The Twinning of West Trunk Sewer

Contract 2
Region of Peel, Ontario Canada
Andrew G. Cushing, P.Eng.
Andrew.Cushing@arup.com

Senior Geotechnical & Tunneling Engineer | Arup | Toronto, Ontario Canada

July 22, 2021

3 – 4 PM ET

Tunnel Association of Canada

 Presentation Outline
• Project Participants
• Alignment Summary
• Microbial Induced Corrosion (MIC) of Sewers
- Mechanisms & Factors
- Concrete Resistance / Concrete Protection Methods

• Concrete Protective Liner (CPL) – Combisegments® by Herrenknecht

• PCTL Lining Details – Steel Fiber Reinforced Concrete (SFRC)
• Georgian Bay Shale Parameters – Time Dependent Deformation (TDD)
• Development and use of compressible grout to mitigate TDD effect in rock
• PCTL Structural Analysis Results
• Acknowledgements

2 Twinning of West Trunk Sewer CC No. 2

 The Twinning of West Trunk Sewer – Contract 2
• Location: City of Mississauga, Ontario Canada
• Owner: Region of Peel
• Owner’s Designer: WSP
• Owner’s Geotechnical Engineer: Golder Associates
• Tunnel Contractor: Technicore Underground
• Contractor’s PCTL Designer: Arup
• SFRC & Compressible Grout Mix: TecMix (Technicore Group)
• Segment Precaster: Ewing Fabricators (Technicore Group)
• Forms & Protective System: Combisegments® by Herrenknecht
• PCTL Inner HDPE Liner: Sure-Grip® by AGRU America

3 Twinning of West Trunk Sewer CC No. 2

 The Twinning of West Trunk Sewer – Contract 2

(Source: Golder Associates)

• Construction of new sewer along Erin Mills Parkway to twin existing trunk sewer
• Starts at NW corner Erin Mills & Burnhamthorpe Rd., south under Erin Mills
• Turns east under Lincoln Green Way (and Close)
• Connects to existing West Trunk Sewer at east side of Loyalist Creek

4 Twinning of West Trunk Sewer CC No. 2

 The Twinning of West Trunk Sewer – Contract 2

• CC2: 3800m length of 3m (ID) tunneling – 80% Rock, 20% Soft Ground
• Each of two drives (two TBMs) had known Soft Ground → PCTL Required

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 The Twinning of West Trunk Sewer – Contract 2

• Known buried valley segment comprised primarily of sand and clayey silt to silty clay

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 Microbially Induced Corrosion (MIC) in a Sewer
• Microbially Induced Corrosion (MIC) Process Above Waterline:
- Hydrogen Sulfide (Gas) + Condensing Moisture → Sulfuric Acid
- H2S + O2 → H2SO4
- Occurs under the reaction of Sulphur Oxidizing Bacteria (SOB) – i.e.,
Thiobacillus
- Sulfuric Acid (H2SO4) reduces the pH of the concrete surface (above waterline)
to 1 to 2.
- Concrete hydration products (portlandite, calcium aluminate hydrate, ettringite
and calcium silica hydrate) dissolve when the pH of solution drops from 12.5 to
8.8 or below.
- H2S concentration as low as 2 PPM known to cause severe acid corrosion
- MIC corrosion rate of concrete can be as high as 12mm per year.

(Source: Wu, L. et al. (2018). The Sustainability of Concrete in Sewer Tunnel—A Narrative Review
of Acid Corrosion in the City of Edmonton, Canada, Sustainability, 24 p.)

7 Twinning of West Trunk Sewer CC No. 2

 Schematic of Microbially Induced Corrosion (MIC)
in a Sewer

(Source: Wu, L. et al. (2018). The Sustainability of Concrete in Sewer Tunnel—A Narrative Review
of Acid Corrosion in the City of Edmonton, Canada, Sustainability, 24 p.)

8 Twinning of West Trunk Sewer CC No. 2

 Factors which increase the MIC rate in sewers

• High Relative Humidity (RH)

• Low Dissolved Oxygen (DO)
• High Biological Oxygen Demand (BOD)
• High Temperature
• Low Flow Velocity / High Retention Time
• High Turbulence
• Low pH
• High Concrete Porosity / Permeability

(Source: Wu, L. et al. (2018). The Sustainability of Concrete in Sewer Tunnel—A Narrative Review
of Acid Corrosion in the City of Edmonton, Canada, Sustainability, 24 p.)

9 Twinning of West Trunk Sewer CC No. 2

 Summary of Factors Affecting MIC Rate

(Source: Wu, L. et al. (2018). The Sustainability of Concrete in Sewer Tunnel—A Narrative Review
of Acid Corrosion in the City of Edmonton, Canada, Sustainability, 24 p.)

10 Twinning of West Trunk Sewer CC No. 2

Improvements in Concrete Mix Design to Resist MIC
• Acid corrosion of cement-based concrete is unavoidable because such concrete is alkaline
in nature, but certain additives can be used to increase MIC resistance:

• Pozzolans: i.e., granulated blast furnace slag, silica fume, low calcium fly ash, etc.
- Consume calcium hydrate Ca(OH)2, which is believed to be the primary reason for the
poor acid resistance of plain concrete
- Act to reduce the porosity of concrete (reduced penetration of aggressive ions)

• GeoPolymer Concrete
- Complete replacement of Portland cement component with Pozzolans (as above) and
proprietary geopolymer binder system
- Hardened product is an aluminosilicate

(Source: Wu, L. et al. (2018). The Sustainability of Concrete in Sewer Tunnel—A Narrative Review
of Acid Corrosion in the City of Edmonton, Canada, Sustainability, 24 p.)
11 Twinning of West Trunk Sewer CC No. 2
Improvements in Concrete Mix Design to Resist MIC
• Biocides: i.e., Conshield®
- Highly charged cationic polymer that kills the gram-negative SOB Thiobacillus on a
concrete surface.
- Inhibits the conversion of H2S into Sulfuric Acid, and hence inhibits MIC.
- However, the cationic polymer is consumptive over time, and the SOB may finally
colonize the concrete surface when it is depleted.

• Calcium Aluminate Cements

- Used as a protective liner against microbial induced corrosion in sewer infrastructure
- Precast concrete pipes can be made either with full mass calcium aluminate cement
concrete or with an internal liner of calcium aluminate cement mortar
- Internal lining in ductile iron pipe
- Can be used as a second pass (double shell) lining for either new construction or as a
remedial measure

12 Twinning of West Trunk Sewer CC No. 2

 Sliplining with GFRP (i.e., Hobas®) Pipe

(Source: Water & Wastes Digest - https://www.wwdmag.com/pipe/protect-humber-river )

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 Concrete Protective Liner (CPL) – Precast Pipe

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 Concrete Protective Liner (CPL) – Double Shell

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 Concrete Corrosion Protection Systems

(Source: Hurt, J. and Hart, J. (2011) – Chapter 3 Precast Concrete Segmental Linings in Concrete for
Underground Structures, Society for Mining, Metallurgy, and Exploration, p. 48.)

16 Twinning of West Trunk Sewer CC No. 2

 The Twinning of West Trunk Sewer – Contract 2
• Requirement for Corrosion Protection was established by the Region of Peel
and their designer WSP
• Original Contract 2 called for two sections of higher turbulence to be protected
with HDPE Concrete Protective Liners (CPL)
- 150m between MH4 & MH5 – To be constructed by EPBM with Segmental
Lining – method of CPL installation left to contractor
- 100m between MH2 & MH4 – To be constructed by open TBM, with initial
support and CPL incorporated into secondary lining
• Technicore proposed using single pass EPBM PCTL lining system for entire
250m length, with the CPL cast integral with the segments
• First use of Combisegments® (by Herrenknecht) in North America (Sure-
Grip® HDPE liner by Agru)

17 Twinning of West Trunk Sewer CC No. 2

 HERRENKNECHT COMBISEGMENTS®

18 Twinning of West Trunk Sewer CC No. 2

 HERRENKNECHT COMBISEGMENTS®

Socket for handling

and fastening

EPDM gasket
integrated in the
frame

HDPE liner 2 to 5
mm thick with
anchor studs

19 Twinning of West Trunk Sewer CC No. 2

 HERRENKNECHT COMBISEGMENTS® - AGRU SureGrip® HDPE
Liner

5 mm

• AGRU SureGrip® HDPE Concrete

Protective Liner (CPL)
• Thickness according to project
requirements
• Different colours available
• Signal layer can be extruded

2.5 mm

20 Twinning of West Trunk Sewer CC No. 2

 HERRENKNECHT COMBISEGMENTS®

PDCPD
Plastic EPDM
Gasket

AGRU SureGrip®
HDPE Liner

21 Twinning of West Trunk Sewer CC No. 2

 HERRENKNECHT COMBISEGMENTS®

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 Gasket Configuration Between Combisegments
and at Transition Without

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 Radial Joint Detail

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 HERRENKNECHT COMBISEGMENTS® - Interface Bond Testing

Test of the
bonding
between
HDPE and
PDCPE

25 Twinning of West Trunk Sewer CC No. 2

 HERRENKNECHT COMBISEGMENTS® - Interface Bond Testing

26 Twinning of West Trunk Sewer CC No. 2

 HERRENKNECHT COMBISEGMENTS® - Backpressure Testing

 1,000 h static pressure: 1.5 bar

 Afterwards: Load increase in steps up to 6 bar

(each step 30 min.)

27 Twinning of West Trunk Sewer CC No. 2

 HERRENKNECHT COMBISEGMENTS® - Trial Ring Erection

28 Twinning of West Trunk Sewer CC No. 2

 HERRENKNECHT COMBISEGMENTS® - Casting Yard (Ewing Fab.)

29 Twinning of West Trunk Sewer CC No. 2

 HERRENKNECHT COMBISEGMENTS® - PCTL in place

30 Twinning of West Trunk Sewer CC No. 2

 HERRENKNECHT COMBISEGMENTS® - PCTL in place

31 Twinning of West Trunk Sewer CC No. 2

 SFRC PCTL Lining Details
• Internal Diameter: 3000mm Thickness: 200mm
• PCTL Configuration: 4 + 2
• Concrete Compressive Strength: 50 MPa
• Concrete Splitting (Tensile) Strength: 4 MPa
• Concrete Peak Bending Strength f’1: 4.1 MPa (ASTM C1609)
- Average from testing of  6 MPa
• Concrete Residual Bending Strength f’D150: 3.5 MPa (ASTM C1609)
- Average from testing of  5 MPa
• Steel Fibers: Lmin = 50mm; Min. Aspect Ratio 50:1; 1035 MPa.
• Target Fiber Dosage: 40 kg/m3
• Bolts: None (not possible with use of Combisegments®)
• Guide Rods: Yes
32 Twinning of West Trunk Sewer CC No. 2
 Rock Swell TDD Test Data – Georgian Bay Shale
1.4
Horizontal
1.2
Vertical
Swelling Strain (%/Log Time)

Log. (Horizontal)
1.0
Log. (Vertical)
0.8

0.6

0.4

0.2

0.0
0.001 0.01 0.1 1 10
Stress (MPa)

Time Dependent Deformation (TDD) Test data by Prof. K.Y. Lo (University of Western Ontario)

33 Twinning of West Trunk Sewer CC No. 2

 Rock Swell & Stress Data – Georgian Bay Shale
• Baseline Free Swell Strain Rates (per Log time): 0.05 - 0.5% (H); 0.1 - 2.5% (V)
• Swelling Suppression Stresses: 300 kPa (H), 1.8 MPa (V)
• Baseline In-Situ Horizontal Stress Values (No Site-Specific Data Available):
- Major Direction: 6 to 12 MPa
- Minor Direction: 2 to 9 MPa

34 Twinning of West Trunk Sewer CC No. 2

 PCTL Analysis Sections
• Section 1: Deepest Overburden Valley
• Section 2: Shallowest Overburden Valley
• Section 3: Deepest Rock
• Section 4: Shallowest Rock
• Section 5: Mixed Face Condition
Section 1 2 3 4 5

Station 3+500 0+030 0+700 1+900 0+100

Ground Surface (Boring Log) +148 +98 +132 +133 +114

Highest GWT +145.5 (GDR) +94 (GBR) +131 (GBR) +118 (GDR) +108
(Interpolated)
Lowest GWT (3.5m below 142 90.5 127.5 114.5 104.5
high)

Top of Rock (Drill Log) +98.41 Below the +129.55 +130 +92.6
tunnel
Springline (3.4m- O.D.) +126.7 +91.7 +93.2 +123.5 +91.8

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 PCTL Analysis – Rock Properties
Rock properties Poor Quality Good Quality Average
Elastic
Elastic modulus, Intact Rock Erock (MPa) 1000 3700 3700
Elastic rock mass modulus, Emass (MPa) 250 2000 2000
Intact Rock Poisson’s ratio, n 0.15
Unit Weight (kN/m3) 25
Additional Props for M-C
Rock Mass Friction Angle, Phi (deg) 22 32 29
Rock Mass Cohesion (kPa) 225 3500 1150
UCS (MPa) 9 35 23
Tensile Strength, (MPa) 0.15 0.15 0.15
Time-dependent swelling
Threshold stress, sth (MPa) 0.001
Ratio of Critical stress to sx0 Varies
Vertical Critical stress, scy (MPa) 1.8
Reference time, t0 (days) 10
Pseudo-Poisson’s ratio, mu 0.6
Free swelling potentials (%/log time)
mx(0) 0.35 0.25 0.25
my(0) 1.3 0.8 0.8
mz(0) 0.35 0.25 0.25
Ground Relaxation Ratio (%) 100% From RocSupport

GSI 30 80 60
mi 6(+-)2 for Shale, 9(+-)3 for Dolomite

36 Twinning of West Trunk Sewer CC No. 2

 PCTL Analysis in Rock
• 100-year swelling analysis performed using Swello® module in FLAC
• The case with the highest difference between the two horizontal in-situ stresses
– 12 MPa in the plane of the tunnel and 2 MPa parallel to the tunnel (GBR
Baseline Range) was the most critical.
• 12 MPa much higher than typical value of 4 MPa.
• Compressible grout required if in situ horizontal stress in excess of 6 MPa
• The addition of external water pressure to the lining at the end of the analysis is
a beneficial load, so the lowest possible water table should be used (3.5m below
the GBR levels).

37 Twinning of West Trunk Sewer CC No. 2

 Compressible Annular Grout to Reduce TDD Effect
• Compressible Grout Mix Developed by TecMix (Technicore) with cooperation
with BASF, with testing at Queen’s University
• Canadian Patent No. 2975614 (A1) – by Mr. Tony DiMillo (TecMix) -
Compressible Grout Mix for Use in Absorbing Compressive or Deformation
Stresses of Subterranean Formations
• Constituents include:
- Hydraulic Binding Agent
- Bentonite Clay
- Polymer Foam Particles
- Water Reducing Admixture
- Water
- Air
• See also Thomas Lardner’s Ph.D. Thesis (2019, U. Western Ontario) – Chapter
4 – Investigation of Swell Mitigating Material

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 Compressible Annular Grout to Reduce TDD Effect

Ei = 250 MPa

Ei = 50 MPa

(Source: Hurt, J., et al. (2017) Innovations on West Trunk Sewer Contract 2, RETC, pp. 989-998.)

39 Twinning of West Trunk Sewer CC No. 2

 Compressible Annular Grout to Reduce TDD Effect

(Source: Hurt, J., et al. (2017) Innovations on West Trunk Sewer Contract 2, RETC, pp. 989-998.)

40 Twinning of West Trunk Sewer CC No. 2

 PCTL Thrust-Moment Diagram with Compressible
6000
Grout Thrust - Moment Diagram
SFRC(ACI 544) for 200mm section
SRFC(ACI 544) for thinner Section (175mm)
after 100 years + GWP FLAC_3A
FLAC_3B
5000 FLAC_4A
FLAC_4B
FLAC_5A

4000
Hoop Thrust (kN/m)

3000

2000

1000

0
0 20 40 60 80 100 120 140 160

Bending Moment (kN-m/m)

-1000

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 Acknowledgements
• Region of Peel
- Anthony Parente, Andrea Pitura, and Ajay Puri
• Technicore Group of Companies
- Tony DiMillo, Vanessa DiMillo, and Michael MacFarlane
• Herrenknecht
- Stefan Medel, Steffen Dube, and Jörg Riechers
• Agru America
• David R. Klug & Associates
• Arup
- Jon Hurt, John Kuyt, Nishal Rao, Michael Dutton, & Andreas Raedle
• Tunnel Association of Canada
- Michael Dutton and Wayne Gibson

42 Twinning of West Trunk Sewer CC No. 2

 HERRENKNECHT COMBISEGMENTS® - PCTL in place

43 Twinning of West Trunk Sewer CC No. 2