Aged Hard Rock TBM Proves Its Value for Second Avenue Subway Project in New York City

"This paper presents an overview and performance evaluation for a reconditioned decades aged open type hard rock TBM utilized for the twin running tunnel excavations of the Second Avenue Subway Project in Manhattan, New York. The TBM tunnel lengths are approximately 2,370 m (7,800 ft, east TBM Tunnel) and 2,190 m (7,200 ft, west TBM Tunnel) with a 6.7 m (22 ft) bored diameter. This “senior” TBM mined through metamorphic rocks consisting of schist, granofels, and pegmatite, and encountered various adverse geological structures, including some relatively heavy groundwater inflows. The ground support was generally pattern friction rock bolts, and steel sets were used in poor ground. This paper presents TBM characteristics and the subsequent performance, such as machine utilization, downtime, cutter consumption rate, net penetration rate, and daily advance rate. Machine operating parameters including thrust, torque, gripping force, and cutterhead RPM, are compared with various accompanying ground conditions. The performance changes between the adjacent tunnel sections are also presented. INTRODUCTION Project Overview The Metropolitan Transportation Authority Capital Construction (MTACC)’s Second Avenue Subway (SAS) Program consists of four (4) phases from 125th Street to Manhattan Battery Park along the 2nd Avenue (see Figure 1) in Manhattan New York. As a part of Phase 1, Contract 1 was awarded to S3 JV (Skanska/Schiavone/Shea) to build a TBM launch box and subsequent twin TBM tunnels from 92nd Street to 63rd Street under 2nd Avenue. Contract 1 was one of the key contracts in Phase 1 to pre-excavate through the footprint of the follow-on underground stations (72nd St. Station, 86th St. Station, and 96th St. Station) by hard rock TBM excavation. The project team included Client MTACC, S3 Tunnel Constructors, Designer, Aecom-Arup JV, and Consultant Construction Manager, Parsons Brinckerhoff. The major elements of Contract 1 included construction of TBM Launch Box supported by secant pile and slurry walls and mining of twin TBM tunnels with a combined tunnel length of approximately 4,560 m (15,000 ft). The dimension of the TBM launch box was approximately 247 m (810 ft) long from 92nd Street to 95th Street, 21 m (70 ft) to 24 m (80ft) wide along the 2nd Avenue, and 18 m (60 ft) to 21 m (70 ft) deep from the ground surface. The launch box was later used for the follow-on 96th Street Station."