1. Civil Design for Tunnel Case Studies
October 12~13, 2011
GDE-CFS Meeting at KEK

2. Common Design
Two tunnels (Beam tunnel and Service tunnel) are allocated for BDS part
On TBM case (Case 1 ~ 5) are the same layout (φ 4.5m for both tunnel)
On NATM case (Case 6 ~ 8) are the same layout (W=4.5m H=4.0m for both tunnel)
RTML loop part is constructed by NATM
Sub tunnel (Case 3, 4, 5 and 6) is allocated Damping ring side BT ST AH AT BT AH AT BT
SbT AT PM BT
SbT AH AT PM KL
Case 1
Case 2
Case 3
Case 4 BT
SbT AH AT LC BT
SbT AH AT LC BT AH AT BT AH AT
Case 5
Case 6
Case 7
Case 8

3. Case 1 D-T-R (Double/TBM/RDR)
Main Transformer
Above Ground
Sub Transformer
A/H
Based on the RDR tunnel design
Inner diameter is 4.5m both
Using TBM to excavate these tunnels
Six access halls with access tunnel (1km long sloped tunnel) from ground surface AC DC PM TR KL
Service-T
Accelerator
Cryo-Module
Beam-T
Beam tunnel
Service tunnel

4. Case 2 S-T-R (Single/TBM/RDR)
Main Transformer
Above Ground
Sub Transformer
A/H
Single large diameter tunnel includes all equipment
Inner diameter is 7.4m
Using TBM to excavate these tunnels
The tunnel is separated with 0.4m thick concrete floor
Six access halls with access tunnel (1km long sloped tunnel) from ground surface AC DC PM TR KL
Beam-T
Accelerator
Cryo-Module
Beam tunnel

5. Case 3 JS-T-X (J Single/TBM/XFEL)
Main Transformer
Above Ground
XFEL layout (TR and KL is located in Beam tunnel, other equipments are in A/H)
Tunnel configuration is composed of Beam tunnel & sub tunnel
Inner diameter is 5.2m and 3.2m for Beam tunnel and sub tunnel respectively
Using TBM to excavate these tunnels
Six access halls with access tunnel (1km long sloped tunnel) from ground surface
Pulse modulators are installed in A/H
Sub Transformer AC DC PM
A/H TR KL
Beam-T
Accelerator
Cryo-Module
Beam tunnel
Sub tunnel

6. Case 4 JS-T-K (J Single/TBM/KCS)
Main Transformer
Above Ground
Sub Transformer
KCS layout
Tunnel configuration is composed of Beam tunnel & sub tunnel
Inner diameter is 4.5m and 3.2m for Beam tunnel and sub tunnel respectively
Using TBM to excavate these tunnels
Twelve access halls with access tunnel (1km long sloped tunnel) from ground surface
All equipments are installed in A/H
A/H AC DC PM TR KL
Accelerator
Cryo-Module
Beam-T
Beam tunnel
Sub tunnel

7. Case 5 JS-T-D (J Single/TBM/DRFS)
Main Transformer
Above Ground
Sub Transformer
A/H
DRFS layout
Tunnel configuration is composed of Beam tunnel & sub tunnel
Inner diameter is 5.7m and 3.5m for Beam tunnel and sub tunnel respectively
Using TBM to excavate these tunnels
Six access halls with access tunnel (1km long sloped tunnel) from ground surface
Local caverns at 617m intervals (4 cryo strings length) for installation of cooling equipment AC
L/C DC PM TR KL
Accelerator
Cryo-Module
Beam-T
Beam tunnel
Sub tunnel

8. Case 6 JS-N-D (J Single/NATM/DRFS)
Main Transformer
Above Ground
Sub Transformer
DRFS layout
Tunnel configuration is composed of Beam tunnel & sub tunnel
Inner section is 5.7m and 3.3m for Beam tunnel and sub tunnel respectively
Using NATM to excavate these tunnels
Six access halls with access tunnel (1km long sloped tunnel) from ground surface
Local caverns at 617m intervals (4 cryo strings length) for installation of cooling equipment
A/H AC
L/C DC PM TR KL
Accelerator
Cryo-Module
Beam-T
Beam tunnel
Sub tunnel

9. Case 7 S-N-D (Single/NATM/DRFS)
Main Transformer
Above Ground
Sub Transformer
A/H
DRFS layout
Appropriate section can be excavated to install various equipments
The tunnel is separated by partition concrete wall (t=0.4m)
The wall thickness is selected to be sufficient to protect installed equipments from radiation
Inner section of Beam Tunnel is W=9m H=4.5m
Using NATM to excavate these tunnels
Six access halls with access tunnel (1km long sloped tunnel) from ground surface
Local cavern can be omitted because of enough space for equipments installation AC DC PM TR KL
Accelerator
Cryo-Module
Beam-T
Beam tunnel

10. Case 8 wS-N-D (Wide Single/NATM/DRFS)
Main Transformer
Above Ground
Sub Transformer
A/H
DRFS layout
Appropriate section can be excavated to install various equipments
The tunnel is separated by partition concrete wall (t=3.5m)
The wall thickness is selected to be sufficient to protect personnel in tunnel from radiation
Inner section of Beam Tunnel is W=11m H=5.5m
Using NATM to excavate these tunnels
Six access halls with access tunnel (1km long sloped tunnel) from ground surface
Local cavern can be omitted because of enough space for equipments installation AC DC PM TR KL
Accelerator
Cryo-Module
Beam-T
Beam tunnel

11. Damping ring

12. Cavern shape Experimental Hall According to KEK’s information
Longitudinal section
Plan
Section

13. Cavern shape Local Cavern In consideration of equipment layout,
1st floor
2nd floor
Cooling system for dispersed power source
Longitudinal section

14. Cavern shape Access Hall Sub transformer Cooling water system
Ventilation & air conditioning facilities
Cryogenic cooling plant
2nd floor
1st floor
Longitudinal section

16. Cavern shape Access Hall (XFEL & KCS)
Attached access hall that contain the following facilities is considered for XFEL & KCS

17. Construction Schedule & Cost Estimation
October 12~13, 2011
GDE-CFS Meeting at KEK

18. Contents Basic condition Construction plan & procedure Schedule
Cost estimation assumption
Unit cost for estimation
Component of unit cost
Unit cost
Construction cost for each case

19. Basic Condition
In consideration of the situation that ILC site is in Japanese mountainous area, tunnel layout and design are planned
As access route to Experimental Hall and Access Hall, inclined tunnel (drift) is adopted in all cases

20. Summary Cost for Case 7 is the lowest
Case 7 and Case 8 have almost the same construction period
The difference between Case 7 and Case 8 is the thickness of partition wall

21. Construction Plan Beam Tunnel (TBM)
After the end of Access Hall (A/H) construction, Beam Tunnel excavation will be commenced
TBM assembling will be carried out in A/H
One way excavation from A/H
In double tunnel case (Case 1, 3~6), 2 months later from first tunnel excavation commencement, second tunnel will be commenced

22. Construction Plan Beam Tunnel (NATM) Beam Tunnel (others)
Construction Adit will be constructed in addition to the Access Tunnel at A/H
As a result, Beam Tunnel and A/H can be excavated in parallel
Tunnel excavation can be carried out in the opposite direction from A/H (2 faces)
Beam Tunnel (others)
Excavation and concrete lining can be carried out in parallel on Case 2, 7 and 8
However, detail construction method should be considered for Case 7 especially, because the tunnel size is comparatively-small
NATM excavation is adopted on RTML loop part in all cases

23. Construction Plan Access Hall (A/H) Approaching through Access Tunnel
Top and bottom drift will be constructed, one is a top drift for the top of A/H, the other tunnel is for the bottom of A/H
Pier and slab which is needed for installation various equipments will be constructed after Beam Tunnel construction in the meantime

24. Construction Procedure (A/H & Beam Tunnel)
TBM
Beam T
Around 5000m
Access T excavation
Concrete lining
Drainage, Partition Wall
A/H
Concrete １ ２ ３ ４ ５ ６
A/H excavation
Beam T excavation
(One way)

25. Construction Procedure (A/H & Beam Tunnel)
NATM
Beam T
Around 5000m
Access T excavation
A/H excavation
Partition wall etc. １ ２ ３ ４
A/H Concrete
Lining concrete for Beam T

26. Construction Plan Experimental Hall (E/H)
Approaching through Access Tunnel
Access Tunnel will be branched into two tunnels along the way, one is a top drift for the top of E/H, the other tunnel is for the bottom of E/H
Excavation method is bench cut
Shaft (glory hole) will be constructed and utilized for mucking
Plan
Longitudinal profile

27. Construction Plan Local Cavern Damping Ring Tunnel (DR)
Local Cavern will be constructed only for Case 5 & 6 for installation of cooling facilities for dispersed power source
Damping Ring Tunnel (DR)
Approaching through Access Tunnel from portal, which is connected with opposite side of E/H access tunnel
In the case of TBM, when the access tunnel come at DR Service Cavern, DR excavation will be commenced, because DR service cavern is needed for TBM assembling
In the case of NATM, when the access tunnel intersect with DR, DR excavation will be commenced. After that when the access tunnel come at DR service cavern, DR will commenced as counter excavation as well

28. Construction Procedure (Central region)１ ２
Access T excavation for DR
(TBM)
DR T excavation
(TBM)
Access T excavation for E/H
E/H excavation
Service cavern excavation ３ ４
Beam Connecting T & Service T excavation from DR side
Lining concrete for DR Tunnel
Beam T & Service T excavation from Beam T side
Lining concrete for DR Tunnel
E/H concrete
Service cavern concrete
Installation of experimental equipment
To the Next Page

29. Construction Procedure (Central region)５ ６
Lining concrete for Beam connecting T & Service T from Beam T side
Drainage and Partition Wall １ ２
In the case of NATM
Access T excavation for DR
DR T excavation
Access T excavation for E/H
E/H excavation
Service cavern excavation

30. P 11 ~ 15
Construction Plan
Difference between TBM and NATM for A/H & Beam Tunnel excavation
<TBM>
Access Hall should be constructed initially because of TBM assembling
One-way excavation for Beam Tunnel between each A/H
<NATM>
Access Hall and Beam Tunnel can be excavated in parallel
Beam Tunnel is constructed through construction Adit that is branched from Access Tunnel.
Counter excavation can be executed (two faces excavation can be carried out from each Construction Adit)
Around 10 months reduction in relation to the construction time between A/H and Beam Tunnel

31. Access Hall Layout (TBM & NATM)
P 3 & 10
Access Hall Layout (TBM & NATM)
TBM (Case 1)
1. Access T
2. A/H
3. Beam T
NATM (Case 8)
1. Access T
2. A/H & Beam T

32. Construction Schedule (TBM)
P 16
Construction Schedule (TBM)
Necessary construction period for TBM
According to Japanese TBM vendor’s information,
Process
Period
Contents
TBM Assembling
2 months
Starting base construction and TBM assembling
Initial Excavation
Installation of following trolley for TBM with excavation
Excavation
Refer to the following table
(next page)
Routinely operation of TBM
Trouble
1 month/time, 3 times/10km
Unforeseeable accident (unstable bedrock, breakdown of TBM, etc.)
Approaching
0.3 month
Removal of following trolley of TBM with excavation
Dismantlement
2 month
TBM dismantlement

33. Construction Schedule (TBM)
P 16
Construction Schedule (TBM)
Item
Unit
φ3.0
φ3.2
φ3.5
φ4.5
φ5.0
φ5.2
φ5.7
φ7.4
Thickness of lining concrete m
0.2
0.3
Excavation diameter
3.5
3.7
4.0
5.2
5.7
5.9
6.4
8.1
1 stroke length
1.5
Tunneling speed
m/h
3.52
3.33
3.08
3.76
3.51
3.42
3.20
2.60
Shotcrete length
5.50
5.81
6.28
8.17
8.95
9.27
10.05
12.72
Shotcrete thickness
0.05
Excavation time period
min/st 26 27 29 24 28 35
Adjustment of survey and gripper position 13
Sub total 39 40 42 37 41 48
Invert segment installation
(10)
Fiber shotcrete 25 32 38 45
Sub total (Tunneling cycle) 64 66 69 74 79 93
Material replacement, others 46 58
Total (whole cycle) 89 98
106
115
116
125
151
Number of stroke per day
st/day
12.13
11.61
11.02
10.19
9.39
9.31
8.64
7.15
Excavation progress per day
m/day
18.2
17.4
16.5
15.3
14.1 14
10.7
Excavation progress per month
m/month
418
400
379
351
324
322
299
246
*) φ5.5 is calculated by interpolative prediction between φ5.2 & 5.7 (308m/month)

34. Construction Schedule (NATM)
P 16
Construction Schedule (NATM)
Necessary construction period for NATM
According to Japanese Standard for excavation (Ministry of Land, Infrastructure, Transport and Tourism),
Process
Period
Contents
Temporary facilities
1~3 month
Portalling, Temporary material installation for excavation in Hall
Excavation
Refer to the following table
Applied National Land Transportation Ministry standard
Bifurcation
1 month
Portalling for tunnel branch

35. Construction Schedule (NATM)
P 16
Construction Schedule (NATM)
Unit: m/week (upper)
m/month (lower)
Cross-section area: 50~100m2
Rock mass rating
Bench tunneling method Cross-section area (m2) 50 55 60 65 70 75 80 85 90 95 C1
24.07
2l.98
21.98
20.22
18.72
18.06
17.43
16.85
16.31
110.72
101.11
93.01
86.11
83.08
80.18
77.51
75.03
Cross-section area: 20~50m2
Rock mass rating
Rail haulage
Cross-section area (m2)
Rubber-tire vehicles haulage 20 25 30 35 40 45 C1
17.43
16.31
14.87
25.28
22.98
21.98
80.18
75.03
68.40
116.29
105.71
101.11
Specific small cross-section
Inner Section
Muck handling
Ex. speed
(m/month)
Application h w
3.00
3.30
Rail haulage 85
Sub tunnel for Case6
3.65
2.50
Rubber-tire vehicles haulage
108
Connecting Tunnel (Evacuation Tunnel)

36. Construction Speed (NATM)

37. Construction Schedule (various halls)
Construction schedule for large cavern apply common cycle time (count by minutes) of underground power plant
Drilling, Charging, Blasting, Chipping (Scaling), Mucking, Shotcrete, Steel Support, Rock Bolt, Loss/Others

38. Construction Schedule (various halls)
Experimental Hall
22.5 month
Access Hall
Cavern
Progress
Case
RDR
H21m×W21m×L123m
10.2 month
Case 1, 2, 3
XFEL
H12.5m×W19×L113m
15.1 month ( month)
Case 4
KCS
H17m×W26×L113m
17.0 month ( month)
Case 5
DRFS
Case 6, 7, 8
Local Cavern (Case 5, 6)
2.8 month (H10 m X W10m X L 45m)

39. Construction Schedule
P 17
Construction Schedule
Case
HLRF
Progress
(month)
Construction Method
Remark
CASE1
D-T-R
RDR
76.0
TBM
Basic case
CASE2
S-T-R
78.6
Excavation and Concrete in parallel
CASE3
JS-T-X
XFEL
82.1
CASE4
JS-T-K
KCS
82.8
CASE5
JS-T-D
DRFS
78.3
CASE6
JS-N-D
78.8
NATM
CASE7
S-N-D
60.9
Excavation and Concrete in parallel *)
CASE8
wS-N-D
62.7
*) Regarding Case 7, detail construction method should be considered especially, because the tunnel size is comparatively-small

40. Construction Schedule
P 17
P18~25
Construction Schedule
The detail of construction schedule is shown in P18~25 of the case studies report.

41. Cost estimation assumption
TBM tunnel
Cost estimation standard issued by NEXCO (Nippon Expressway Company Limited) applied to TBM cost estimation
Concrete lining support was adopted
As a result of pre-cost-estimation for TBM lining in three types, one is concrete lining, another concrete segment, the other shotcrete lining, concrete lining was adopted because of inexpensive
However, in the case of sub tunnel of Case 3, 4 and 5, shotcrete lining was adopted

42. Cost estimation assumption
NATM tunnel
Japanese Standard (Ministry of Land, Infrastructure, Transport and Tourism) applied to NATM cost estimation
However, this standard doesn’t cover small section tunnel (under 20m2), therefore previous standard in which standard cycle time for excavation is shown applied to the small section tunnel

43. Cost estimation assumption
Experimental Hall
There is not a standard for large cavern cost estimation, that’s why, the cost is referred to the past cost record of similar cavern (underground power plant)
Access Hall & Local Cavern
Japanese Standard (Ministry of Land, Infrastructure, Transport and Tourism) applied to the excavation cost

44. Unit cost for estimation
Labor
Work on a two-shift
10hrs working for one-shift
Transmittal unit cost for labor for public work issued by Ministries
Equipment
Japanese Standard issued by Ministry applied to equipment cost estimation
As for TBM, Japanese vendor’s quotation applied to equipment cost estimation

45. Unit cost for estimation
Material
Economics research firm data applied to material cost estimation
Material cost for TBM is referred to vendor’s quotation

46. P 27 ~ 28
Component of unit cost
Excavation (= Direct Cost + Indirect Cost + Others)
Direct cost
Excavation (labor, material, equipments, repair, maintenance, electricity, consumption articles, etc.)
Mucking (labor, materials, equipments, conveyer, electricity, etc.)
Shotcrete (labor, materials, equipments, electricity, etc.)
Support (material, equipment, electricity, etc.)
Invert segment (labor, materials, equipments, etc.)
Concrete lining (labor, materials, formwork, equipments, etc.)
Wave guide (labor, materials, etc.)
Partition wall (labor, materials, formwork, equipments, etc.)
Grouting (10% of TBM sum, 20% of NATM sum)
Miscellaneous work
Auxiliary cost

47. Component of unit cost Indirect cost Others
65% of TBM works + 100% of NATM & auxiliary cost
TBM transportation, assembling, dismantlement
Temporary works
Common works
Others
10% of total cost (direct + indirect cost) as contingency expense

48. Unit rate for excavation
P 26
Unit cost
Unit cost for cavern excavation
Structure
Shape
Unit rate for excavation
(m)
(yen / no.)
(thousand yen / no.)
Experimental Hall
W=30, h=40, L=120
7,130,934,000
7,130,934
Access Hall
W=20, h=21, L=123
560,560,000
560,560
Case3 Access Hall
W=18.9, h=11.45, L=113.5
330,116,000
330,116
Case4 Access Hall
W=26, h=16.5, L=113.5
479,396,000
479,396
Damping Ring Service Cavern, Local cavern
W=15, h=11.1, L=42.5,
W=10, h=11, L=40
57,953,000
57,953

49. Unit rate for excavation
Unit cost
P 26
Unit cost for tunnel excavation
Structure
Shape
（m）
Tunnel Section
(m2)
Unit rate for excavation
(yen / m)
(thousand yen / m)
Case3, 4 Sub Tunnel
φ3.2
10.179
712,027
712
Case5 Sub Tunnel
φ3.5
11.946
759,055
759
Case1, 4 Beam Tunnel, Case1, BDS Service Tunnel
φ4.5
21.237
915,816
916
Case3 Beam Tunnel
φ5.2
27.340
1,015,661
1,016
Damping Ring, Beam Connecting Tunnel
φ5.5
30.190
1,061,171
1,061
Case5 Beam Tunnel
φ5.7
32.170
1,091,512
1,092
Case2 Beam Tunnel
φ7.4
51.530
1,382,010
1,382
Case6 Beam Tunnel
W=5.7, h=4.65
31.191
501,600
502
Case6 Sub Tunnel
W=3.3, h=3
11.481
290,000
290
Case7 Beam Tunnel
W=9, h=4.5
45.193
582,100
582
Case8 Beam Tunnel
W=11.0, h=5.5
64.738
720,000
720
Connecting Tunnel
W=2.5, h=3.65
9.900
280,000
280
Damping Ring Tunnel, Beam Connecting Tunnel,
Service Tunnel
W=5.5, h=4.7
29.761
451,000
451
RTML Loop Part, Beam Tunnel (BDS part), Service Tunnel (BDS part)
W=4.5, h=4
21.896
470,000
470
E/H Access Tunnel
W=11, h=11
1,201,000
1,201
Access Tunnel
W=8, h=7.5
61.724
552,000
552

50. Construction cost for each case
P 26
Construction cost for each case
Part
Case 1
Case 2
Case 3
Case 4
Case 5
Case 6
Case 7
Case 8 ML
51,980,868
41,307,401
48,027,490
53,027,462
58,002,102
36,088,023
23,076,292
33,461,856
RTML
4,293,726
3,866,726
4,716,358
4,924,918
4,343,042
3,442,142
3,077,152
3,525,794
BDS
12,140,628
12,372,440
6,918,812
6,687,000 DR
4,715,773
2,551,981
E/H
8,689,394
Auxiliary Method
11,494,507
10,387,262
11,033,124
12,310,184
12,710,262
12,538,070
9,816,364
11,983,205
Direct Cost
93,314,896
81,107,184
89,322,767
95,808,359
100,833,013
70,228,422
53,898,183
66,899,230
Indirect Cost
68,647,518
60,802,955
65,673,559
72,535,916
75,583,611
65,840,098
50,462,456
62,705,108
Contingency Expense
16,162,641
14,184,294
15,466,033
16,800,828
17,608,062
13,606,852
10,436,064
12,960,434
Amount
178,125,055
156,094,433
170,462,358
185,145,103
194,024,687
149,675,371
114,796,702
142,564,772
（hundred million yen）
1,781
1,561
1,705
1,851
1,940
1,497
1,148
1,426

51. Total cost for each case
P 26
Total cost for each case

52. Summary of construction schedule and cost
The construction period for Case 3 & 4 are longer than other cases because of large A/H
Case 5 has the highest cost because of large diameter tunnel
Case 7 has the lowest cost because of only one tunnel excavation and the tunnel size is comparatively small
Case 7 & 8 has the almost same construction period
The reason that Case 8 has bigger cost than case 7 is due to concrete partition wall cost