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Modeling Microtunneling Projects using Computer Simulation

Article in Journal of Construction Engineering and Management · June 2010

DOI: 10.1061/(ASCE)CO.1943-7862.0000169

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 Modeling Microtunneling Projects using Computer
Simulation
Mohamed Marzouk1; Moatassem Abdallah2; and Moheeb El-Said3

Abstract: Tunnels projects are constructed to facilitate the execution of underground works with minor disturbance on surface structures
and traffic. This is deemed important especially in downtown cities where disturbances should be minimized to assure flowability on
surface and underground infrastructures. Microtunneling involves the use of a remotely controlled, guided pipe-jacking process in order
to support excavation face. Microtunneling aids in avoiding the need of open trench for pipe laying, which causes extreme disruption to
the surrounding. This paper presents a tool for planning microtunnels projects using computer simulation. The proposed tool aids
contractors in planning microtunneling by estimating their associated time and cost of construction. There are six models that are coded
in the proposed tool in order to capture the construction of microtunnels and shafts. The tool breaks down microtunnels projects into
microtunnels segments and shafts which constitute several construction zones. An application example is presented to demonstrate the
features of the proposed tool.
DOI: 10.1061/共ASCE兲CO.1943-7862.0000169
CE Database subject headings: Planning; Microtunneling; Computer simulation; Costs; Scheduling; Construction management.
Author keywords: Planning; Microtunneling; Computer simulation; Cost and scheduling.

Introduction been made in planning construction operations using computer

simulation. These include earthmoving operation 共Marzouk
Microtunneling are executed in different site conditions which 2002兲, concrete operations 共Hassan and Gruber 2008兲, bridges
increase uncertainties that influence rate of production that might 共Marzouk et al. 2006兲, and tunnels 共Tanaka 1993; AbouRizk et al.
lead to deviation from original work plan. These uncertainties 1999兲.
include unexpected soil types, unusual or complex works, and Studying microtunnel projects have been carried out in litera-
ture by introducing decision aid tools 共Sinfield and Einstein 1996;
equipment breakdown. Traditional planning techniques such as
Ueki et al. 1999; Myers et al. 1999; Nido et al. 1999; Chung et al.
critical-path method, precedence diagram method, or line of bal-
2004; Luo and Najafi 2007兲. Sinfield and Einstein 共1996兲 studied
ance method do not account for such uncertainties. In addition,
the effect of changes in tunneling technology on tunneling cost
they do not plan the construction operation along with the total
and time. The study dealt with tunneling with a closed-face TBM.
available number of resources. Also, microtunneling construction Ueki et al. 共1999兲 presented a decision tool that outputs appropri-
projects are characterized by a high degree of mechanization and ate underground pipeline installation methods for specific site
repetitive operations. These features of microtunneling construc- conditions. The tool aids in three major processes: method selec-
tion propose computer simulation as suitable modeling technique tion, pipe selection, and machine selection. Myers et al. 共1999兲
to mimic tasks found in construction sites. Computer simulation discussed the economic, productivity, and safety issues associated
has proved to be an efficient planning tool for construction with microtunneling. They presented the key factors affecting the
projects, taking into consideration the interaction among available selection of the microtunneling technology for conduit construc-
resources. Also, it allows the use of several probability density tion. Nido et al. 共1999兲 used simulation to study microtunneling
functions in defining tasks duration in order to account for uncer- operations to identify problems at the different stages of the
tainties that may happen during construction. Several efforts have project. They analyzed and evaluated the factors that affect the
productivity in microtunneling operations. Further, they used CY-
1
Associate Professor, Dept. of Structural Engineering, Faculty of En- CLONE simulation methodology to study an actual project; Holes
gineering, Cairo Univ., 12613 Giza, Egypt 共corresponding author兲. Creek Tunnel Project site in Montgomery County, Ohio.
E-mail: mm_marzouk@yahoo.com Chung et al. 共2004兲 presented a computerized decision support
2
Graduate Student, Dept. of Structural Engineering, Faculty of Engi- system 共DSS兲 for microtunneling to support decision making for
neering, Cairo Univ., 12613 Giza, Egypt. E-mail: engmoatassem@ contractors who want to bid on microtunneling projects. To use
yahoo.com the system, the user enters basic information about the potential
3
Professor of Construction Engineering and Management, Dept. of project such as drive length, installation depth, pipe diameter, and
Structural Engineering, Faculty of Engineering, Cairo Univ., 12613 Giza, soil condition, the DSS evaluates the economic feasibility and
Egypt. E-mail: elsaid1204@yahoo.com
advice on the appropriate types of microtunneling methods. Luo
Note. This manuscript was submitted on August 9, 2008; approved on
October 28, 2009; published online on May 14, 2010. Discussion period and Najafi 共2007兲 analyzed the factors that affect the productivity
open until November 1, 2010; separate discussions must be submitted for in microtunneling operations. They presented a computer simula-
individual papers. This paper is part of the Journal of Construction tion model which is used to study microtunneling operations.
Engineering and Management, Vol. 136, No. 6, June 1, 2010. ©ASCE, They conducted an actual microtunneling field study conducted at
ISSN 0733-9364/2010/6-670–682/$25.00. Louisiana Tech University. None of previous efforts takes into

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consideration the different methods that are used in the construc-
tion of microtunneling and shafts. This paper presents a tool that
aids in planning microtunneling projects by modeling microtun-
nels and shafts using computer simulation. The tool is generic
since it models three construction methods of microtunneling and
three construction methods of shafts. First, the paper reviews the
construction methods and techniques that are used in execution of
microtunneling and shafts. Then, it describes the developments
made in the tool, illustrating its main components along with their
designated functions. Finally, an actual case example is presented
to illustrate the practical use of the developed tool.

Fig. 1. Mechanical excavation using MTBM

Microtunneling Construction Methods

Microtunneling is a competing alternative method to the open-cut existence of groundwater; 共ii兲 it provides low advance rates; and
method from different aspects including; economics and environ- 共iii兲 it cannot be used for long tunnel length and extreme size of
mental conditions. As such, there is a need to increase its appli- diameters 共very big and/or very small兲.
cations and accuracy 共Yoshida and Tsujimura 2002兲. Casing sizes
of microtunneling usually range from 0.9 to 2.4 m in diameter,
with the casing being made of steel, reinforced concrete, or fiber- Mechanical Excavation
glass. In recent years, pipe-jacking methods have been developed
for microtunneling 共Brusey 1998兲. Pipe-jacking is a trenchless In order to facilitate microtunneling through firm ground and to
excavation technique for installing pipes where a hydraulic jacks increase advance rates in lose ground, a closed-face mechanical
push the pipe through the ground behind a microtunneling boring excavation tool is applied. In mechanical excavation, the soil is
machine. The microtunnel boring machine 共MTBM兲 excavates excavated by revolving the cutting head in front of the MTBM.
the soil while the pipe is being pushed. Pipe-jacking using me- The excavated soil is transported, in this system, using skip from
chanical excavation methods have several advantages: the tunnel face to the ground level. The system provides the fol-
• Mechanization and high advance rate; lowing advantages over manual excavation: the tunnel profile is
• Keeping exact tunnel profile; cut very accurately. It provides higher level of safety for the per-
• Construction is performed under existing utilities and obstruc- sonnel, and it provides less impact to the surface structures. The
tions; including small rivers, so, there is minimal surface dis- main components of the system are: MTBM, skips, jacking unit,
ruption; and bentonite pump, crane, control chamber, and guiding system. The
• Least impact on the surface structures. construction of microtunneling using closed-face mechanical ex-
On the other hand, the main disadvantages of pipe-jacking cavation is divided into three processes: site setup, tunnel con-
technique are: struction, and dismantling equipment and finishing tunnel. Fig. 1
• Long preparation time for planning, manufacturing, and as- illustrates mechanical excavation using MTBM.
sembling; The first process 共named site setup兲 starts by construction of
• Varying ground conditions causes risk on system performance; supporting wall behind the jacking unit. Then, the jacking unit
and can be installed into shaft. During the construction of supporting
• Difficult in the preparation of the construction-site and associ- wall and installing jacking unit, the MTBM can be erected. After
ated costs, 共only economic with long driving lengths兲. words, the MTBM is lowered into the shaft by using a high ca-
The pipe-jacking technique is classified into three methods, pacity crane. Then, the jacking arms are connected to it. After
depending on type of excavation and removal of excavated soil, lowering the MTBM into shaft, the bentonite pump can be in-
including; manual open face excavation, mechanical closed-face stalled. The second process 共named tunnel construction兲 is started
excavation, and mechanical excavation using slurry system. The by excavating the tunnel entrance ring to get into soil. During
following subsections describe those excavation methods that are excavation, the excavated soil is collected in the skip and the
used in microtunneling. surface between pipe and ground is lubricated by a bentonite
pump. After filling the skip with excavated soil, the excavation is
stopped and the skip is transported to the shaft, then, hoisted to
Open Face Manual Excavation ground using crane to dump its soil. Once the load is dumped, the
skip is lowered to the shaft and transported to tunnel face. At this
Hand excavation is usually accomplished inside a shield attached time, the MTBM can resume its excavation again. Each time the
to the leading section of pipe. The shields are typically articulated pipe is installed in the soil, the excavation is stopped and the
which allows some degree of alignment and grade control. The jacking arms are retrieved back. After that, a new pipe is lowered
purpose of the shield is to provide a safe working environment for into the shaft, in front of the jacking unit. Then, the jacking arms
the workers and to allow the bore to stay open for the pipe to be are extended to pipe. At this time, the excavation can be resumed.
jacked into place. Open face manual excavation is one of the The processes of excavation and lowering pipe are repeated till
oldest methods of microtunneling. This system is economic in the MTBM reaches the receiving shaft. In case of double driving
case of very short driving lengths and accessible shield diameter. shaft 共construction of two tunnels with the same driving shaft to
The accessible diameter is defined as the minimum diameter that save time required for site setup兲, the MTBM is used to construct
allows a labor to enter and excavate the tunnel face 共about 1.3 m兲. the first tunnel, then, it is transported back to the driving shaft to
The disadvantages of this system are: 共i兲 it cannot be used in the construct the second tunnel 共see Fig. 2兲. The final process 共named

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 TBM returns to construct the TBM
First concrete part
second tunnel Site setup above the cutting Slip form
edge

Collar Cutting edge

Receiving shaft

Receiving shaft
Driving shaft

First microtunnel Second microtunnel

Receiving shaft Double driving Receiving shaft

shaft Fig. 4. Wall construction using slip forms

Fig. 2. Construction of two microtunnels with the same driving shaft

pump, separation plant, crane, control room, and guiding system.
The construction of microtunnels by slurry closed-face mechani-
dismantling equipments and finishing tunnel兲 is started by dis- cal excavation is divided into three processes: site setup, tunnel
mantling the MTBM, jacking unit, and bentonite pump. Subse- construction, and dismantling equipment and finishing tunnel.
quently, tunnel cleaning is performed followed by injecting grout The first and third processes are similar to the corresponding pro-
around pipes. Once the grout is injected around pipes, the space cesses in mechanical excavation.
between pipes is filled with cement, and welded by T-lock. The second process 共named tunnel construction兲 is started by
excavating the tunnel entrance ring to get into soil. During exca-
vation, the excavated material is handled to the shaft by using
Slurry Mechanical Excavation either water or bentonite. The transportation medium is pumped
to the tunnel face from the driving shaft by one or several feed
In this method, the ground soil is excavated mechanically while pumps using the tunnel boring machine’s feed line to stabilize and
the slurry supports tunnel face. The muck is transported by the support the tunnel face. The mixture of soil and transportation
slurry discharge system from the suspension chamber right behind medium is exhausted out of the excavation chamber through the
the cutter head to the surface. The main components of the system slurry line and conveyed to the separation plant. To prevent slurry
are: MTBM, jacking unit, bentonite pump, slurry pump, feeding line from getting blocked, any major lumps of rock are crushed
by the cone crusher in the working chamber before passing into
the slurry line. In the separation plant, the charged transportation
Aggregate layer medium is separated from the loose soil using screens, cyclones
and, if necessary, centrifuges as well. Efficient separation means
Water table
that a large proportion of the medium can be treated and sent back
Process 1: Construction preparation to transportation circuit. The separated soil is loaded into trucks to
be hauled to the dumping area. To install a new pipe in the soil,
Inner the following steps are followed: 共1兲 the excavation is stopped;
First concrete part form
Next wall 共2兲 the jacking arms are retrieved back; and 共3兲 the feed pump and
above the cutting
part slurry pump are disconnected at shaft zone. After that, the new
edge
Cutting pipe is lowered into the shaft in front of the jacking unit. Then,
edge the feed pump and slurry pump are connected again with line
Collar extension and the jacking arms are extended to pipe. As such, the
excavation can be resumed. The process of excavation and low-
Process 2: Wall construction ering pipe is repeated till the MTBM reaches the receiving shaft.

Shafts Construction Methods

Most of microtunneling are built through urban areas that require

shafts to reach the working area and to provide outlet for tunnel

Process 3: Caisson sinking

Excavated
Material
Additional
Weight

Concrete Ground
Water Collar
plug
Level
Seal

Cutting
Process 4: Plug construction edge

Fig. 3. Processes of shafts construction using traditional forms Fig. 5. Shafts constructing using precast concrete segments

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 /*('*

!"#$! &!$!'() (*(

#23 923

#2#83 92983

!"#$! ;#<',*=$$!) 4#$%5

!"#$! /.("* 4 !"5 (*(
(*( Fig. 7. Interaction between microtunnel analyzer module and simu-
lation module

6!- 6!-
# + $, ," -.("*- 9 + $, ," -.("*-:3

7, 7,
Shafts Construction using Tradition Forms
>=$ /#?=)(*#,$ ;,1=)!
The essential feature of a caisson is that the circular structure is
constructed above ground and then sunk as a single unit to the
required depth, where it remains part of the permanent work.
0-*#?(*! @',9!<* ='(*#,$A B,-*A ($1
C*#)#D(*#,$ ," >!-,='<!-
Excavation, which is carried out during the caisson sunk, is often
under water work and soft ground conditions. The construction of
shafts using traditional forms is divided into four processes: con-
0EF,'* G=*F=*-
struction preparation, wall construction, caisson sink and plug
construction, and ground injection 共see Fig. 3兲. The first process
共named construction preparation兲 is executed by locating the po-
sition of shaft using survey. Then, excavating soil with the re-
0$1 quired depth 共1–2 m兲 is performed. After excavating soil, the soil
is covered with aggregate layer of 共0.5–1.0 m兲 thickness. The
Fig. 6. Flowchart of microtunnel analyzer module processes second process 共named wall construction兲 is started by setting and
welding segments of the cutting edge. After that, the inner form of
the wall shaft can be erected. During the erection of inner form-
work, the outer form can be erected for the first part above the
cutting edge. Once the forms are assembled, the reinforcement
muck. The dimension of the shaft relates to the type of equipment bars are placed to form the reinforcement of the first part above
being used. The diameter of shaft is in direct relationship to the the cutting edge. At this stage, the concrete of first part can be
diameter of the pipe being driven, plus an allowance for working poured and cured. After curing the concrete of the first part, the
space. Also, it is determined by the length of pipe section to be outer forms can be dismantled then the concrete of the collar can
installed and the space needed for jacking equipment. The choice be poured and cured. The rest of the wall is divided into seg-
of shaft construction for driving and receiving shafts depends on ments, each segments is constructed by fixing the prepared rein-
the required depth, the size of equipment and pipe section, soil forcement bars 共either in shop or site兲 into wall segment. After
condition, and groundwater. The following sections present three fixing steel bars into segment, the outer form of the wall can be
methods for caisson construction of driving and reception shafts. erected. At this stage, the concrete of the segment can be poured
and cured. This process is repeated for each wall segment.
The third process 共named caisson sink and plug construction兲
is started after dismantling the inner and outer form of the shaft.
This process is started by excavating the inner ground soil of the
Table 1. Developed Simulation Models shaft while the caisson is sinking. Excavation is usually done by
File name Description clamshell excavator to facilitate more efficient excavation. During
excavation, a bentonite pump may be used to lubricate the surface
Shaft1 Shaft construction using traditional forms
between shaft’s wall and ground through small pipes, installed
Shaft2 Shaft construction using slip form
into wall during construction. It is necessary to sink caisson at
Shaft3 Shaft construction using precast concrete segments least 6 m below the final manhole base. After sinking the shaft to
Microtunneling1 Microtunneling construction using manual excavation the required level, concrete plug can be poured and cured. Once
Microtunneling2 Microtunneling s construction using mechanical concrete is cured, the water in the shaft can be pumped out to get
excavation a dry caisson. It should be noted that the inlet and outlet of the
Microtunneling3 Microtunneling construction using slurry mechanical tunnel are not concreted during construction by filling the hole
excavation
with brick or wooden forms.

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Table 2. Tasks Involved in Tunnel Construction Process Shafts Construction using Slip Forms
MD1PJ02
Shafts construction using slip form is similar to traditional forms
Excavate, pipe-jacking, and hydraulic soil removal
except for the second process which starts also by setting and
Resources TBM machine, TBM crew, and two dummy queues welding segments of the cutting edge. After welding the cutting
Start condition It draws one resource from each of “Q1” and “Q5” edge segments, the slip form is erected to be used in the construc-
dummy queues. The dummy queue “Q5” contains tion of the wall. Once the slip form is assembled, the reinforce-
number of pipes needed forconstruction of the ment bars 共which are either fabricated in site or outer workshop兲
microtunnel are placed to form the reinforcement of the first part above the
Finish It sends one resource to a dummy queue named “Q2” cutting edge. At this stage, the concrete of the first part can be
poured and cured. After curing the concrete of the first part, the
MD1PJ03 concrete of the collar can be poured and cured. After pouring the
Lowering, and laying pipe into position collar concrete, the slip form starts moving upward with very
Resources Cranes and two dummy queues slow rate. During the movement of the slip form, the steel bars
Start condition It draws one resource from cranes queue, and one are fixed into wall to form the steel mesh of shaft’s wall and
resource from each of two dummy queues named concrete is pored and cured for each finished part. The slip form
“Q2,” and “Npipes.” The dummy queue, named moves continuously until it reaches the required height of the
“Npipes,” contains total number of pipes required for shaft then it stops 共see Fig. 4兲.
construction of the microtunnel
Finish It returns the drawn resource from cranes queue, and
sends one resource to each of “Q1” and “Q3” dummy
queues Shafts Construction using Precast Concrete Seg-
ments
MD1PJ04
Segments are also used to build caissons which can be sunk to
Receiving equipment in the second shaft
construct underground shafts. The bottom ring is installed into
Resources TBM machine, TBM crew, and two dummy queues
cutting shoe to assist sinking action. At the surface, a concrete
Start condition It draws number of pipes needed for construction of ring collar is casted around the caisson to act as a guide during
microtunnel from dummy queue named “Q3”
sinking. Shaft construction using precast concrete segments in-
Finish It sends one resource to dummy queue named “Q4”

Resources

TBM GrutPumps WeldCrews Crane1 Crane2

NTBM NP NWC NC1 NC2

NPipes
N
>0 , 1 Q5 >0 , 1 Crane2
Crane1
NC1 N NC2
>0 , 1
1
>0 , 1

1 Q1 >0 , 1 1 Q2 >0 , 1 1
Start >0 , 1 MD1PJ01 0 MD1PJ02 0 MD1PJ03 1
1
1
Q3
>0 , 1 TBM 0
GrutPumps NTBM
1
NP ==N , N
1 >0 , 1

1 >0 , 1 Q7 1 >0 , 1 Q6 1 >0 , 1 Q4 1

MD1PJ07 MD1PJ06 MD1PJ05 0 MD1PJ04
Q8 1 >0 , 1

GrutPumps Crane1
WeldCrews
NP NC1
NWC
>0 , 1 1 >0 , 1 1
>0 , 1
First Shaft Second Shaft
1 Q9 >0 , 1 1 End
MD1PJ08 MD1PJ09
Pipe Jacking

Fig. 8. Simulation model for slurry mechanical excavation

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Table 3. Tasks Involved in Dissembling Equipment and Finishing Tun- Table 4. Tasks of Slurry Shafts Construction using Traditional Forms
nel Process
Process Task ID Description
MD1PJ05
Construction preparation Shaft201 Survey to locate shaft position
Dissembling equipment Shaft202 Excavate the required depth and
put of aggregate layer
Resources TBM, crane1, and dummy queues
Wall construction Shaft203 Set and weld cutting edge
Start condition It draws one resource from crane1 queue, and another
segments
one resource from dummy queue named “Q4”
Shaft204 Shuttering inner forms of the
Finish It sends one resource to each of the following: crane1
wall and outer part above the
queue, TBM queue, and dummy queue named “Q6”
cutting edge
Shaft205 Steel work for the wall part
MD1PJ06 above the cutting edge
Clean the tunnel Shaft206 Concrete pouring of the wall part
Resources Dummy queue above the cutting edge
Start condition It draws one resource from dummy queue named Shaft207 Concrete curing
“Q6” Shaft208 Concrete pouring for collar
Finish It sends one resource to dummy queue named “Q7” Shaft209 Concrete curing for collar
Shaft210 Steel work for the next wall part
MD1PJ07 Shaft211 Shuttering forms for the next
Grout injection wall part
Resources Grouting pump and dummy queues Shaft212 Concrete pouring of the next
Start condition It draws one resource from grouting pump queue and wall part
other one resource from dummy queue named “Q7” Shaft213 Concrete curing of the next wall
Finish It returns the drawn resource from grouting pump part
queue, and sends one resource to dummy queue Caisson sinks and Shaft214 Excavation and caisson sink
named “Q8” construction of plug Shaft215 Concrete pouring of plug under
water 共if exist兲
MD1PJ08 Shaft216 Concrete curing of plug
Putting material fillers between pipes Shaft217 Dewatering for the surplus 共if
Resources Grouting pump and dummy queues exist兲
Start condition It draws one resource from grouting pump queue and Ground injection Shaft218 Injecting of cement grout around
other one from dummy queue named “Q8” the shaft 共if required兲
Finish It returns the drawn resource from grouting pump
queue, and sends one resource to dummy queue
checked for accuracy of sinking by using a spirit level or plumb
named “Q9”
line. Adjustments can be made by applying pressure to the highest
point. Selective excavation of ground helps to control sinking. A
MD1PJ09 bentonite pump may be used to lubricate the surface between the
Weld T-lock between pipes concrete segments and ground by injecting bentonite between
Resources Welding crew and dummy queues them. Excavation should proceed and caisson segments are added
Start condition It draws one resource from welding crew queue and until the required depth is reached. Once the bottom segments
other one from dummy queue named “Q9” reach the required depth, the concrete plug can be poured and
Finish It returns the drawn resource from welding crew cured. After curing of concrete plug, the water can be pumped out
queue, and sends one resource to dummy queue to get a dry caisson. The final process 共named ground injection兲 is
named “END” executed only in weak soil to increase the bearing capacity of
soil, or to provide a firmer soil in beginning the construction of
volves three processes: construction preparation, wall construc- the tunnel.
tion and caisson sinking, and plug construction and ground
injection 共see Fig. 5兲. The first process 共named construction Proposed Tool
preparation兲 is executed by locating the position of shaft using
survey. Then, soil excavation is performed to the required depth The proposed tool aids contractors in planning microtunneling
共1–2 m兲. After excavating soil, the soil is covered with aggregate projects by estimating the total cost and duration of construction.
layer 共0.5–1.0 m兲 thickness. The second process 共named wall con- It consists of two main components: microtunnel analyzer module
struction兲 is started after placing aggregate layer by setting and and simulation module. The tool is coded in a computer system
welding the cutting edge segments. After that, the first part of wall using MS Visual Basic 6.0 to assure the connectivity among its
segments is installed. Once the segments of the first part are in- components. The following sections describe the main compo-
stalled, the concrete collar can be poured and cured to provide nents of the proposed tool.
permanent support to the excavation of shaft and acts as a guide
for shaft sinking. At this stage, the excavation is started to sink
caisson. Microtunnel Analyzer Module
The caisson sinks under its own weight in very soft soil. In
case of hard soils, it is necessary to use the arms of the hydraulic Microtunnel analyzer module is considered the planning unit of
excavator to exert pressure on the top section. The shaft should be the proposed tool. It is responsible for entering and processing

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 SurCrew Excavators weldcrew FormCrews
SC NEXC1 WC FC
>0 , 1 1 >0 , 1 1 >0 , 1 1 >0 , 1 1

Start >0 , 1 1 Q1 >0 , 1 1 Q2 >0 , 1 1 Q3 >0 , 1 1 Q4

Resources 1 Shaft201 0 Shaft202 0 Shaft203 0 Shaft204 0

>0 , 1 1 >0 , 1 1

Cranes Cranes
ConPumps injeqps
NC NC >0 , 1
NP IE
Q10 1 ConPumps ConPumps RFTCrews
0
Shaft209 1 NP NP RFTC
1 >0 , 1 1 >0 , 1 1 >0 , 1
Dpumps Cranes
DC NC
1 >0 , 1 Q6 1 1 >0 , 1 Q5 1
Shaft208 0 Shaft207 Shaft206 0 Shaft205
1 >0 , 1 1 >0 , 1
penMchins Excavators
NBM NEXC1 ConCrew ConCrew
CC CC
Nwalls
InjCrews weldcrew Q7 N
FormCrews ConCrew CSExcs
IC WC 0 NEXC2
FC CC
>0 , 1 1 >0 , 1 >0 , 1 1 >0 , 1 1
>0 , 1

SurCrew RFTCrews
1 Q8 >0 , 1 1 Q9 >0 , 1 1 1 Q10 >N , N+1
SC RFTC
Shaft210 0 Shaft211 0 Shaft212 Shaft213 0 Shaft214
>0 , 1 1 >0 , 1 1 >0 , 1 1 >0 , 1
1
ConCrew RFTCrews Cranes penMchins
CSExcs ConPumps
CC RFTC NC
NBM
NEXC2 NP
1 1

FormCrews ConCrew
InjCrews Dpumps
FC CC
IC DC 1 >0 , 1
1 >0 , 1 1 >0 , 1

End 1 >0 , 1 Q13 1 >0 , 1 Q12 1 1 >0 , 1 Q11

0 Shaft218 Shaft217 0 Shaft216 Shaft215 0
1 >0 , 1 >0 , 1 1

injeqps ConPumps
IE NP

Fig. 9. Simulation model for shafts construction using traditional forms

data, and it exports the results of the tool. This is performed by sources, labors and equipments rates, materials costs, and
analyzing and breaking down microtunneling projects into zones number of simulation runs. The module allows the use of 10
that consist of a number of shafts and microtunnels’ segment. The probability distributions to estimate tasks’ duration: beta, er-
module provides three techniques for construction of microtun- lang, exponential, gamma, normal, pert, pertpg, scaled beta,
neling using pipe-jacking: manual excavation, mechanical exca- triangular, and uniform;
vation, and slurry mechanical excavation. Also, it provides three 4. Trigger simulation module to estimate the duration and re-
techniques for construction of shafts using: traditional forms, slip sources utilization for each zone. Then, simulation data are
forms and precast concrete segments. Microtunneling projects are sent to tunnel analyzer module in order to calculate project
broken down into zones, taking into consideration the following execution time and cost; and
aspects: 5. Export outputs in a form of cost, duration, and utilization of
1. Used construction method; resources.
2. Assigned resources in each zone are independent of the other Fig. 6 shows a flowchart of the processes that are followed by
zones 共e.g., resources might be assigned differently for each microtunnel analyzer module. It is worth to note that project cost
construction location even for the same construction is estimated based on labors and equipments utilization, materials
method兲; and costs, and indirect costs. While project duration is calculated, de-
3. Construction sequence and logic. pending on the relationship between shafts and microtunnels
The processes that are followed by microtunnel analyzer mod- zones, shafts duration and zones’ duration.
ule to perform a planning session for a microtunnel can be sum-
marized as follow:
1. Define general data for the project such as: number of work-
ing hours per day, number of working days per week, project Simulation Module
start date, number of zones in the project, and indirect cost of
the project; The simulation module is responsible for estimating duration and
2. Define shafts data and their associated construction meth- utilization of resources in each shaft and microtunnel segment in
od共s兲 such as: tasks’ duration, available resources, labors and the project. It utilizes STROBOSCOPE as a general purpose
equipments rates, and materials costs; simulation engine 共Martinez 1996兲. It is implemented using Mi-
3. Define the microtunnel construction method in each zone and crosoft Visual Basic 6.0 to control and facilitate data flow from/to
its associated data such as: tasks’ duration, available re- STROBOSCOPE simulation engine. Six simulation modules have

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 Fig. 10. Tasks screen of slurry mechanical excavation

been coded and developed to represent methods of construction queue, and dummy queue named “start.” At finish, it returns the
for shafts and microtunnel segments 共see Table 1兲. These simula- drawn resource from crane1 queue, and sends one resource to
tion models were built based on the sequence of construction and dummy queue named “Q1.” The details for the second and third
adopting the elements of STROBOSCOPE simulation language. processes are illustrated in Tables 2 and 3.
Fig. 7 illustrates the interaction between microtunnel analyzer Shafts construction using traditional forms is one of the tech-
module and simulation module which is performed as follows: niques that is used in construction of microtunnels’ shafts. It in-
1. Simulation module receives project data from microtunnel volves four processes with 18 tasks. Shafts construction using
analyzer module, then, it depicts the model共s兲 that represents traditional forms is one of the techniques that is used in construc-
the construction method共s兲 for each zone from models that tion of microtunnels’ shafts. It involves four processes with 18
are stored in simulation module’s library. Subsequently, each tasks as listed in Table 4. Fig. 9 depicts the simulation model of
model is fed by its data 共general data, tasks’ duration, avail- shafts construction using traditional forms. Detailed description
able resources, and number of runs兲 to generate simulation of the remaining simulation models can be found elsewhere 共Ab-
model共s兲 that represents the project under consideration; dallah 2008兲.
2. STROBOSCOPE is triggered to run the generated model共s兲
in order to get the total duration and utilization of resources
for each zone; and
3. The output data are transferred to microtunnel analyzer mod- Tool Implementation
ule to perform the calculations of total project duration and
total cost. This section presents the implementation of the proposed tool.
Slurry mechanical excavation is one of the most common tech- The developed program is used to provide an easy graphical user
niques that is used in construction of microtunneling for its high interfaces for contractors to: enter data for STROBOSCOPE
advancement rate, full control on tunnel construction by the con- simulation engine and estimate project duration and cost. The
trol chamber, highest level of safety for the personnel, and least system runs in Microsoft Windows 98, ME, 2000, or XP. Entering
impact to the surface structures. It involves three processes with data for microtunnel projects is performed in five steps: project
nine tasks. Fig. 8 depicts the simulation model for construction of general data, zones’ relationships, project zones information,
pipe-jacking microtunnels using slurry mechanical excavation. zones construction data, and indirect costs. Project general data
The first process, named site setup, involves one task called “In- includes project start date, number of zones, number of working
stall equipment inside the first shaft.” This activity starts by draw- hours and days, and number of tunnel zones. Zones’ relationships
ing one resource from each of the following: crane1 queue, TBM indicate the type of relationships between zones; either finish to

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 Fig. 11. Results screen for microtunnels tool

start or start to start. Tunnel zones information defines the con-

struction technique for microtunnel segments. Whereas, zones
construction data defines tasks durations, available resources and
resources’ rates. Fig. 10 shows tasks’ durations assigned for mi-
crotunnel construction using slurry mechanical excavation. Fig.
11 shows the output of the proposed tool.

N Khairy El-
Gendy St.
Shaft 5
MSeg 4
MSeg 3
El-Amamien Shaft 2
area Shaft 3 Shaft 4
MSeg 2 MSeg 1 El-Fayoum
St.

Shaft 1

Hamdy
Gouda St.

Fig. 13. Execution of traditional forms shafts in El-Salam microtun-

Fig. 12. Layout of Dar El-Salam microtunneling neling

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 Equipment Cost
Shaft 1 Shaft 2 Shaft 3 Shaft 4 Shaft 5
11,903,205
42%

Labors Cost
MSeg 1 MSeg 2 MSeg 3 MSeg 4 6,735,620
24%

Fig. 14. Construction sequence of shafts and microtunnel segments

Application Example Materials Cost

9,433,510
34%
Case Description
a) Direct Cost Categories
This case study considers the construction of Dar El-Salam
共Cairo, Egypt兲 branch for wastewater which was constructed,
adopting microtunneling. It conveys wastewater from El-Fayoum
Microtunnel
Street to El-Amamien area. It goes through Khairy El-Gendy Segments Cost
Street and Hamdy Gouda Street 共see Fig. 12兲. The tunnel has a 22,614,875
81%
total length of 692 m and 2,500 mm diameter. The total contract
value of this microtunneling branch is 45 million L.E. and it was
planned to be executed in three years. The contract scope in-
cluded the construction and finishing works of Dar El-Salam
branch and surveying works for surrounding structures before and
after construction. Dar El-Salam branch consists of five shafts and
four microtunnel segments. The lengths of the four microtunnel
Shafts Cost
segments; MSeg 1, MSeg 2, MSeg 3, and MSeg 4 are 77.5, 402, 5,457,460
70, and 142.5 m, respectively. Shafts number 1 and 4 are jacking 19%
shafts while the remaining shafts 共2, 3, and 5兲 are receiving
shafts. The construction of shafts was executed using slip forms
b) Cost Perc
centage of Microtunnel Segments and Shafts
for Shafts Number 1, 2, and 5 and traditional form method for
Shafts Number 3 and 4. The four microtunnels segments are con- Fig. 15. Cost breakdown of Dar El-Salam microtunnel
structed using slurry mechanical excavation. The execution of
microtunnel segment and shafts of Dar El-Salam microtunneling
is depicted in Figs. 1 and 13, respectively.

Case Modeling Site setup durations are considered the same for MSeg 3 and
MSeg 4. Table 5 lists the duration of tasks that are involved in the
First, the general data of the project is defined including working construction of microtunnel segments. It is worth to note that the
hours per day and working days per week which are 12 h and 6 construction of wall in Shaft 3 and Shaft 4 are divided into four
days, respectively. The sequence of construction for the five
parts. Tables 6 and 7 list tasks’ durations of shafts involved in Dar
shafts and the four microtunnel segments 共MSeg兲 is shown in Fig.
El-Salam branch. Subsequently, the available resources and their
14. Tasks involved in the construction of the four microtunnel
segments are represented according to the sequence of work de- respective rates are user defined to calculate the direct costs of
scribed before, i.e., for MSeg 1, the duration for dismantling Dar El-Salam microtunnel. The indirect costs are entered to the
MTBM is considered zero as it is used for construction of MSeg tool in two forms: time dependent and time independent indirect
2. Also, the duration for installing MTBM components and site cost. Table 8 lists indirect cost items that are considered in the
setup is less than MSeg 1 as machines already installed in Shaft 1. case under consideration.

Table 5. Duration of Microtunnel Segments’ Tasks

Duration
Process Task description MSeg 1 MSeg 2 MSeg 3 MSeg 4
TBM setup Install equipments inside the first shaft N关14, 2兴d N关9 , 1兴d N关14, 2兴d N关9 , 1兴d
Microtunnel construction Excavate, pipe-jacking, and hydraulic soil removal N关8 , 2兴h N关8 , 2兴h N关8 , 2兴hr N关8 , 2兴h
Lowering and laying pipe into position N关60, 15兴m N关60, 15兴m N关60, 15兴m N关60, 15兴m
Receiving equipment in the second shaft U关8 , 12兴h U关8 , 12兴h U关8 , 12兴h U关8 , 12兴h
Dissembling and finishing Dissemble equipments — N关14, 2兴d — N关14, 2兴d
Clean the tunnel N关4 , 1兴d N关20, 5兴d N关4 , 1兴d N关7 , 2兴d
Grout injection N关7 , 1兴d N关35, 5兴d N关7 , 1兴d N关13, 2兴d
Putting material fillers between pipes N关8 , 1兴d N关40, 5兴d N关7 , 1兴d N关15, 2兴d
Welding T-lock between pipes N关7 , 1兴d N关35, 5兴d N关7 , 1兴d N关13, 2兴d
Note: U关N1 , N2兴: U: uniform distribution, N1: lower limit, N2: upper limit; N关N1 , N2兴: N: normal distribution, N1: average duration, N2: SD; d: days, h:
hours, m: minutes.

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Table 6. Tasks Duration for Shafts using Slip Forms
Duration
Process Task description Shaft 1 Shaft 2 Shaft 5
Construction preparation Survey to locate shaft position U关2 , 3兴h U关2 , 3兴h U关2 , 3兴h
Excavate the required depth and putting of aggregate layer N关8 , 2兴d N关7 , 2兴d N关7 , 2兴d
Wall construction Set and weld cutting edge segments N关8 , 1兴d N关7 , 1兴d N关7 , 1兴d
Slip formwork for the wall part above the cutting edge N关8 , 1兴d N关7 , 1兴d N关7 , 1兴d
Steel work for the wall above the cutting edge N关4 , 1兴d N关4 , 1兴d N关4 , 1兴d
Concrete pouring of the wall part above the cutting edge U关10, 12兴h U关9 , 11兴h U关9 , 11兴h
Concrete curing of the wall part above the cutting edge N关7 , 0兴d N关7 , 0兴d N关7 , 0兴d
Concrete pouring for collar U关8 , 12兴h U关7 , 11兴h U关7 , 11兴h
Concrete curing for collar N关7 , 0兴d N关7 , 0兴d N关7 , 0兴d
Jacking the slip form, steel work, concrete pouring, and N关16, 2兴d N关14, 2兴d N关14, 2兴d
concrete curing for the wall
Concrete curing for the last wall part and removal of forms N关4 , 0兴d N关4 , 0兴d N关4 , 0兴d
Caisson sink and plug construction Excavation and caisson sink N关30, 2兴d N关30, 2兴d N关30, 2兴d
Concrete pouring of plug N关12, 2兴h N关12, 2兴h N关12, 2兴h
Concrete curing for plug N关1 , 0兴d N关1 , 0兴d N关1 , 0兴d
Dewatering for the surplus 共if exist兲 N关10, 2兴h N关10, 2兴h N关10, 2兴h
Note: U关N1 , N2兴: U: uniform distribution, N1: lower limit, N2: upper limit; N关N1 , N2兴: N: normal distribution, N1: average duration, N2: SD; d: days, h:
hours, m: minutes.

Case Analysis expected total duration of the project is 709 working days which
Once the case data are feed to the system, it simulates Dar El- is equivalent to 828 calendar days. Table 9 shows 共shortest, mean,
Salam microtunnel segments and shafts. The system retrieves and longest兲 duration, 共minimum, average, and maximum兲 project
simulation module outputs to perform time and cost calculations. cost of the four microtunnel segments and five shafts. Table 10
Simulation module provides minimum, mean, maximum duration shows the shortest, mean, longest duration, minimum, average,
for each microtunnel segment and shaft, in addition to resources’ and maximum project cost categories of Dar El-Salam wastewater
utilization. The system estimated the mean direct and indirect branch. The system generates a text output file that includes a
costs to be 28,072,335 and 7,874,030 L.E., respectively. The detailed description of each microtunnel segment and shaft. Also,
mean total cost was estimated to be 35,946,365 L.E. The mean the file includes the materials, labors, and equipments costs for

Table 7. Tasks Duration for Shafts using Traditional Forms

Duration
Process Task description Shaft 3 Shaft 4
Construction preparation Survey to locate shaft position U关2 , 3兴h U关2 , 3兴h
Excavate the required depth and putting of aggregate layer N关1800, 0兴d N关8 , 2兴d
Wall construction Set and weld cutting edge segments — N关8 , 1兴d
Shuttering inner forms of the wall and outer part above the — N关8 , 1兴d
cutting edge
Steel work for the wall part above the cutting edge — N关4 , 1兴d
Concrete pouring of wall part above the cutting edge U关10, 12兴h U关10, 12兴h
Concrete curing of wall part above the cutting edge N关2 , 0兴d N关7 , 0兴d
Concrete pouring for collar — U关8 , 12兴h
Concrete curing for collar — N关7 , 0兴d
Steel work for the next wall part N关5 , 1兴d N关5 , 1兴d
Shuttering forms for the next wall part U关1 , 2兴d U关1 , 2兴d
Concrete pouring of the next wall part U关10, 12兴h U关10, 12兴h
Concrete curing of the next wall part N关7 , 0兴d N关7 , 0兴d
Caisson sink and plug construction Excavation and caisson sink — U关25, 30兴d
Concrete pouring of plug under water 共if exist兲 — N关12, 2兴h
Concrete curing of plug — N关1 , 0兴d
Dewatering for the surplus 共if exist兲 — N关10, 2兴h
Note: U关N1 , N2兴: U: uniform distribution, N1: lower limit, N2: upper limit; N关N1 , N2兴: N: normal distribution, N1: average duration, N2: SD; d: days, h:
hours, m: minutes.

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Table 8. Indirect Cost Items of Dar El-Salam Microtunnel ent construction techniques. These characteristics lead to
Category Indirect cost Items Rate/Amount uncertainty in the estimated duration and cost. This paper pre-
sented a tool that aids contractors in planning of microtunneling
Time dependent Site staff salaries 1,840 projects using computer simulation. The proposed tool estimates
indirect cost 共L.E./day兲 Site offices 180 duration and cost required for construction of microtunnels. It
Field services 180 provides three methods for construction of microtunnels using
Land renting 95 pipe-jacking techniques: manual excavation, mechanical excava-
Site equipments 1,100 tion, and slurry mechanical excavation. Also, it provides three
Main office administration 180 methods for construction of microtunneling shafts: traditional
Site operation 95 forms, slip forms, and precast concrete segments. The paper pro-
Others 0 vided an overview of the tool components: microtunnel analyzer
Total 3,670L.E./day module and simulation module. Microtunnel analyzer module is
Time independent Mobilization 260,000 considered the planning unit of the proposed tool. It analyzes and
indirect cost 共L.E.兲 Field offices 260,000 breaks down microtunneling projects into zones that consist of a
Field services 260,000 number of shafts and microtunnels’ segments according to used
Roadways 524,000 construction method, assigned resources, and construction se-
Construction camp 260,000 quence. The simulation module is responsible for estimating du-
ration and utilization of resources in each shaft and microtunnel
Consultant 524,000
segment in the project. It utilizes STROBOSCOPE as a general
Sales and taxes 1,300,000
purpose simulation engine. Six simulation modules have been
Insurance 260,000
coded and developed to represent methods of construction for
Bank expenditures 524,000 shafts and microtunnel segments. A case study of Dar El-Salam
Others 1,100,000 branch wastewater microtunnel was presented in order to demon-
Total 5,272,000L.E. strate the important features of the proposed tool and its capabili-
ties in the planning of microtunneling.

each microtunnel segments and shaft in the project. It should be

noted that equipment represents a sizable portion with respect to
the remaining direct cost components 共labor and materials兲 as References
shown in Fig. 15共a兲. This is attributed to the high cost of MTBM
that is used in construction of microtunnels. Microtunnel seg- Abdallah, M. 共2008兲. “Decision support tool for planning tunnels projects
using computer simulation.” MS thesis, Structural Engineering Dept.,
ments cost represents 81% of the direct cost while the remaining
Cairo Univ., Egypt.
19% represents the direct cost needed for the construction of AbouRizk, S. M., Ruwanpura, J. Y., Er, K. C., and Fernando, I. 共1999兲.
shafts 关see Fig. 15共b兲兴. “Special purpose simulation template for utility tunnel construction.”
Proc., 1999 Winter Simulation Conf., 948–955.
Brusey, W.G. 共1998兲. “Microtunneling technology benefits port authority
Conclusions of New York and New Jersey.” TR NEWS, Vol. 195, Transportation
Research Board, Washington, D.C., 30–31.
Microtunneling construction is characterized by complexity, re- Chung, T. H., Abraham, D. M., and Gokhale, S. B. 共2004兲. “Decision
petitive operations, difficult construction environment, and differ- support system for microtunneling applications.” J. Constr. Eng. Man-

Table 9. Durations and Costs of Microtunnel Segements and Shafts

Shortest duration Mean duration Longest duration Minimum direct cost Maximum direct cost
Type ID 共days兲 共days兲 共days兲 共L.E.兲 Average direct cost 共L.E.兲 共L.E.兲
Microtunnel segement 1 59 66 74 2,280,020 2,705,880 3,266,110
2 282 304 331 11,284,250 12,620,760 14,374,780
3 53 60 69 2,010,830 2,399,315 2,887,835
4 101 114 124 4,232,920 4,888,920 5,539,290
Shafts 1 80 90 97 1,010,610 1,064,620 1,122,040
2 79 85 96 918,510 969,525 1,044,765
3 177 208 231 1,163,820 1,363,285 1,531,180
4 116 125 132 1,024,360 1,073,450 1,120,315
5 77 86 96 925,590 986,580 1,052,140

Table 10. Cost and Duration of Dar El-Salam Microtunnel

Shortest duration Mean duration Longest duration
共days兲 共days兲 共days兲 Cost type Minimum cost 共L.E.兲 Average cost 共L.E.兲 Maximum cost 共L.E.兲
638 709 776 Direct 24,850,910 28,072,335 31,938,455
Indirect 7,613,460 7,874,030 8,119,920
Total 32,464,370 35,946,365 40,058,375

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