafts

•1 Ramp and Cut & Cover structure for TBM launch and access to the Control and Maintenance Center

•M&E Installations

The TBM construction shall be primarily through the Copenhagen limestone.The tunnel depth varies from approximately 15 m to 35 m

Page 6: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

2. Process – Check, Validation & Approval

Metroselskabet (Employer), ISA (Independent Safety Assessor) and SRA (Safety Regulatory Authority)

Copenhagen Metro Team (CMT) - Contractor

Tecnimont Civil Construction / EKJ (TCC/EKJ) - Designers

PARTIES INVOLVED IN DESIGN & APPROVAL PROCESS

Conteco – Independent Verification Body

Page 7: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Design Team Organization

Page 8: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

CMTCONTECODESIGN TEAM

DESIGN MANAGERPROJECT LEADERS

Design package Kick-off meetingDesign package Kick-off meeting

Definition of WBS for design and design package

Definition of WBS for design and design package

TECHNICAL DIRECTORDESIGN COORDINATOR

Assessment of laws and regulations Assessment of laws and regulations

RESPONSIBILITY FLOW CHARTPhase

List of Laws and Regulations

Start up meeting

Design Quality PlanDesign schedule

List of documents

Working Site LayoutWorking Site Layout

Preliminary GIR & Groundwater ConditionsPreliminary GIR & Groundwater Conditions

Risk AssessmentRisk Assessment

Specific Environmental IssuesSpecific Environmental Issues

Interface Main Issues (ICDD to be opened and followed up)Interface Main Issues (ICDD to be opened and followed up)

ConstructabilityConstructability

Construction SequencesConstruction Sequences

Existing Building / MonitoringExisting Building / Monitoring

Page 9: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

CONTECOINDIPENDENT BODY

DESIGN MANAGER

Conteco Calculations

DESIGN TEAM

First Design AssessmentFirst Design AssessmentDESIGN TEAM

Input to Conteco forAlternative CalculationInput to Conteco for

Alternative Calculation

RESPONSIBILITY FLOW CHARTPhase

VC1INTERNAL

VERIFICATION

VC1INTERNAL

VERIFICATION

- Geotechnical- Parameters- Formwork Drawings- M&E input

Preliminary ReportsSketches

Documents and reports

DESIGN MANAGER DESIGN TEAM

Design package development

Design package development

Periodical design review

Periodical design review

Document and reports update if

necessary

Page 10: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

TECHNICAL DIRECTORDESIGN COORDINATOR

RESPONSIBILITY FLOW CHARTPhase

DESIGNERDOCUMENT CONTROL

Distribution to CMT for reviewDistribution to CMT for review

CMT CHECKCMT CHECK

CONTECOINDIPENDENT BODY

INTERFACES ASSESSMENT

SAFETY ASSESSMENT

RISK ASSESSMENT

CONSTRUCTABILITY ASSESSMENT

INTERFACES ASSESSMENT

SAFETY ASSESSMENT

RISK ASSESSMENT

CONSTRUCTABILITY ASSESSMENT

VC2/VC3 CHECK

Review Sheets Check and Homogenization

DESIGN COORDINATOR CommentsTransmission to

Designers

CommentsTransmission to

Designers

Page 11: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

RESPONSIBILITY FLOW CHARTPhase

DESIGN TEAM

DESIGN MANAGER

Distribution to Design LeadersDistribution to Design Leaders

DESIGN UPDATEDESIGN UPDATE

ANSWERS TO CMT/CONTECO COMMENTSANSWERS TO CMT/CONTECO COMMENTS

V1 CHECKV1 CHECK

DesignDocument Package

Approval

DesignDocument Package

ApprovalDESIGN MANAGER

DESIGNERDOCUMENT CONTROL

Submission to CMT for issueSubmission to CMT for issue

Design Certificates

DESIGNERSDOCUMENT CONTROL

Page 12: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

DESIGN COORDINATOR

RESPONSIBILITY FLOW CHARTPhase

CMT/CONTECO FINAL CHECK

CMT/CONTECO FINAL CHECK

CHECK OF UPDATED DOCUMENT AND ANSWERS TO COMMENTS

CHECK OF UPDATED DOCUMENT AND ANSWERS TO COMMENTS

CHECK OF UPDATED DOCUMENT AND ANSWERS TO COMMENTS

CHECK OF UPDATED DOCUMENT AND ANSWERS TO COMMENTS

VC2/VC3INDIPENDENT BODY

Check Certificate by

Conteco

DesignDocument Package

Approval

DesignDocument Package

Approval

TECHNICAL DIRECTORVC2/VC3INDIPENDENT BODY

DESIGN ISSUE TO MS

DESIGN ISSUE TO MS

CMTDOCUMENT CONTROL

DESIGN COORDINATORTECHNICAL DIRECTOR

Monitoring status of design documents

Monitoring status of design documents

Monthly report

BUILDING PERMITBUILDING PERMIT

MS REVIEWMS REVIEW ISA/SRA REVIEWISA/SRA REVIEWMETROSELSKABET

Page 13: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

3. Design Structure

Page 14: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Station/Shafts-Preliminary Design 21 Packages

-Detailed Design 192 Packages (Civil Works only)

Tunnel Stretches-Preliminary Design 21 Packages

-Detailed Design 21 Packages

Total Number of Design Packages 272

-Average number of revisions considering all the involved actors 4

-Total Number of Design Packages considering 4 Revision 936

Approximate Design Duration ≈ 3 years ≈ 780 working days

Design Packages to be managed per day 1.2

Design Packages to be managed per week 6

Design Packages

Page 15: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

4. Conteco Review Process

Verification Scope of Works as per Main Contract Requirements

Page 16: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

4. Conteco Review Process

1st Phase – Revision on Internal Submission (Rev. 0.1)

Page 17: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

2nd Phase – Documents Update (Rev. 1.0) and Answers to Conteco Remarks by Designers

Page 18: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

If the Documents have been correctly updated and the answers to remarks are satisfactory Conteco issues the Final Verification Report and the Check Certificates

3rd Phase – Conteco Final Check of Revision 1.0

Page 19: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

5. Special Stations

Marmorkirken

Gammel Strand

Page 20: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Marmorkirken Station – Tender Design• During the Tendering phase of the Project, CMT proposed a concept design of the station which was

modelled on the recently constructed Station Piazza Bologna of Rome Line 3 Metro. The conceptual design of the station consisted of a narrow station box, providing the space for a concourse area as well as escalators with a stacked platform solution requiring the tunnels to run one above the other.

Page 21: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Marmorkirken Station – Design Optimization proposed by CMT during the Tender• The concept of the stacked solution required a deepening of the station box but limited all works from

course level downwards to be contained within the diaphragm wall retaining structure thus avoiding the necessity of cavern works or additional ground treatment such as freezing

Page 22: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Marmorkirken Station – Design Optimization proposed by CMT during the Tender

Additional Mitigation Measures to avoid Volume Loss under the Church and the Ancient Buildings

Page 23: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Gammel Strand Station – Tender Design

• The station is a special station located at Gammel Strand partly below Slotsholmskanalen.

• Gammel Strand station is classed as a “special” station due to its unique location and layout.

• All station elements at street level, including the emergency exit stair and ventilation openings are located close to and along the quay wall. Also the lift is located close to the quay wall behind the main stair.

• Due to the station being located partly below the Slotsholmskanalen the station box has been lowered

so that the roof of the technical level, which is equivalent to the normal station roof level, is below the bottom of the canal.

Page 24: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Gammel Strand Station – Construction SequencesTemporary Works – Phase 1

Diversion of navigation within canal / Installation of navigation buoys / Installation of silt curtain

Page 25: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Gammel Strand Station – Construction Sequences

Temporary Works – Phase 2

Mobilization of pontoon / Placing of drill rigs on pontoon / Installation of micro- piles for temporary bridge deck

Page 26: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Gammel Strand Station – Construction Sequences

Temporary Works – Phase 3

Installation of precast bridge decking / Concreting of bridge decking /Installation of micro- piles for tie back of bridge

Page 27: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Gammel Strand Station – Construction Sequences

Temporary Works – Phase 4

Installation of sheet pile wall / Installation of gabions / Backfilling to create job site area

Page 28: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Gammel Strand Station – Construction Sequences

Permanent Works – Stage 2

Construction of Top Slab

Excavation within station with the installation of struts at specific levels

Installation of water proofing membrane and Concreting of Bottom Slab

Permanent Works – Stage 1

Construction of Guide Walls and DW

Installation of Strut on DW Head

Start of Archaeological Excavations

Page 29: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Gammel Strand Station – Construction Sequences

Permanent Works – Stage 3

Construction of Inner Lining& Intermediate Slabs

Completion of Waterproofing

Removal of Backfill within canal anddemolishing of DW above top slab

Reinstatement of quay wall

Page 30: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

6. Optimized Construction Sequence

Page 31: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Secant Piles Secant Piles

King Post Piles

Top Slab Top Slab

Optimised Construction Sequence - Typical Station - Phase 1

Page 32: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Excavation Excavation

Demolition of King Post piles

1st level of strut

Optimised Construction Sequence - Typical Station - Phase 2

Page 33: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Installation of waterproofing and connection to retaining wall

Connection to King Post Piles

Intermediate Slab Construction

Excavation Resumes Excavation Resumes

Installation of 2nd Strut level

Optimised Construction Sequence - Typical Station - Phase 3

Page 34: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

2nd Strut Level 3rd Strut Level

Excavation Resumes with King Post Piles Intact

Excavation Resumes

Optimised Construction Sequence - Typical Station - Phase 4

Page 35: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Construction of Slab in presence of King Post Piles

Construction of Slab. Subsequent placing of

metallic King Post

Optimised Construction Sequence - Typical Station - Phase 5

Page 36: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

ADVANTAGES OF OPTIMISED CONSTRUCTION SEQUENCES

Excavation methodology remains unchanged from start to end. No requirement to excavated under intermediate slab with alternative equipment and lower rates of production No execution of King Post Piles No pre-installation and of waterproofing membrane at intermediate slab level No predisposition of connection of intermediate slab to retaining wall and king post piles to permit excavation to resume below intermediate slab Concreting of structure performed in a traditional bottom up method without complications for waterproofing membrane and coupler connections Reduced risk for delays in construction due to simplified construction sequences No secondary concreting of bottom slab at location of king post locations with complications in sealing of waterproofing membrane

DISADVANTAGES OF OPTIMISED CONSTRUCTION SEQUENCES

Additional installation of 1 level of struts Installation of scaffolding for the construction of intermediate slab

Optimised Construction Sequence - Typical Station – Advantages/Disadvantages

Page 37: Infrastrutture: Qualità sotto controllo Il Valore delle Verifiche Indipendenti Ing. Matteo Buzzetti Copenhagen Metro Team CMT Design Coordinator 31-01-2013

Thank you for your attention

Special Thanks to Sergio Notarianni – CMT Technical DirectorAll CMT Technical Office