Soft Ground Tunnelling in Melbourne - Investigation and Design of the Melbourne Main Reliever

Melbourne Water (MW) is responsible for a section of existing gravity trunk sewer servicing the Melbourne central business district, Docklands, Port Melbourne and other adjacent areas, known as the Melbourne Main Sewer (MMS). MW has determined that the 2.2 km long 110 year old sewer will not adequately service these areas into the future or provide the level of reliability needed. The Melbourne Main Sewer Replacement project (MMSR) involves the replacement of the MMS with a new gravity sewer main and six key manhole shafts, known as the Melbourne Main Reliever (MMR).The majority of the MMR sewer tunnel is situated south of the Yarra River and will be constructed using an earth pressure balance (EPB) tunnel boring machine (TBM) and will be lined with precast concrete segments. The tunnel will be 2.4 m internal diameter and will have a 1.8 m diameter glass fibre reinforced plastic (GRP) sewer pipe positioned within it. This project represents the first large-scale, modern, mechanised tunnel project in MelbourneÆs Yarra Delta Quaternary sediments. There is little precedence known to the authors of similar scale tunnelling projects in these particular geological units. During the recent detailed investigation and design stages of the project, significant effort has been spent on characterising the geotechnical conditions along the alignment and predicting the effects of the new tunnel on the existing environment. Some of the key design issues that have been identified and managed through the design process include short-term surface settlement due to tunnel excavation and the predicted effects on surface infrastructure, potential spalling of the steel fibre reinforced concrete segments under full TBM ram loads and tunnel lining design in geological units with highly variable stiffness.Construction of the new MMR sewer tunnel is expected to commence in mid-2008 with a capital cost of approximately $160 million. Sewer system commissioning is scheduled for completion by early 2012.