NIAGARA
TUNNEL
PROJECT
2005-2011
Last updated on April 29, 2008
A special THANK YOU is extended to the following companies for allowing access
to obtain the photographs contained herein.
STRABAG AG INC, ONTARIO POWER GENERATION and THE ROBBINS COMPANY
while the information contained on this site is believed to be accurate
it has not been reviewed or approved by the above named companies
On Friday June 25th 2004, the Ontario Government announced that Ontario Power Generation has been given approval to proceed with the 3rd tunnel under the City of Niagara Falls.
The first two tunnels were built during the 1950's.
On Thursday August 18th 2005, Ontario Power Generation (OPG) announced the selection of the Austrian - STRABAG AG COMPANY to build the $600 million dollar hydro tunnel. The 10.4 kilometer (6.4 miles) water tunnel will run under the City of Niagara Falls from the upper Niagara River to the Sir Adam Beck Power Stations at Queenston at a maximum depth of 140 meters (459 feet). This third tunnel project is expected to be one of the largest tunnels built in North America.
The new tunnel will parallel the existing water tunnels but at a lower depth. The current tunnels reach a maximum depth of 100 meters (328 feet).
On Wednesday September 14th 2005, the official ground breaking ceremonies were held to announce the beginning of this massive project.
Currently, Sir Adam Beck Power Group generates 2,080 megawatts. Approximately 1,800 cubic meters (63,566 cubic feet) of water per second from the existing twin tunnels and the hydro canal supply the Sir Adam Beck Stations. The new tunnel will divert an additional 500 cubic meters (17,657 cubic feet) of water per second.
Strabag AG will also undertake remedial work on the former Ontario Power Station, the Ontario Power Station Water Intake Gate House and the former Toronto Power Station increasing the contract cost to $985 million dollars.
The project has now been projected to be completed in 2011 from the initial date of 2009.
Queeenston Shale strata is exposed at Queenston-Lewiston
at the beginning of the Niagara Gorge
The course and depth for the new Niagara Tunnel had been predetermined many years ago as a result of the location of the original hydro canal (1921), the subsequent twin water tunnels (1955), the ancient buried St. David's Gorge and urban development.
The hydro canal was initially designed to consist of two canals leading from the Welland River to the Chippawa-Queenston Power Station (Sir Adam Beck #1). The course of the canal dissected the city in an area that was predominately rural at that time. After the first canal was built, the second canal plan was abandoned. The excess hydro land was returned to the city for urban development.
In the early 1950's, twin 14 meter (45 feet) diameter water tunnels were built under the city at a maximum depth of 330 feet nearest Chippawa and slowly rising before surfacing and terminating near Whirlpool Road into an open cut canal. The existing tunnels and canal would have been too hazardous and expensive to continue as they passed underground through the glacial silt of the buried St. David's Gorge. In both instances the water is channeled on the surface across the buried gorge through concrete lined trapezoidal sections.
The corridor of land utilized for the location of the twin tunnels was previously owned by the hydro company and/or upon city land that was for the most part undeveloped. Interestingly, the twin tunnels pass underneath the hydro canal near Thorold Stone Road.
Since the 1950's, the urban development of the City of Niagara Falls has grown exponentially so that today, little if any excess land was available.
History, geology and urban development has dictated the current location of the new Niagara Tunnel with little flexibility. The new tunnel had to begin in an area of land near the forebays' of the Sir Adam Beck Power Generating Stations.
The Niagara Tunnel had no alternative than to bore steeply underground in order to tunnel underneath the ancient buried St. David's Gorge and to maintain a safe separation from the existing tunnels . The current path of the Niagara Tunnel is (for the most part) to follow the path of the existing twin tunnels.
The Niagara Tunnel is 14.4 metres (47.2 feet) in diameter at a maximum depth of 140 meters (459.3 feet). Both are unprecedented in size and depth in Niagara. The rock strata at the current depth of the tunnel boring machine is predominately Queenston Shale (mudstone). The reddish-purplish shale is fractured and has resulted in many roof-line rock falls slowing the boring operation. Although test boring samples were conducted in preparation for this project, none uncovered the vertical fracturing in the rock strata that the tunneling crews are currently experiencing.
INDEX
Rowa Tunneling Logistics Company
McNally International Construction & Marine Company
Morrison Hershfield Consulting Engineers
Bermingham Construction Company
Niagara River & Water Diversion
Need For The New Niagara Tunnel
Strata of the Niagara Gorge Chart
Upper Niagara River Construction - Niagara Tunnel Project -
January 25th 2008
tunnel water intake entrance channel being constructed in dry river bedrock
Upper Niagara River Construction - Niagara Tunnel Project -
January 25th 2008
tunnel water intake entrance channel being constructed in dry river bedrock
Upper Niagara River Construction - Niagara Tunnel Project -
September 24th 2007
a panoramic picture of the cofferdam
surrounding Water Control Dam gate # 1 at the International Water Control
Dam.
Ontario Power Generation (OPG) is owned by the Province of Ontario and is an electricity generation company whose principle business is the generation and sale of electricity in the Province of Ontario. OPG has approximately 11,300 employees. Power generation is produced by nuclear, hydroelectric, fossil and wind. Ontario Power Generation produced 109 TWh or 70% of Ontario's electricity in 2005.
Strabag AG is an Internationally world renown engineering and construction company based in Spittal, Austria. It was established by Anton Lerchbaumer is 1835 and has become the largest construction company in Germany and Austria.
Strabag's current CEO is Peter Haselsteiner. The company has approximately 40,000 employees world wide. Revenues in 2005 amounted to €9.8 billion euros.
Strabag has extensive experience in road construction, structural engineering and other building fields including tunneling, civil engineering, bridge construction, power plant construction, rail construction, environmental technology and specialized underground engineering and project development.
Cleanup of the tunnel outlet continues - August 18th 2007
With more than 50 years on innovation and experience, The Robbins Company is the world's foremost developer and manufacturer of advanced underground construction machinery.
In 1952 James S. Robbins, the founder of the Robbins Company, built the first successful hard rock tunnel boring machine (TBM). That success provided the foundation of innovation upon which Robbins continues to build.
Over the past 50 years Robbins has been involved in hundreds of tunnel boring projects around the world. Robbins is an international organization with four primary manufacturing facilities, seven international sales & service locations, and representatives worldwide.
The largest hard rock TBM in the world (14.4 m in diameter) will be designed and manufactured by The Robbins Company. Austria based Strabag AG, the contractor for the Niagara Tunnel Project, awarded the TBM order to The Robbins Company based in Solon, Ohio USA. The Robbins tunnel boring machine (TBM) will be an open, hard rock, main beam TBM that utilizes the proven Robbins floating gripper design. The TBM will be manufactured with a state-of-the-art ground support system.
HATCH MOTT MACDONALD ENGINEERING COMPANY
Hatch Mott MacDonald is an international award winning full service consulting engineering firm offering public and private clients multi-disciplined expertise and comprehensive capabilities in planning, environmental assessments, studies and analysis, design, procurement, construction engineering and inspection, project, program and construction management and facility maintenance and operations.
With more than a century of experience, Hatch Mott MacDonald has approximately 10,000 employees world-wide providing the absolute best and highest engineering technical service.Hatch Mott MacDonald is a North American company which has earned a reputation for technical excellence, innovation and client responsiveness on some of the most prominent and challenging projects. They have an extensive record of major accomplishments in the fields of transportation, tunnels, water conveyance, wastewater/CSO, environmental, gas pipelines, buildings and utilities.
Hatch Mott MacDonald's tunneling expertise began over 100 years ago, in the development of the London underground road and rail systems, and Toronto's subway system more than 50 years ago.
Peter Wickens is the current President and CEO.Hatch Mott MacDonald and Hatch Acres are acting as Owner’s Representatives to Ontario Power Generation on the Niagara Tunnel Project.
Niagara Tunnel Project Sign
ROWA TUNNELING LOGISTICS COMPANY
Rowa Tunneling Logistics AG is a worldwide construction and engineering company specializing in tunneling installations and logistics systems. It is headquartered in Wangen, Switzerland.
Rowa Tunneling Logistics serves tunnel projects around the globe. Rowa logistics systems and back-up equipment have proved themselves in the construction of the Channel Tunnel, in Manapouri (New Zealand) and in Siberia. They have been involved in Swiss projects such as the Vereina Tunnel and the high-performance rail transit through the Alps in the St. Gotthard and Lötschberg mountain ranges. They have been involved in more than one hundred large construction sites, many of them prestige projects.
Strabag has contracted Rowa Tunneling Logistics to develop and manufacture a backup system compatible with the 14.4 meter (47.2 feet) diameter Robbins gripper TBM. This 105 meter (344.48 feet) long backup unit will consist of four elements on four levels. The first element will consist of a stepper installation while the remaining three are towed on running gears.
Rowa Tunneling Logistics Company will be providing for the essentials required to facilitate the tunneling to proceed in a safe and efficient manner. This includes removal of debris, air ventilation, dust control and mortar installation. In addition to the typical infrastructure components, two rock bolt drilling machines for anchor lengths up to 6 meters (19.6 feet). Two longitudinal displaceable 360° round spray robots are included. The removal of the excavated material will be by way of a conveyor belt assembly.
McNALLY INTERNATIONAL CONSTRUCTION & MARINE COMPANY
McNally International Incorporated and its group of companies was established in 1949, under the name S. McNally & Sons Limited.
Post-war house building was the main activity in the early years but soon changed to heavy civil engineering projects. Since the 1950's, the name "McNally" has become synonymous with difficult and demanding projects.
Throughout the years, McNally International has completed projects including roads, bridges, sewage treatment plants, sewers, and water mains. They are best known for their experience in underground tunnel work.Tunnel construction is still one of the most exacting sectors of the construction industry. McNally International is recognized as Canada's leading Tunnel Contractor. They built tunnels for water, sewer, steam, subways, power transmission, traffic and pedestrians.
In the 1980's we started McNally Tunneling Corporation expanded operations in the United States. Based in Cleveland, Ohio, McNally Tunneling has completed projects in Birmingham, Cleveland, Houston, Seattle, Chicago, Minneapolis and Columbus.
Construction like many industries has its own cycle of activities. One sector most acutely affected has been marine construction. In the 90's McNally purchased the marine assets of the Beaver Construction Group of Montreal, and started a new company called Beaver Marine Limited based in Nova Scotia. After a couple of years, McNally acquired the marine assets of Canadian Dredge and Dock, Pitts Engineering and MacNamara Marine all major players in the Construction industry in their day.Under the new McNally International flag these assets help make up one of the best equipped and manned construction fleets anywhere in Canada.
Together with Beaver, McNally Construction Group is capable of completing marine construction or dredging projects anywhere in the Great Lakes, St. Lawrence River or Eastern Canada.
McNally International Incorporated with its team of experienced and dedicated professionals is ready for the future.McNally International - Marine Division is employed at the Niagara Tunnel Project in the preparation and construction of the Upper Niagara River intake.
Founded in 1912, Dufferin Construction is part of the St. Lawrence Cement Group, the largest cement producer in eastern Canada. Dufferin is a leader in its own right - Canada's biggest concrete paving company and one of Canada's largest heavy civil engineering contractors. Dufferin Construction has headquarters in Oakville Ontario. One of their many major projects included the building of Highway #407. Dufferin Constructions principal area of operation is Southern Ontario from Windsor to Ottawa.
Strabag has contracted Dufferin Construction for surface and concrete works.
MORRISON HERSHFIELD CONSULTING ENGINEERS
Morrison Hershfield is a multidisciplinary engineering and management firm. Engineering and design build services are provided to clients in the Transportation, Building, Life Sciences, Municipal, Utilities and Telecommunications sectors.
Morrison Hershfield Group Inc. is an employee owned organization. It is a corporate holding company with a mandate to operate national and international professional consulting engineering businesses through the Morrison Hershfield Group of Companies.
Morrison Hershfield has been employed in the design of the Niagara Tunnel Project.
ILF Consulting Engineers was founded by Mr. P.Lässer, M.Sc., and Mr. A.H.Feizlmayr, M.Sc., in 1969. The abbreviation ILF is derived from the German company name "Ingenieurgemeinschaft Lässer-Feizlmayr".
On the basis of its well-tested know-how, ILF has continually extended its mission to all continents. Today, ILF ranks among the world's leading independent engineering consultants; particularly with regard to tunneling, underground construction and pipeline engineering.
ILF has been employed in the design of the Niagara Tunnel Project.
Peter Kiewit Sons Co. was founded in Omaha, Nebraska in 1884. Canadian operations began in 1941 and currently comprise Eastern and Western Districts, with permanent offices in Newfoundland, Quebec, Ontario, Alberta, and British Columbia.
The Eastern Canada District is responsible for all construction work from Newfoundland to Manitoba and Construction Kiewit Cie builds work in Quebec. All other work is performed by Peter Kiewit Sons Co.
The District is certified ISO 9001 and employs 160-180 engineers, superintendents and technicians. An annual university-recruiting program ensures the continuity and growth of the district. Some 300-500 craft employees are hired each year to complement permanent staff.
In recent years, the District has built some of the most challenging work in Eastern Canada, including major participation in the gigantic James Bay hydroelectric complex, the development and ongoing open pit mining of the Raglan nickel mine, the Hibernia offshore oil platform and the Thousand Islands and Humber bridges in the transportation sector.On March 30th 2006, Ontario Power Generation awarded Peter Kiewit Sons Company a contract worth $17 million dollars for the decommissioning of the retired Toronto Power Generating Station (TPGS), the retired Ontario Power Generating Station (OPGS) Power Generating Stations and the Ontario Power Generating Station Gate House in Niagara Falls.
The work at the three sites includes electrical and mechanical removals of existing equipment down to the thrust deck floor. Additional work includes:
Toronto Power Generating Station - sealing of twenty-three (23) portals and backfilling the inner forebay of the power station. This required the dewatering of the inner and outer forebays by means of a rock cofferdam approximately 80 meters (262 feet).
Ontario Power Generating Station - sealing of the penstock openings
Ontario Power Generating Station Water Intake Gate House - removal of the existing head-gates and concrete seals constructed in their place. This work required the dewatering by means of a sectional stop-log cofferdam.
Work is scheduled for completion in the Spring of 2007.
BERMINGHAM CONSTRUCTION COMPANY
Established in 1897, Bermingham Foundation Solutions is an internationally renown company having works in more than 33 countries worldwide.
Bermingham Construction has been instrumental in building the infrastructure of Canada. The company worked on the famous Crow’s Nest Pass for the Canadian National Railway, as well as ports, docks, bridges and highway overpasses all over the country.
Today, the company is active in building foundations for bridges, condominium towers, power plants, water treatment plants, and docks mostly in Ontario and Eastern Canada.
Bermingham is an industry leader and innovator. It is known for developing the StatnamicTM Load test which is used extensively in Asia, North America and Europe.Bermingham is introducing a revolutionary green technology to North America - geothermal foundations that produce heating and cooling.
Bermingham Construction Company has been employed in the building of cofferdams and steel sheet pile-driving for the Niagara Tunnel Project.
Upper Niagara River Construction - Niagara Tunnel Project - September 24th 2007
the cofferdam surrounding Water Control Dam gate # 1 has been completed
Niagara Tunnel Project - August 18th 2007
the rock debris conveyor belt is a continuous loop that lengthens as the Tunnel Boring Machine (TBM) progresses. When required the conveyor is cut and sections are added and vulcanized on site. A spool of rubber conveyor belt is on the left and the wall mounted conveyor carrying rock debris from the tunnel is on the right
Niagara Tunnel Project - August 18th 2007
The length of the primary power cord that supplies power to the Tunnel Boring Machine (TBM) expands as the tunnel progresses.
A spool of the expandable power cord is ready and waiting
Niagara Tunnel Project - August 18th 2007
A dust control building is being constructed to reduce airborne pollution as rock debris is deposited in a remote section of the construction site.
NIAGARA RIVER AND WATER DIVERSION
The Niagara River is 35 miles (59 km) long and runs in a north-south direction from Lake Erie to Lake Ontario. It is an International Boundary between Canada and USA. The average flow of the river is estimated at 6,000 cubic meters per second (211,887 cubic feet per second).
The Niagara River Water Diversion Treaty between Canada and the United States concerning the uses of the waters of the Niagara River was signed on February 27th 1950 and came into force October 10th 1950. Its purpose is to preserve and enhance the scenic beauty of Niagara Falls and the Niagara River, while providing for the most beneficial use of the river waters.
Limitations on the amount of water diverted from the Niagara River for power generation purposes initially established by the Boundary Waters Treaty of 1909 were terminated and replaced by the 1950 treaty. Temporary diversion agreements for power generation in 1941 and 1948 agreements between the two Governments were rescinded.
The Niagara River Water Treaty of 1950 established new limitations of water diversion for power generation.
The amount of water available for diversion under the provisions of the latest treaty was specified to include:
1. the total outflow from Lake Erie through the Welland Canal
2. the total outflow from lake Erie through the Niagara River (including the Black Rock Canal)
3. not to include the amount of water used and necessary for domestic/sanitary purposes and for the canals for navigation purposes.
In order to preserve the scenic beauty of the Falls, the
Niagara River Water Diversion Treaty of 1950 stipulated that no water diversions
for power generation would be allowed that would reduce the flow of water over
Niagara Falls as follows:
no less than 100,000 cubic feet of water per second (cf/s) From April 1st to September 15th (inclusive) between 8 a.m. and 10 p.m.
no less than 100,000 cubic feet of water per second (cf/s) from September 16th to October 31st (inclusive) between 8 a.m. and 8 p.m.
no less than 50,000 cubic feet of water per second (cf/s) from November 1st to March 31st (inclusive)
The specified rates of water flow over the Falls (listed above) are mandatory minimums. All water specified in this Treaty in excess of water reserved for scenic purposes may be diverted for power purposes.
On April 17th 1973, the governments agreed to use Eastern Daylight Savings Time as the basis of interpreting the hours specified by section IV of the treaty.
Under the terms of this treaty all excess waters available for water diversion for power generation shall be divided equally between Canada and the United States. An exception allows Canada to divert an additional 5,000 cubic feet of water per second from the Welland Canal or the Niagara River by a 1940 government agreement pertaining to the downstream use of waters from Canada's Long Lac and Ogoki water diversions into the Great Lakes. These water diversions are specifically excluded from the waters allocated in the Niagara River Water Diversion Treaty of 1950.
The Niagara River Water Diversion Treaty came into force upon the date of the exchange of ratifications [Oct. 10, 1950] and continues in force for a period of fifty (50) years and thereafter until one (1) year from the day on which either party shall give notice to the other party of its intention of terminating the Treaty.
NEED FOR THE NEW NIAGARA TUNNEL
The 1950 Treaty stipulated: "Until such time as there are facilities in the territory of one party to use its full share of the diversions of water for power purposes agreed upon in this Treaty, the other party may use the portion of that share for the use of which facilities are not available".
In order to best utilize the water available for diversion, the New York State Power Authority and Ontario Power Generation signed an agreement on January 19th 1965 to share generation capacity. Both power companies have rented available power generating capacity from each other to maximize utilization of their respective shares of water available for power production. Original ownership of the water shares has been maintained. This agreement allows each company to minimize the costs of equipment outages and to provide for the handling of ice problems. In simple terms, when Ontario Power Generation (OPG) - Sir Adam Beck Power Stations (Canada) has surplus water shares available for diversion and no extra generation capacity, they rent the generation capacity available at New York State Power Authority (NYSPA) - Robert Moses Power Station for power generation. The power generated is for the use of Ontario Power Generation. This agreement is reciprocal and NYSPA does the same with their surplus water share.
The power companies of both countries continue to upgrade their power generators to increase power capacity however their respective abilities to draw water are limited by not only the terms of this treaty but their capacity to draw available waters (refer below).
|
POWER STATION INTAKE CAPACITY |
|
|
Power Station Name |
Cubic Feet Per Second |
|
Robert Moses Generating Station (NYSPA) |
109,000 |
|
Sir Adam Beck Generating Stations (OPG) |
64,400 |
|
DeCew Falls Generating Station (OPG) |
8,000 |
|
Canadian Niagara Power (Fortis)- Rankine Generating Station - not producing |
35 |
Ontario Power Generation has a combined water drawing capacity of 72,400 cubic feet per second (includes DeCew Falls Generating Station). At present, New York State Power Authority - Robert Moses Generating Station has a water drawing advantage of approximately 36,600 cubic feet per second.
There are occasions when power generation is reduced below actual capacity at times of low water flow rates in order to maintain the treaty minimal flow over the Falls.
There are occasions when the amount of water in the Niagara River available for diversion exceeds the ability of the power stations to draw this excess. Ontario Power Generation and the Ontario Government are currently studying methods upon which to increase their water share drawing capacity in order to increase power generation capacity.
"...The two countries share the water for power production as per Article VI. This amount, of course, depends on the river flow which changes constantly. When the level of Lake Erie, and its corresponding outflow, is low, there may not be sufficient water available for maximum power generation.....in either country. On the other hand, when the opposite is true i.e. high lake levels and river flows the amount of water available for power production exceeds generation/diversion capacity and water will be "spilled" over the Falls (in other words in amounts greater than the required Falls flow minimum).
A program of unit upgrades at both Ontario Power Generation's Sir Adam Beck and the New York Power Authority's Robert Moses Niagara Power Project, begun in the 1990s and due for completion in the next couple of years has been increasing this generation/discharge capacity. While the tunnels on the U.S. side are capable of handling their diversions, in all but the most extreme case (short term storm events which can result in very high flow conditions), a new OPG tunnel or tunnels and additional generating station would increase the frequency of maximum water diversion for power generation on the Canadian side..."
Len Falkiner, Secretary, International Niagara Board of Control (IJC)
|
ONTARIO POWER GENERATION |
||||
|
SIR ADAM BECK HYDRO-ELECTRIC GENERATING STATIONS - NIAGARA GROUP CAPACITY TABLE - NIAGARA RIVER DIVERSION |
||||
| GENERATING STATIONS | YEAR IN SERVICE | DIVERSION CAPACITY cubic meters/second (cubic feet/second) |
POWER
CAPACITY megawatts |
AVERAGE ANNUAL ENERGY |
| Sir Adam Beck #1 GS | 1922 |
625 cm/s |
487 | 2,700 |
| Sir Adam Beck #2 GS | 1955 | 1,200 cm/s (42,377.4 c/ft/s) |
1,472 | 9,200 |
| Sir Adam Beck Pump GS | 1958 | n/a | 122 | -100 |
| CURRENT TOTALS | 1,825 cm/s (64,448.9 c/ft/s) |
2,081 | 11,800 | |
| Niagara Tunnel Project | 2009 | 500 cm/s (17,657.2 c/ft/s) |
N/A | 1,600 |
| FUTURE TOTALS | 2,325 cm/s (82,106.2 c/ft/s) |
2,081 | 13,400 | |
The megawatt (symbol: MW) is a unit for measuring power equal to one
million (106) watts.
The gigawatt (symbol: GW) is a unit for measuring power equal to one
billion (109) watts.
On Thursday August 18th 2005, Ontario Power Generation awarded a $600 million dollar contract to Strabag AG Company to design and build the new Niagara Tunnel.
On Wednesday September 14th 2005, Ontario Power Generation announced the start of construction of its $985 million dollar, 10.4 kilometer (6.46 mile) Niagara Tunnel project to increase the output of power from Niagara Falls. The Niagara Tunnel project is estimated to cost $600 million dollars and $385 million dollars for remedial and other work costs.
The project involves boring a tunnel 14.4 meters ( 47.24 feet) at a depth of up to 140 meters (459.3 feet) below the City of Niagara Falls . The tunnel will enhance the original engineering accomplishment of the Sir Adam Beck Hydro-Electric Generating Stations - Niagara Group in transporting water from a location up river from the Falls of Niagara to the power stations at Queenston to increase its power output.
The new tunnel will complement the upgrading of the 16 generators at the Sir Adam Beck Power Station #2. This 9 year upgrading project cost $220 million dollars increased the potential peak output by 194 megawatts.
When the new Niagara Tunnel project is completed, it will enable the Beck Power Group to produce an additional 1.6 terawatt-hours of electricity for at least the next ninety (90) years. It will allow enough energy production to serve an additional 160,000 homes and increase power output at Sir Adam Beck by 14%. - enough to meet the annual needs of a city of 700,000 persons.
Currently 1,800 cubic meters of water per second (63,566 cubic feet of water per second) are available to be diverted to the Sir Adam Beck Generating Stations for power production. The new Niagara Tunnel will allow an additional 500 cubic meters of water per second (17,657.2 cubic feet of water per second) when available to be diverted for power generation.
On average, the Niagara Tunnel project will employ approximately 230 workers however this number will peak to about 350 employees.
The Tunnel Boring Machine (TBM) to be used on the Niagara Tunnel project will be 14.4 meters (47.2 feet) in diameter and will be one of the largest to be used in the world. In comparison the Robbins TBM will be 2½ times the size of the Toronto Subway tunnel and 1½ times the size of the English Channel tunnels.
The Robbins Company will design and manufacture the largest hard rock TBM in the world for the Niagara Tunnel project. It will be an open, hard rock, main beam TBM that utilizes the Robbins floating gripper design. The TBM will be equipped with a state of the art ground support system. The cutter-head will be powered with a 4,725 kW variable frequency drive system that can be increased to 5,040 kW. For optimum performance Strabag has chosen to use Robbins 20-inch cutters mounted in a back-loading cutter-head. Alternately, Robbins 19-inch cutters can be used without modification of the cutter-head. The cutting head will typically revolve at 4 to 10 revolutions per minute (rpm).
The geology is varied consisting of limestone, dolostone, sandstone, shale, and mudstone. The rock strength ranges from 15 to 180 MPa, with most of the rock in the 100 to 180 MPa range. With the exception of sandstone, the geology is basically non-abrasive. Most of the rock debris (80%) removed from the tunnel will consist of Queenston Shale.
The Niagara Tunnel is expected to advance at a daily rate of 10-15 meters (32.8 feet - 49.2 feet). Approximately 1.6 million cubic meters of material excavated from the tunnel will be dumped on Ontario Power Generation property between the two existing canals.
The new Niagara Tunnel will follow the same basic route as the existing two tunnels parallel to Stanley Avenue. The new tunnel starts on Ontario Power Generation property at Queenston with a -7.82% drop over a length of approximately 1,500 meters (4,921 feet) reaching a depth of up to 140 meters (459.3 feet) below the City of Niagara Falls. Here the tunnel proceeds with a relatively horizontal plane over a distance of approximately 7,400 meters (24,277.9 feet). The alignment will follow a horizontal curve radius of over 1,000 meters (3,280.8 feet) in length. The tunnel ends on the Niagara River at the International Water Control Dam located one mile upriver from the Horseshoe Falls with an ascent gradient of +7.28% over the final 1,500 meters (4,921 feet).
The inside diameter of the finished tunnel will be 12.5 meters (41.1 feet) and will be lined with 50 centimeters (23.62 inches) of un-reinforced concrete with double layer seal and pre-stressed injection concrete.
The Tunnel Boring Machine will reach its maximum depth of 140 meters (459.3 feet) within the first 1.5 kilometers of operation. The TBM will operate 24 hours a day - 365 days a year on a 3 shift rotation (8 hours) until completed. The Tunnel Boring Machine will be operated by two Chief Operators per shift with a crew of approximately 10 workers onboard. An additional 20-30 men will be employed on each shift for the required surface support.
On Thursday May 18th 2006, Province of Ontario, Minister of Energy - Donna Cansfield on tour of the construction site announced the nickname of the Tunnel Boring Machine as "BIG BECKY". A grade 6 class at Port Weller Elementary School came up with the winning entry to name the TBM. Under the direction of computer and science teacher - Kevin Dyck, his class selected the name after much "brainstorming". They called it BECKY because it is a feminine version that pays tribute to Sir Adam Beck.
On Tuesday August 8th 2006, a ceremony attended by Ontario Premier - Dalton McGuinty and other officials was held at the starting location of the Niagara Tunnel Project near the Sir Adam Beck Power Generating Stations. Premier McGuinty threw a switch to turn on the cutter head of the Tunnel Boring Machine (TBM).
Importing a European tradition, Doctor Robin Williams - Regional Municipality of Niagara - Medical Officer of Health was named the patroness of the Niagara Tunnel Project by officials of Strabag AG. Naming a patroness is based upon a religious tradition of St. Barbara - the patron saint of miners, construction workers and engineers. Doctor Williams will keep up to date on the tunneling project and will be a public ambassador for it. According to traditions associated with tunneling, naming a patroness of the tunnel will keep the workers safe.
In August 2006, the Regional Municipality of Niagara and Ontario Power Generation drafted an agreement that will see approximately 3.5 million tonnes of Queenston Shale excavated provided to the brick manufacturing industry for free. Queenston Shale is the sole raw material used for the production of clay bricks in Ontario.
In August 2007, the tunnel boring machine (TBM) is nearing the 1,000 meter (3,281 feet) mark. Progress has been extremely slow because of frequent vertical rock falls as a result of unforeseen geological rock structures. It is hoped that the unstable rock sections will soon be behind them as the TBM bores deeper underground . Several rock falls weighing an estimated 10-20 tons have stopped the boring progress for lengthy periods. The maximum depth of 140 meters (459.3 feet) will soon be reached as the TBM reaches the 1,500 meters mark. In order to reduce the frequency of rock falls, horizontal support rods are being installed in the rock above the TBM in advance of the cutter head.
In order to reduce airborne dust pollution at the debris dump site, a containment building has been erected.
On September 22nd 2007, the tunnel boring machine (TBM) has reached a milestone of the first 1000 meters (3,281 feet).
On January 21st 2008, the tunnel boring machine (TBM) is approximately 1,650 meters (5,413 feet) and is located at it's maximum depth. It's current location is under the ancient buried St. David's Gorge. Because of very difficult, unpredictable and unstable rock conditions, the TBM has been progressing at forward rate of several meters per day. This unfortunate delay in progress has setback the targeted completion date of this project from 2009 to 2010.
Six shafts from the surface to the tunnel are being drilled near the Whirlpool Road site. Each of these shafts will allow the tunnel to be dewatered using massive mobile water pumps if ever necessary.
On March 5th 2008, Strabag has announced further delays in the Niagara Tunnel Project.
The Tunnel Boring machine (TBM) has been making very slow progress under very unstable rock conditions.
Big Becky might have to chart a new course and revise her schedule to make up for time lost while digging through difficult rock conditions.
Progress on the Niagara Tunnel Project continues to be slower than both Ontario Power Generation and Strabag AG, the Austrian company hired to build the 10.4-kilometre tunnel, expected, officials with both companies say.
"You're dealing with nature. You can't predict the
rock condition for 10 kilometres," said Ernst Gschnitzer, Strabag's project
manager, who oversees the construction of a third hydro tunnel under the city of
Niagara Falls.
What excavators call "overbreak" continues to be the problem, the same situation
that slowed progress last year. Once Big Becky, the nickname for the $35-million
tunnel-boring machine, cuts a portion of the tunnel, loose rock from the ceiling
falls in behind the machine.
The cavities will be filled in to make a smooth surface before the tunnel is
finished, he said. But for now, removing the rock and digging through "unstable"
material is hindering progress.
To compensate for the delays, Strabag wants to alter the alignment of the
tunnel, both vertically and horizontally.
On the south side of the St. David's Gorge, the tunnel will go higher than first
planned. That will allow the excavation to get out of the difficult conditions
and into more predictable rock, said Gschnitzer.
According to the Niagara Peninsula Conservation Authority, the buried St. David's Gorge is
an abandoned channel that has been filled in with a glacial debris including
gravels, sands, tills, silts and clays. The ancient gorge is thought to have
been 116 metres (380 feet) wide and up to 79.25 metres (260 feet) deep. It has been estimated at approximately 22,000 years old.
A portion of the tunnel will also be shifted a bit to the east - or toward the
Niagara River - from its original alignment, which ran approximately underneath
Stanley Avenue.
Strabag has applied for necessary approvals to make that change. The company
expects to hear a decision in a few months, Gschnitzer said. The August 2010
target for completion also needs to be adjusted.
"We hope it won't change that much. It will go into 2011," said Gschnitzer.
Last fall, Ontario Power Generation's board approved August 2010 as the
completion date for the tunnel. When work began in September 2006, Strabag
expected it could complete the work by fall 2009.
OPG says Ontario taxpayers are protected from cost overruns because it gave
Strabag a design-build contract meaning the company agreed to build the tunnel
for a fixed price, said OPG spokesman John Earl. The tunnel work is pegged at
$600 million.
At the beginning of March 2008, the TBM had excavated 1,800 metres of the
10.4-kilometre tunnel.
By December 31st 2007, the TBM had excavated 1,609 metres of the tunnel.
By September 2007, the TBM had excavated 1,350 metres of the tunnel, less than
half the distance Strabag had hoped for at that point.
Once the TBM excavation reaches 2,300 metres (2.3 kilometers), Strabag will be
in a position to reassess how to make up for lost time in the remaining 8.1
kilometres of the tunnel.
STRATA OF THE NIAGARA GORGE CHART
Ontario Power Generation Inc. (“OPG” or the “Company”) reported its financial and operating results for the third quarter and nine months ended September 30, 2007. Net income for the three months ended September 30, 2007 was $113 million compared to net income of $167 million for the same period in 2006. For the nine months ended September 30, 2007, net income was $409 million compared to $509 million for the same period last year.
The report stated in part:
Niagara Tunnel
The Niagara tunnel project will increase the amount of water flowing to existing turbines at OPG’s Sir Adam Beck generating stations in Niagara Falls, allowing the stations to utilize available water more effectively. Upon the completion of the 10.4 km tunnel, the average annual generation from the Sir Adam Beck generating stations is expected to increase by approximately 1.6 TWh.
At September 30, 2007, the tunnel boring machine had advanced 1,028 metres. The progress of the tunnel boring machine by the design-build contractor through a fractured rock formation has been slower than expected. As a result, the contractor’s forecast completion date has been delayed from late 2009.
Considerable uncertainty remains with respect to the schedule until the tunnel boring machine advances sufficiently beyond the St. David’s Gorge to approximately 2,300 metres and establishes consistent tunneling performance. Potential deviation from the original project completion schedule approved by OPG’s Board of Directors of June 2010 will be assessed at that point.
The contract structure puts the onus on the contractor to mitigate schedule delays, including liquidated damages provisions for failure to meet the contractual in-service date. The project is still expected to be completed within the budgeted cost estimate of $985 million.
The capital project expenditures for the three months ended September 30, 2007 were $10 million and life-to-date capital expenditures were $281 million. The project is debt financed through the Ontario Electricity Financial Corporation (“OEFC”).
OPG negotiated an agreement with the OEFC to finance the Niagara Tunnel project for up to $1 billion over the duration of the project. The funding is advanced in the form of 10-year notes, on commercial terms and conditions. Advances under this facility commenced in October 2006, and amounted to $240 million as at September 30, 2007.
Conveyor and Dust Control Building - Niagara Tunnel Project -
August 18th 2007
in order to reduce airborne particulate a dust control structure has been
constructed at the end of the conveyor
The Niagara Tunnel Boring Machine (TBM) will approach the water intake at the International Water Control Dam in a line of approach that follows a path to the river which differs from the existing tunnels (under Dufferin Islands and Rapids Drive).
The TBM will reach the Niagara River by following a path from the Fallsview tourist district and under Niagara Parks Commission land east of the former Toronto Power Station reaching the river west of Dufferin Islands.
The intake complex will consist of a submerged bell-mouth structure in the Niagara River beneath gate #1 of the existing International Water Control Dam and an underwater approach channel excavated in the riverbed. The intake structure will include a portal with space for sectional gates (stop-blocks) for closure of the tunnel when the need to dewater the tunnel is required. The existing weir of the ice acceleration channel extending up river from the control dam will be removed from between gates 3 and 4 and moved further outwards from shore between gates 4 and 5.
September 2007 - a large area 61 meters (200 feet) by 122 meters (400 feet) upriver surrounding gate #1 has been enclosed by a cofferdam consisting of concrete, pile driven sheet of steel, grout and rock. The area has been dewatered and is being prepared for rock blasting. The blasting will enable the construction of a 42 meter (138 feet) deep shaft and shaping of the intake approach to be created in the bedrock. The tunnel boring machine (TBM) will intersect this shaft and end at this location .
An intake structure will be created to allow water to access the new tunnel at a flow rate of approximately 4-7 feet per second (slow enough to prevent a surface vortex) and allow the flow of surface water through the renewed functioning of gate #1.
January 2008 - At the intake area, blasting and excavating of the entrance channel is well underway. To date, the access channel is approximately 122 meters (144 feet) long and approximately 18 meters (60 feet) wide. It is located in the dewatered area located upriver of the Water Control Dam Gate #1.
This channel has been blasted and carved into the
river bedrock consisting primarily of dolostone and limestone. Holes are drilled
into the bedrock and then packed with explosives. The area to be detonated is
covered with thick and heavy blast mats. After ensuring all workers and others
are at a safe distance, the explosives are detonated. The rock debris is then
removed by being loaded onto large trucks and taken a short distance where it is
dumped. The rock is then placed into an onsite rock crusher which reduces the
debris into highway grade stone. At night the crushed stone is trucked from the
construction site to the Queen Elizabeth Highway expansion project currently
underway between the cities of St. Catharines and Niagara Falls.
On average, there have been two explosive detonations daily followed by a
lengthy clearing period. The explosions occur only between the hours of 8 a.m.
and 6 p.m. during weekdays with few exceptions. Each explosion is strictly
controlled to ensure there is no collateral damage to the existing Water Control
Dam Structure and to any nearby residences. There are three seismic devices
strategically located surrounding the blast area to record the strength of each
blast to ensure each is within the acceptable limits set by project engineers.
The depth of this access channel is approximately 30 meters (100 feet) deep and has reached the location of the dam structure. At this location, the access channel is below the level of the dam structure. Work is now being done on the third blasting bench. The entrance hole that is known as the "grout gallery" will not be commenced until later this year.
The Grout Gallery is an underground tunnel that will be bored through the bedrock underneath the Water Control Dam Structure at Gate #1 extending approximately 400 meters (1,312 feet) downriver ending near Dufferin Islands. The tunnel will have a downward slope to end at a maximum depth of approximately 42 meters (138 feet). This tunnel will be approximately 8 meters (26 feet) in diameter and have a flat bottom with arched walls and ceiling. It is at this terminus that the Robbins Company TBM will meet up to the Grout Gallery and end its long journey.
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Upper Niagara River Construction - Niagara Tunnel Project - September 24th 2007
the cofferdam surrounding Water Control Dam gate # 1 has been completed and the area within dewatered. Preparations are underway to begin controlled rock blasting to create a 42 meter deep shaft and to shape the bedrock for the water intake
The concrete tunnel outlet structure will be located will be located at the Sir Adam Beck Pump/Generating Station. The outlet canal will be 350 meters (1148.28 feet) long - 23 meters (75.46 feet) wide and 35 meters (114.83 feet) deep. This new outlet will be connected to the current feeder canal leading to the water reservoir from the hydro feeder canal. A lift type closure gate will permit the new tunnel to be closed in the event of an emergency.
August 2007 - cleanup of the tunnel outlet has begun. The rock walls at starting point of the tunnel boring machine near the tunnel entrance will be scaled and a bell shaped outlet containing a hydraulic steel closure gate will be constructed. The gate will allow the flow of the water to be stopped in the event of an emergency.
An Aerial View of the Sir Adam Beck Generating Stations - Niagara Group
The Starting Location of the Niagara Tunnel Project
The Starting Location of the Niagara Tunnel Project
Preparations are made for the installation of a coffer dam to block gate #1that will become the entrance of the new tunnel. In addition construction includes the removal of the existing ice acceleration weir (extending upriver of the water control dam located between gates #3 ) and a new weir is being built between gates #4 
The International Water Control Dam
The assembly of the Robbins Tunnel Boring
Machine (TBM) at the Niagara Tunnel Project construction site
June 18th 2006
Moving a new crane into place at Upper
Niagara River construction site
July 14th 2006
Building a cofferdam at the former Toronto Power Station
July 19th 2006
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Building a Cofferdam at the former Toronto Power Station
July 19th 2006
Building up the Cofferdam at the former Toronto Power Station
August 1st 2006
Workers on Rock Debris Conveyor Bridge Crossing Hydro Canal
August 13th 2006
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Niagara Tunnel Project
August 13th 2006
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Niagara Tunnel Project
August 13th 2006
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Niagara Tunnel Project
August 13th 2006
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The Chief Operators Control Panel of the Robbins Tunnel Boring Machine
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Construction work at the Niagara Tunnel Project Intake on
Upper Niagara River
August 14th 2006
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Upper River Construction - Niagara Tunnel Project - September 20th 2006
Upper River Construction - Niagara Tunnel Project - December 12th 2006
the new ice acceleration weir has been completed as the cofferdam surrounding Water Control Dam gate # 1 nears completion. Once completed the water within the cofferdam will be drained and blasting for the tunnel inlet will begin in the Fall of 2007
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Tunnel Boring Machine - Niagara Tunnel Project - January 7th 2007
To learn more about the Niagara Tunnel project visit following educational web sites:
Ontario Power Generation Niagara Tunnel Project
Strabag Company's Niagara Tunnel Project
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THANK YOU FOR VISITING THE
ONTARIO POWER GENERATION & STRABAG AG INC.
