NCHRP Project 20-68A Scan 09-05 Best Practices For Roadway .

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NCHRP Project 20-68AScan 09-05Best Practices For Roadway TunnelDesign, Construction, Maintenance,Inspection, And OperationsSupported by theNational Cooperative Highway Research ProgramApril 2011The information contained in this report was prepared as part of NCHRP Project 20 68A U.S. Domestic Scan,National Cooperative Highway Research Program.SPECIAL NOTE: This report IS NOT an official publication of the National Cooperative Highway ResearchProgram, Transportation Research Board, National Research Council, or The National Academies.

AcknowledgmentsThe work described in this document was conducted as part of NCHRP Project 20-68A, the U.S.Domestic Scan program. This program was requested by the American Association of StateHighway and Transportation Officials (AASHTO), with funding provided through the NationalCooperative Highway Research Program (NCHRP). The NCHRP is supported by annual voluntarycontributions from the state departments of transportation. Additional support for selected scansis provided by the U.S. Federal Highway Administration and other agencies.The purpose of each scan and of Project 20-68A as a whole is to accelerate beneficial innovationby facilitating information sharing and technology exchange among the states and othertransportation agencies, and identifying actionable items of common interest. Experience hasshown that personal contact with new ideas and their application is a particularly valuable meansfor such sharing and exchange. A scan entails peer-to-peer discussions between practitionerswho have implemented new practices and others who are able to disseminate knowledge of thesenew practices and their possible benefits to a broad audience of other users. Each scan addressesa single technical topic selected by AASHTO and the NCHRP 20-68A Project Panel. Furtherinformation on the NCHRP 20-68A U.S. Domestic Scan program is available y.asp?ProjectID 1570.This report was prepared by the scan team for Scan 09 05, Best Practices for Roadway TunnelDesign, Construction, Maintenance, Inspection, and Operations, whose members are listed below.Scan planning and logistics are managed by Arora and Associates, P.C.; Harry Capers is thePrincipal Investigator. NCHRP Project 20 68A is guided by a technical project panel and managedby Andrew C. Lemer, Ph.D., NCHRP Senior Program Officer.Kevin Thompson, P.E., Caltrans, AASHTO Co-ChairJesus Rohena, P.E., FHWA, FHWA Co-ChairAlexander K. Bardow, P.E., Massachusetts DOTBarry B. Brecto, P.E., FHWA Washington State DivisionBijan Khaleghi, Ph.D., P.E., S.E., Washington State DOTLouis Ruzzi, P.E., Pennsylvania DOTMichael G. Salamon, Colorado DOTFulvio Tonon, Ph.D., P.E., Liaison, TRB Tunnels and Underground Structures CommitteeMary Lou Ralls, P.E., Report FacilitatorB E ST P R AC T I C E S F O R R OA DWAY T U N N E L D E S I G N , CO N ST R U C T I O N , M A I N T E N A N C E , I N S P E C T I O N , A N D O P E R AT I O N S

DisclaimerThe information in this document was taken directly from the submission of the authors.The opinions and conclusions expressed or implied are those of the scan team and are notnecessarily those of the Transportation Research Board, the National Research Council, or theprogram sponsors. This document has not been edited by the Transportation Research Board.

Scan 09-05Best Practices For Roadway TunnelDesign, Construction, Maintenance,Inspection, And OperationsREQUESTED BY THEAmerican Association of State Highway and Transportation OfficialsP R E PA R E D B YKevin Thompson, P.E.,Caltrans, AASHTO Co ChairLouis Ruzzi, P.E.,Pennsylvania DOTJesus Rohena, P.E.,FHWA, FHWA Co ChairMichael G. Salamon,Colorado DOTAlexander K. Bardow, P.E.,Massachusetts DOTFulvio Tonon, Ph.D., P.E.,Liaison, TRB Tunnels and UndergroundStructures CommitteeBarry B. Brecto, P.E.,FHWA Washington State DivisionMary Lou Ralls, P.E.,Report FacilitatorBijan Khaleghi, Ph.D., P.E., S.E.,Washington State DOTS C A N M A N AG E M E N TArora and Associates, P.C.Lawrenceville, NJApril 2011The information contained in this report was prepared as part of NCHRP Project 20 68A U.S. Domestic Scan,National Cooperative Highway Research Program.SPECIAL NOTE: This report IS NOT an official publication of the National Cooperative Highway ResearchProgram,Transportation Research Board, National Research Council, or The National Academies.B E ST P R AC T I C E S F O R R OA DWAY T U N N E L D E S I G N , CO N ST R U C T I O N , M A I N T E N A N C E , I N S P E C T I O N , A N DO P E R AT I O N S6

Table of ContentsAbbreviations and Acronyms. VIIExecutive Summary. ES-1Introduction. .ES-1Scan Purpose and Scope . ES-1Summary of Findings and Recommendations . ES-21) Develop standards, guidance, and best practices for roadway tunnels. ES-22) Develop an emergency response system plan unique to each facility whichtakes into account human behavior, facility ventilation, and fire mitigation. ES-33) Develop and share inspection practices among tunnel owners. ES-44) Consider inspection and maintenance operations during the design stage.ES-55) Develop site-specific plans for the safe and efficient operation of roadway tunnels.ES-56) A tunnel includes a long-term commitment to provide funding for preventivemaintenance, upgrading of systems, and training and retention of operators.ES-67) Share existing technical knowledge within the industry to design a tunnel. ES-78) Provide education and training in tunnel design and construction.ES-7Planned Implementation Actions. ES-71.0 Introduction. 1-1Background.1-2Methodology.1-2Scan Itinerary.1-2Host Agencies. 1-2Alaska Department of Transportation and Public Facilities (AKDOT&PF). 1-3California Department of Transportation (Caltrans). 1-3Colorado Department of Transportation (CDOT). 1-4District of Columbia Department of Transportation (DDOT). 1-5Massachusetts Department of Transportation (MassDOT). 1-6Pennsylvania Department of Transportation (PennDOT). 1-6Port Authority of New York and New Jersey (PANY&NJ). 1-7Virginia’s Chesapeake Bay Bridge and Tunnel District (CBBT District). 1-7Virginia Department of Transportation (VDOT). 1-8Washington State Department of Transportation (WSDOT). 1-9City of Seattle (Seattle DOT and Seattle Fire Department).1-10Sound Transit. 1-10Scan Team . 1-11B E ST P R AC T I C E S F O R R OA DWAY T U N N E L D E S I G N , CO N ST R U C T I O N , M A I N T E N A N C E , I N S P E C T I O N , A N D O P E R AT I O N SI

TA B L E O F C O N T E N T S2.0 Findings and Observations. 2-12.1 US Tunnel Inventory. 2-12.1.1 Number of Tunnels in Inventory. 2-22.1.2 Ages of Tunnels . . 2-22.1.3 Tunnel Definition . . 2-32.1.3.1 Current Definitions Used by Owners. . 2-32.1.3.2 Proposed Changes to AASHTO Tunnel Definition. . 2-42.1.4 Differentiation between Wide Bridges over Highways and Short Tunnels. 2-62.1.5 Inventory Numbering System. 2-62.1.6 Inventory of Geometric Characteristics Relative to NBIS. 2-72.1.7 Referencing System. 2-82.1.8 Inventory of Changes in Tunnel Cross Section. . 2-82.1.9 Inventory of Tunnel Approaches . 2-92.2 Standards, Guidance, and Best Practices for Existing and New Roadway Tunnels.2-92.2.1 Design. 2-92.2.1.1 Documents. 2-92.2.1.2 Rationale for Choosing Parameters for Tunnel Projects.2-122.2.1.3 Clearance Envelope Requirements for Design. 2-142.2.1.4 Seismic Design Criteria.2-152.2.1.5 Correlation of Seismic Strains to Liner Collapse Mechanism and toAcceptable Damage and Leakage Rates. .2-172.2.1.6 Seismic and Other Criteria for Portals and Approach Structures. 2-182.2.1.7 Tunnel Life Expectancy. 2-192.2.1.8 Poor Soils.2-202.2.1.9 Maintenance Considerations in Design. 2-212.2.2 Construction.2-232.2.2.1 Recent “Best Practice” Construction Methods. 2-232.2.2.2 Tunnel Boring Machine Manufacturer Support and Maintenance.2-242.2.3 Maintenance, Repair, and Rehabilitation . 2-252.2.3.1 Maintenance Issues Related to Age. 2-252.2.3.2 Maintenance Effectiveness in Decreasing Age-Related Issues.2-282.2.3.3 Definition of “Good Repair” and Process for Deferral of Maintenance. 2-292.2.3.4 Most Significant Tunnel Maintenance Problem. 2-312.2.3.5 Concrete-Lined Tunnel Repair and Rehabilitation. 2-322.2.3.6 Ventilation Systems. 2-332.2.3.7 Maintenance of Devices in Tunnel Environment with Tunnel Washing. 2-342.2.3.8 Frequency of Tunnel Washing.2-35II

2.2.3.9 Maintenance Workforce. 2-372.2.3.10 Mechanism to Maintain, Debug, and Troubleshoot Operation. 2-382.2.3.11 Timing of Maintenance Activities. 2-482.2.3.12 Capacity of Maintenance Yard Facilities.2-402.2.3.13 Current “Best Practices”. 2-402.2.4 Inspection.2-422.2.4.1 Inspection Frequency of Systems and System Components. 2-422.2.4.2 Inspection Documentation and Tracking.2-432.2.4.3 Inspection Program Manuals. 2-442.2.4.4 Tunnel Segments for Inspection and Reporting. 2-452.2.4.5 Procedures to Inspect Rock Tunnels with No Lining. 2-462.2.4.6 Timing of Inspections. 2-462.2.5 Operations. 2-472.2.5.1 Integration of Operation Controls for Traffic and Support Facilities. 2-472.2.5.2 Measures to Reduce Operating Costs.2-492.2.5.3 Trials of Emergency Response Systems.2-502.2.5.4 Procedures to Keep Records on Fire Incidents. 2-532.2.5.5 Mechanisms Deployed for Fire Safety and Minimized Damage.2-532.2.5.6 Procedure for Communicating with Local Emergency Services. 2-562.2.5.7 Systems and Protocols for Emergency Information to Public. 2-572.2.6 General. 2-592.2.6.1 Recommended Changes to 2009 FHWA Technical Manual forDesign and Construction of Road Tunnels – Civil Elements.2-592.2.6.2 Use of a Tunnel Management System to Track Condition,Inspection, Repair, and Needed Funds. 2-592.2.6.3 Recommended Additional Standards, Guidance, and Best Practices.2-612.3 Specialized Technologies Currently Used for Existing and New Roadway Tunnels.2-622.3.1 Design. 2-622.3.1.1 Lighting Luminance.2-622.3.1.2 Air Quality and Opacity Air Quality Requirements.2-642.3.1.3 Waterproofing Systems. 2-662.3.2 Construction.2-672.3.2.1 Tunnel Construction Technologies. 2-672.3.2.2 Accelerated Construction. 2-682.3.2.3 Prefabricated Elements. 2-692.3.3 Maintenance, Repair, and Rehabilitation.2-702.3.3.1 Improved Maintenance and Reconstruction Efficiency.2-702.3.3.2 Water Leakage. 2-72B E ST P R AC T I C E S F O R R OA DWAY T U N N E L D E S I G N , CO N ST R U C T I O N , M A I N T E N A N C E , I N S P E C T I O N , A N D O P E R AT I O N SIII

TA B L E O F C O N T E N T S2.3.3.3 Steel Fiber-Reinforced Concrete Liners for Rehabilitation. 2-732.3.3.4 Roadway Slab over Plenum Rehabilitation. 2-742.3.4 Inspection.2-752.3.4.1 Improved Inspection Efficiency. 2-752.3.4.2 Electronic Methods to Document Conditions during Inspection. 2-772.3.4.3 Access Equipment for Inspections.2-782.3.5 Operations. 2-792.3.5.1 Incident and Speed Detection, Smoke Detection, Back-up Power,and Automated Incident Response Systems.2-792.3.5.2 Detection and Prevention of Hazardous Cargo Entering Tunnels.2-822.3.5.3 Utility Cost Efficiencies. 2-832.3.6 General. .2-842.3.6.1 Other Advanced Technologies under Consideration.2-842.3.6.2 Additional Recommended Specialized Technologies. 2-873.0 Recommendations and Implementation Plan.3-1Introduction. 3-1Strategies and Actions. 3-11) Develop standards, guidance, and best practices for roadway tunnels.3-22) Develop an emergency response system plan that is unique to each facilityand takes into account human behavior, facility ventilation, and fire mitigation. 3-33) Develop and share inspection practices among tunnel owners. 3-44) Consider inspection and maintenance operations during the design stage. 3-55) Develop site specific plans for the safe and efficient operation ofroadway tunnels. 3-66) A tunnel includes a long term commitment to provide funding forpreventive maintenance, system upgrades/replacements, operatortraining and retention. 3-77) Share existing technical knowledge within the industry to design a tunnel. 3-88) Provide education and training in tunnel design and construction. 3-8Implementation Plan Research. 3-9Process for Following Up on Status of Implementation Actions.3-10IV

List of AppendicesAPPENDIX A – Amplifying Questions.A-1APPENDIX B – Recent and Ongoing Research.B-1APPENDIX C - Scan Itinerary. C-1APPENDIX D – Host Agency Contacts. D-1.APPENDIX E – Tunnel Inventories .E-1APPENDIX F – Scan Team Contact Information. F-1APPENDIX G – Scan Team Biographical Information. G-1B E ST P R AC T I C E S F O R R OA DWAY T U N N E L D E S I G N , CO N ST R U C T I O N , M A I N T E N A N C E , I N S P E C T I O N , A N D O P E R AT I O N SV

List of FiguresFigure 1.1Fourth two-lane Caldecott Tunnel bore on SR 24 under construction. 1-4Figure 1.2Devil’s Slide Tunnel under construction on Route 1 near San Francisco. 1-4Figure 1.3Eisenhower/Johnson Memorial Tunnel on I-70 in Colorado. 1-5Figure 1.4Chesapeake Bay Bridge Tunnel. 1-7Figure 1.5Mount Baker Ridge Tunnel on I-90 in Seattle. 1-9Figure 1.6aOne bore of the Battery Street Tunnel. 1-10Figure 1.6bBattery Street Tunnel control room. . 1-10Figure 1.7aDowntown Seattle transit station. 1-11Figure 1.7bSound Transit tunnel. 1-11Figure 1.8Scan team members in Central Artery/Tunnel during a MassDOTovernight maintenance closure. 1-11Figure 2.1Examples of equipment used to wash tunnel walls. 2-36Figure 2.2Integrated operations control centers. 2-48Figure 2.3Fire safety equipment in a highway tunnel in 2009. 2-54Figure 2.42010 AASHTO Technical Manual for Design and Constructionof Road Tunnels – Civil Elements. 2-59Figure 2.5Equipment and location of access for tunnel inspection. 2-75B E ST P R AC T I C E S F O R R OA DWAY T U N N E L D E S I G N , CO N ST R U C T I O N , M A I N T E N A N C E , I N S P E C T I O N , A N D O P E R AT I O N SVI

A B B R E V I AT I O N S A N D A C R O N Y M S

AcronymsAASHTOAmerican Association of State Highway and Transportation OfficialsACIAmerican Concrete InstituteADAAmericans with Disabilities ActADECOAnalysis of Controlled Deformations tunneling methodADTAverage Daily TrafficAFF60Tunnels and Underground Structures Committee (TransportationResearch Board)ANSIAmerican National Standards InstituteASCEAmerican Society of Civil EngineersASMEAmerican Society of Mechanical EngineersASTMAmerican Society for Testing and MaterialsBMSBridge Management SystemAWVAlaska Way Viaduct (WSDOT)CA/TCentral Artery/TunnelCBBTChesapeake Bay Bridge Tunnel (Virginia)CCTVClosed Circuit TelevisionCEEConstruction Earthquake EvaluationCEMContinuous Emissions Monitoring ProgramCFMCubic Feet per MinuteCFRCode of Federal RegulationsCOCarbon MonoxideDEPDepartment of Environmental ProtectionDOTDepartment of TransportationEJMTEisenhower/Johnson Memorial Tunnel (Colorado)EPAEnvironmental Protection Agency (U.S.)FEEFunctional Earthquake EvaluationFHWAFederal Highway AdministrationB E ST P R AC T I C E S F O R R OA DWAY T U N N E L D E S I G N , CO N ST R U C T I O N , M A I N T E N A N C E , I N S P E C T I O N , A N D O P E R AT I O N SVIII

A B B R E V I AT I O N S A N D A C R O N Y M SFTAFederal Transit AdministrationGPRGround Penetrating RadarHARHighway Advisory RadioHLTHanging Lake Tunnel (Colorado)HOCHighway Operations CenterHPSHigh Pressure SodiumHRBTHampton Roads Bridge Tunnel (Virginia)IESNAIlluminating Engineering Society of North AmericaIPCSIntegrated Project Control SystemIRTInfrared ThermographyITSIntelligent Transportation SystemsLEDLight Emitting DiodeLPSLow Pressure SodiumLRFDLoad and Resistance Factor Design (AASHTO)M&EMechanical and ElectricalMassDOTMassachusetts Department of TransportationMDEMaximum Design Earthquake (Port Authority of NY&NJ)MMISMaintenance Management Information SystemMMMBTMonitor Merrimac Memorial Bridge Tunnel (Virginia)NATMNew Austrian Tunneling Method (aka Sequential Excavation Method)NBINational Bridge InventoryNBISNational Bridge Inspection StandardsNCHRPNational Cooperative Highway Research ProgramNECNational Electrical CodeNEMANational Electrical Manufacturers AssociationNFPANational Fire Protection AssociationNFPA 502Standard for Road Tunnels, Bridges, and Other LimitedAccess HighwaysIX

NOxNitrogen OxidesOMCOperations, Maintenance, and Control Building (Caltrans)OSHAU.S. Occupational Safety and Health AdministrationPANY&NJPort Authority of New York and New JerseyPennDOTPennsylvania DOTPLCProgrammable logic controllerPMParticulate MatterPM 10Particulate Matter Standard That Includes Particles with a Diameterof 10 Micrometers or LessPTCPennsylvania Turnpike CommissionRCTReverse Curve Tunnel (Colorado DOT)SCADASupervisory Control and Data AcquisitionSCOBSHighway Subcommittee on Bridges and Structures (AASHTO)SEESafety earthquake evaluationSEMSequential Excavation Method (aka New Austrian Tunneling Method)SM&IStructure Maintenance & Investigations (Caltrans)T 20AASHTO SCOBS Technical Committee for TunnelsTBMTunnel boring machineTMCTraffic Management CenterTMSTunnel Management SystemTRBTransportation Research BoardUPSUninterruptible power supplyVDOTVirginia Department of TransportationVHFVery High Frequency (30 to 300 Megahertz)VMSVariable Message SignWSDOTWashington State DOTB E ST P R AC T I C E S F O R R OA DWAY T U N N E L D E S I G N , CO N ST R U C T I O N , M A I N T E N A N C E , I N S P E C T I O N , A N D O P E R AT I O N SX

EXECUTIVE SUMMARY

Executive SummaryIntroductionMost highway facility components in the United States are governed by design, construction, maintenance, inspection, and operations codes and regulations of theAmerican Association of State Highway and Transportation Officials (AASHTO)and the U.S. Federal Highway Administration (FHWA). However, to date, highwaytunnels in the U.S. do not have comparable national codes and regulations. Recent events, such asthe July 2006 ceiling collapse of the I-90 Central Artery/Tunnel (CA/T) in Boston, Massachusetts,have called attention to the need for such national standards.After investigating the CA/T ceiling collapse, the National Transportation Safety Board (NTSB)recommended that the FHWA seek legislation to establish a mandatory tunnel inspection programthat would identify critical inspection elements and specify an appropriate inspection frequency.The FHWA requested clearance from the Office of the Secretary of Transportation to proceed withregulatory action to develop National Tunnel Inspection Standards similar to the National BridgeInspection Standards (NBIS) contained in the Code of Federal Regulations, 23 CFR 650, Subpart C.An Advance Notice of Proposed Rulemaking was published in the Federal Register in November2008. In July 2010, a Notice of Proposed Rulemaking that addressed comments received onthe ANPRM was published in the Federal Register. As of the writing of this report, FHWA ispreparing a Final Rule to address comments received on the NPRM.Scan Purpose and ScopeDomestic Scan 09 05, Best Practices for Roadway Tunnel Design, Construction, Maintenance,Inspection, and Operations, conducted during August and September 2009, is one of theactivities initiated to assist in addressing the need for national tunnel standards and a nationaltunnel inventory. The nine member team consisted of two representatives from FHWA, fiverepresentatives from state Departments of Transportation (DOTs), an academic memberrepresenting the Transportation Research Board (TRB) Tunnels and Underground StructuresCommittee (AFF60), and the report facilitator.The team selected scan hosts that have significant tunnels in their inventories and use innovativeapproaches; agencies with ongoing or upcoming tunnel construction projects were also of interest.Hosts along the East Coast were the Chesapeake Bay Bridge and Tunnel (CBBT) District, theMassachusetts Turnpike Authority1, the Port Authority of New York and New Jersey, and theVirginia DOT. Hosts in the western U.S. were the California DOT (Caltrans), the Colorado DOT,1The Massachusetts Turnpike Authority became part of the Massachusetts DOT (MassDOT) effective November 1, 2009.B E ST P R AC T I C E S I N A D D R E SS I N G N P D E S A N D OT H E R WAT E R Q UA L I T Y I SS U E S I N H I G H WAY SYST E M M A N AG E M E N TES-1

EXECUTIVE SUMMARYthe Washington State DOT, the City of Seattle (DOT and Fire Department), and the Seattle SoundTransit System. In addition to site visits with scan hosts, the team held Web conferences withrepresentatives from the Alaska DOT, the District of Columbia DOT, and the Pennsylvania DOT.The scan team investigated tunnels that are part of the state, regional, and local highway systems.While the scan’s scope was roadway

Nov 01, 2009 · BEST PRACTICES FOR ROADWAY TUNNEL DESIGN, CONSTRUCTION, MAINTENANCE, INSPECTION, AND OPERATIONS. Acknowledgments. The work described in this document was conducted as part of NCHRP Project 20-68A, the U.S.

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