Event Name: Himalayan Hydro Expo
Dates: January 18-20, 2019
Location: Kathmandu, Nepal
The Robbins Company is excited to announce that we will be exhibiting at the Himalayan Hydro Expo January 18 through 20 in Kathmandu, Nepal. Stop by our booth to discuss the Bheri Babai Diversion Multipurpose Project, one of Nepal’s 11 National Pride Projects, currently being bored by the country’s first tunnel boring machine.
Event Name: STUVA Expo and Conference
Dates: November 26-27, 2019
Location: Frankfurt, Germany
Venue: Messe Frankfurt
The Robbins Company will be exhibiting at the 2019 STUVA Expo and Conference being held in Frankfurt, Germany November 26 and 27. Stop by stand D126 to discuss current projects with a Robbins tunneling expert.
Event Name: International Construction & Utility Equipment Exposition
Dates: October 1-3, 2019
Location: Louisville, Kentucky, USA
Venue: Kentucky Exposition Center
The Robbins Company is looking forward to seeing you in Kentucky, IL for the International Construction & Utility Equipment Exposition (ICUEE) between October 1 and 3. Visit booth 3065 to discover how renting or owning a Robbins Small Boring Unit (SBU) can save you time and money on your next boring project.
Event Name: Rapid Excavation & Tunneling Conference
Dates: June 16-19, 2019
Location: Chicago, Illinois, USA
Venue: Hyatt Regency Chicago
Join us at the 2019 Rapid Excavation & Tunneling Conference (RETC) June 16 through 19 in Chicago, Illinois. Attend a presentation by a Robbins Tunneling professional or come talk to us at booth 306 to learn more about current techniques being used on tunneling projects throughout the world.
Monday, June 17, 2019
Tunneling in Mixed Face Conditions: An Enduring Challenge for EPB TBM Excavation
Jim Clark, The Robbins Company, and Paul Verrall, Afcons Infrastructure Ltd.
Presented by Tyler Sandell, The Robbins Company
Rebuilding TBMs: Are Used TBMs as Good as New?
Doug Harding, The Robbins Company
Tuesday, June 18, 2019
Breaking Through Tough Ground in the Himalayas: Nepal’s First TBM
Missy Isaman, The Robbins Company
Wednesday, June 19, 2019
7.93 m Open TBM Shotcrete System Improvement and Innovation at China’s Jilin Project
Desiree Willis, The Robbins Company and Ya Jun Guo, Robbins China
Presented by Brad Grothen, The Robbins Company
Event Name: World Tunnel Congress
Dates: May 3-9, 2019
Location: Naples, Italy
Venue: Mostra d’Oltremare
The Robbins Company looks forward to attending the World Tunnel Congress (WTC) and ITA-AITES General Assembly in Naples, Italy. Visit stand 68 during exhibition hours May 3 through 9 to learn more about past project successes and exciting current tunneling endeavors.
Challenging Mixed Face Tunneling at India’s Sleemanabad Carrier Canal
by Jim Clark, Robbins
Time & Date: May 8, 12:20-12:40
Session: Long and Deep Tunnels
Location: Palacongressi, Europa Room
Location: Teatro Mediterraneo
Extreme Ingress: Managing High Water Inflows in Hard Rock TBM Tunneling
by Brad Grothen, Robbins & Danny Kough, Kiewit
Overcoming extreme tunneling conditions on Vietnam’s longest tunnel
by Sindre Log, Biyue Li & P.N. Madhan, Robbins
Rescuing and rebuilding TBMs in adverse ground conditions
by Detlef Jordan, Robbins & Barrie Willis, iPS
Event Name: BAUMA
Dates: April 8-14, 2019
Location: Munich, Germany
Venue: Messe München
Meet us in Munich, where The Robbins Company will be exhibiting at BAUMA, the largest construction machinery trade show in the world. Join us at Hall C2, stand 403 between April 8 through 14 for presentations on current projects and cocktail hours, all being held within our booth.
Tuesday, April 9
5:30 pm – 6:30 pm CET
“Avoid Disasters in TBM Tunneling: Proven Strategies” presented by Robbins President Lok Home
Thursday, April 11
5:30 pm – 6:30 pm CET
“A Powerful Solution for Renewable Energy: Hydro Tunneling” presented by Cutters Product Manager Sindre Log
If you would like to join one or both of our events, email Sarah Brooks at email@example.com to RSVP.
Event Name: NASTT No-Dig
Dates: March 17-21, 2019
Location: Rosemont, Illinois, USA
Venue: Donald E. Stephens Convention Center
The Robbins Company will be attending NASTT’s No-Dig Show March 17 through 21. Be sure to visit booth 921 to learn more about Robbins Small Boring Units (SBUs)—the most cost effective and time efficient way to bore through hard rock.
In Nepal, the greeting ‘Namaste’, while pressing both palms together in front of the chest, signifies both ‘hello’ and ‘goodbye’. It implies a circular concept of time that I rather like—I certainly think I will be coming back to this country of high mountains, valley forests, and yes, tunnels.
The Adventure Begins
When I first learned that I would be visiting Nepal to see a swift-moving tunnel project making an impact in a local community, I was pretty jazzed. I also took it upon myself to overpack. The Bheri Babai Diversion Multipurpose Project (or BBDMP for short) is a 12 km long tunnel that travels below protected forest considered part of the Bardia National Wildlife Reserve. This is an area home to tigers, rhinos, Asian elephants, leopards, and more. And, most worryingly for me, mosquitoes.
Mosquitoes love me. I’m not entirely sure why they love me so much, but let’s just say that if there’s a mosquito within a 2 km radius it will find me. Thus, I decided to be prudent and go all out when packing. I purchased a whole new set of safari clothes, the most potent bug spray I could find in copious amounts, and much, much more. I stuffed everything into two suitcases and set off on my journey.
A full 24 hours of traveling later (the journey from Seattle, USA to Kathmandu is no joke, folks), and I arrived in the Kathmandu airport…with no checked luggage. Through a gross miscalculation (what a way to learn a lesson!) I also had not packed hardly anything in my carry-on bag. I had no clothing with me, and more importantly, no bug spray. What was I to do?
Rolling with It
After discovering that my bags were several days away, I decided to forego any hope of reuniting with them during my trip. Instead, I rolled with it. After a one-hour local flight from Kathmandu to Nepalgunj, we arrived at our destination. Nepalgunj is a frenetic, dusty town located around 8 km from the Indian border and one hour from the BBDMP site. The culture is heavily influenced by India, and we had many meals of delicious spicy curry and fried bread. The streets were lined with small shops and marketplace stalls, but to my dismay, no department stores.
After a quick Google search my coworkers and our guests with us for the site visit headed to the nearest approximation, known as Rani Mart (Rani means ‘queen’ in Hindi). To my surprise, I purchased a whole new wardrobe and everything I needed for 1/10th of the price I would have paid for it in the U.S. (though the sizing on the tags was quite a bit larger!) I was feeling very pleased with myself.
A Little Perspective
The next day we were ready to visit the jobsite. I couldn’t help but notice the rolling blackouts that plagued the city and the vast stretches of farmland requiring huge water resources. The people in the surrounding area make do with limited resources in ingenious ways—I was intrigued to see, for example, that every outlet requires you to flip an on-switch before the current becomes available. Perhaps we Americans could save significant energy if we made a setup like this a national standard. Local hotels, including one we stayed at, use solar panels for their power and air conditioning, and harvest rain water in order to reduce their usage.
All of this made me realize how much the BBDMP will impact the surrounding areas. This was confirmed in a meeting we had with Nepal’s Department of Irrigation (DOI), the project’s contractor China Overseas Engineering Group Co. Ltd. (COVEC), and consultant Geodata. The tunnel is sourcing water from the Bheri River to the Babai River, traveling through mountainous Himalayan geology known as the Siwalik Range. The water, as the project’s name suggests, is for multiple purposes. The estimated annual benefit in Nepalese Rupees is $2.9 billion for irrigation, and $4.3 billion for hydropower, making a total of $7.2 billion in benefits once the project becomes active.
The completed tunnel will irrigate 51,000 Ha of land and provide 48 MW annual generating capacity. That’s not to mention the environmental benefits: The Babai River currently swells each monsoon season and then runs extremely low in drier seasons. It is connected directly to the groundwater table, which is being aggressively depleted. With a regulated flow during all seasons, the groundwater table will see less depletion year-round.
The impact, in other words, is huge. Learning all of this made my obsession with my missing luggage seem inconsequential in comparison. I had my bug spray and some clothes. That was all I needed.
The First Nepalese TBM
With such a landmark project for the region, its proponents were willing to look to the latest technology during the planning phase. Our local representatives, MOSH Tunnelling, had been working since the 1990’s to bring a TBM to Nepal, a country known for its Drill & Blast tunneling. While TBMs had been considered multiple times, each time conventional tunneling had been chosen.
When the BBDMP was fast-tracked as one of the country’s “National Pride Projects” feasibility studies showed that Drill & Blast excavation could take as long as 12 years. The DOI needed a faster option, and they found it in TBMs. They began working with MOSH Tunnelling and Robbins to bring what would be the first Nepalese TBM ever into the country—a 5.06 m diameter Robbins Double Shield. The process for the DOI to acquire funding for the project and select a contractor through international competitive bidding took seven years, spanning from 2007 to 2015, when project commencement officially began.
Fast forward to our site visit in November 2018 and the project is far exceeding expectations. Tunneling has topped out at 1,202 m in one month with an average of around 740 m per month. The knowledgeable COVEC team have traversed a major fault zone, the Bheri Thrust, with no problems, and overcome a stuck TBM shield with a bypass tunnel constructed in just five days. Overall, the TBM is far ahead of schedule and the results are of national importance.
The local community, national media, and government are all watching how the TBM excavation plays out at BBDMP. Given the strong performance, they are now considering TBMs for a host of future multipurpose water projects. It’s the kind of result that opens up a whole new marketplace.
Into the Forest
After a great site visit, we chose to relax for one day at a spectacular local lodge that offered jeep safaris into the Bardia Wildlife Reserve. Currently home to nearly 90 tigers (a number that is rapidly increasing through conservation efforts) we were hopeful of perhaps seeing one of the striped cats in the forest. Our guide was knowledgeable, our jeep sturdy and our driver adept as we traversed bumpy roads and forded a few streams on our safari drive. We saw mischievous macaques, tree-dwelling langurs, a host of brightly colored birds, and various deer. We saw several enticing tiger prints…but the tiger itself remained elusive. Obviously, this means that I must go back!
A Lesson Learned
After traversing a tunnel, traipsing through the forest, and some swift sight-seeing in Kathmandu on our last day, I felt I had come full circle. I was ready to head home, but with an eye towards future opportunities to return to Nepal, whether for business or vacation. I will be back. But next time, you can rest assured, I will only bring what I can fit in my carry-on.
On October 4, 2018, onlookers watched as a 3.8 m (12.5 ft) diameter Robbins Main Beam TBM completed its epic journey. The TBM, christened “Driller Mike”, after local rapper and activist “Killer Mike”, overcame extremely hard rock conditions along a curving 8.0 km (5.0 mi) tunnel to bolster the city of Atlanta, Georgia, USA’s water supply.
The new tunnel brings the Atlanta Water Supply Program one step closer to increasing the city’s water capacity to between 30 and 90 days depending on daily usage. “Our schedule for the project was very aggressive but the project team stayed together to overcome issues related to the mining of the tunnel,” said Bob Huie, Project Director for the PC Russell JV, the Construction Manager at Risk (CMAR) for the project.
The unique structure of the project team is credited with the overall project success despite challenges. “I’m proud of our team. They had obstacles and challenges and challenging ground, but they stuck together and didn’t give up, and they were successful. There was great leadership and supervision all around,” said Larry Weslowski, Tunnel Superintendent for the PC Russell JV.
The project is only the third such large construction project in the U.S. to use the CMAR structure. The PC Construction/HJ Russell JV was selected as the CMAR for the project, who then purchased the Robbins Main Beam TBM for the tunnel. The designer for the construction works including tunnel and shafts, JP2—consisting of Stantec, PRAD Group, Inc., and River 2 Tap—specified the hard rock TBM. Operation and assembly of the TBM was then sub-contracted to the Atkinson/Technique JV.
The robust TBM was assembled using Onsite First Time Assembly (OFTA) at the massive Bellwood Quarry site with help from Robbins personnel. “The guys built everything per the specs to help with scheduling. It was a challenge but there was no negativity during the process,” said Weslowski. Despite summer temperatures hitting 43 degrees Celsius (110 degrees Fahrenheit) and 100 percent humidity, the TBM was ready to launch by October 2016.
Hard granitic rock challenged the 19-inch disc cutters from the outset. “There was ground so hard that it would take eight hours to go 1.5 m (5 ft). It was between 117 and 310 MPa (17,000 and 45,000 psi) UCS. The beginning of the job was tough,” said Weslowski, but he added that once the learning curve had been overcome “they started breaking project records left and right towards the end. We got a best day of 38.4 m (126 ft). Rates just kept increasing.”Other challenges included groundwater encountered during tunneling. “We did encounter groundwater contamination that required remediation. This remediation work was completed successfully,” said Huie.
With tunneling complete, the USD $300 million project for the City of Atlanta’s Department of Watershed Management is on track to meet its scheduled overall completion date of September 2019. The project will turn the inactive Bellwood quarry into a 9.1 billion liter (2.4 billion gallon) raw water storage facility connecting with the Chattahoochee River and various water treatment facilities.
On September 18, 2018, a Robbins mega-sized slurry machine, measuring 13.7 m (44.8 ft) in diameter, made its first cut into hard rock. The epic launch at an urban jobsite was made possible by Onsite First Time Assembly (OFTA) of the TBM in Japan for the Hiroshima Expressway Line 5 project. The contractor, a joint venture of Obayashi-Taisei-Kosei, had a strict timeline of eight months to adhere to when it came to machine assembly. “This deadline was very important. After assembling the TBM, I think OFTA was appropriate for this project,” said Mr. Ryota Akai, Deputy Project Manager for the Obayashi JV.
Due to the project location there were also restrictions on delivering the TBM—in order to meet controlled transportation limits within the city, the TBM had to be divided into small transportable weights and sizes, then assembled in a small jobsite measuring just 30 m (100 ft) wide x 60 m (200 ft) long. The 2,400 metric ton (2,650 US ton) machine will bore 1.4 km (0.9 mi) of the 1.8 km (1.1 mi) long tunnel that, once completed, will significantly improve traffic conditions in Hiroshima.
The massive machine is the country’s first foreign-made large diameter Slurry TBM to excavate hard rock in Japan. “There is a lot of hard rock in Hiroshima,” said Mr. Akai, “and Robbins has a lot of experience boring hard rock.” The machine is expected to encounter granite with rock strengths up to 130 MPa (19,000 psi) UCS. Those involved in the project are excited to see what effect this will have on how Slurry TBMs are used in the future. “The development of this TBM is a milestone,” said Mr. Kiyomi Sasaki, General Manager of Robbins Japan, “it will lead to new tunnel applications worldwide.”
The design of the Slurry machine is robust in anticipation of potentially abrasive rock conditions and water pressures up to 13 bars. “The Robbins machine is very tough, for example the weight is very heavy. The cutterhead, both its material and structure, are very tough. It will not break in hard rock,” said Mr. Akai.
In preparation for the conditions, the machine was designed for 20-bar water pressure. The robust cutterhead was fitted with 20-inch and 17-inch diameter pressure compensating cutters, which utilize a patented design to effectively operate under high pressure. The joint venture intends to change the disc cutters an estimated 10 times during the bore as part of the machine’s maintenance.
Throughout the assembly and launch process the joint venture crew worked with Robbins Supervisors who assisted and provided guidance. “Robbins crews have a lot of experience; they help us every day despite the language barriers. I appreciate it,” said Mr. Akai.
The new Expressway Line 5 tunnel will directly connect Hiroshima’s urban area with a major national highway network and is expected to improve access to Hiroshima Airport. Tunnel completion is planned for 2020.
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- Robbins unveils Largest Hard Rock TBM in the U.S. at Mill Creek