CASE STUDY - RESCUE OF CUTTER

FROM PANEL (P-13)

(GREATER CAIRO METRO LINE(4) PHASE (1))
EL Ahram STATION - (ST. 06)

OWNER:
NATIONAL AUTHORITY FOR TUNNEL

CONSULTANT:
ENGINEERING CONSULTANT’S CONSORTIUM

MAIN CONTRACTORS:
AHPC CONSORTIUM

SPECIALIZED CONTRACTOR:
TUNNEL & SLIPFORM DEPARTMENT – THE ARAB CONTRACTORS
 THE ARAB CONTRACTORS
‫الموقع العام‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT

‫محطة األهرام‬ Figure 3-1: Ariel photo for Al-Ahram

station layout

Figure 2-1

The project is the greater Cairo metro line 4, which is considered the best
route to connect 6th of October City with the center of the capital and its

DESCRIPTION
other parties to the metro network and provides passenger trANDport service

PROJECT
and connects it to areas with high population densities in the pyramid, Faisal,
Omraneya and Giza. The Greater Cairo Metro Line 4 shall be
approximately 18.8km in length.

The greater Cairo metro line 4 phase new CP401 consists of 12 stations from
Hadaek El- Ashgar station to El- Mesaha square with 13.60 km in length.
Figure 2-1 shows the tunnel alignment of greater Cairo metro line 4,
including Phase New CP401.
 THE ARAB CONTRACTORS
‫مكونات المشروع‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT

Figure 3-2: Plan view of Al-Ahram station

THE UNDERSTUDY STATION (AL-AHRAM STATION)

overview
PROJECT
The station understudy is Al-Ahram station. Figure 3-1 shows the location
of Al-Ahram station on map. Al-Ahram stations are considered
underground station with dimensions approximately 17.70m x 192.4m X
32m as in Figures 3-1 and 3-2. The station shall be executed by the topdown
method with a permanent diaphragm wall supported with horizontal
slabs as in Figure 3-3.
 THE ARAB CONTRACTORS
‫مكونات المشروع‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT

Figure 3-3: Section view of Al-Ahram station

THE UNDERSTUDY STATION (AL-Ahram STATION)

overview
PROJECT
The station understudy is Al-Ahram station. Figure 3-1 shows the location
of Al-Ahram station on map. Al-Ahram stations are considered
underground station with dimensions approximately 17.70m x 192.4m X
32m as in Figures 3-1 and 3-2. The station shall be executed by the topdown
method with a permanent diaphragm wall supported with horizontal
slabs as in Figure 3-3.
 THE ARAB CONTRACTORS
‫مكونات المشروع‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT

Figure 3-4: Section of the diaphragm wall with slabs at Al-Ahram station
(Top- down construction method)

THE UNDERSTUDY STATION (AL-Ahram STATION)

overview
PROJECT
The station understudy is Al-Ahram station. Figure 3-1 shows the location
of Al-Ahram station on map. Al-Ahram stations are considered
underground station with dimensions approximately 17.70m x 192.4m X
32m as in Figures 3-1 and 3-2. The station shall be executed by the topdown
method with a permanent diaphragm wall supported with horizontal
slabs as in Figure 3-3.
TUNNELS AND SLIPFORMS DEPARTMENT
SCOPE
 THE ARAB CONTRACTORS
‫نطاق العمل‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
 THE ARAB CONTRACTORS
‫نطاق العمل‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
 THE ARAB CONTRACTORS
‫نطاق العمل‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
 THE ARAB CONTRACTORS
‫الجدول الزمني للمشروع‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT

CRITICAL
PANEL
 THE ARAB CONTRACTORS
‫نطاق العمل‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
REFERENCE GEOTECHNICAL DATA
 THE ARAB CONTRACTORS
‫تقرير التربة‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT

Figure 6-1: Geological section of soil at Al-Ahram station

GEOTECHNICAL
The geotechnical data needed as a reference in the execution of the diaphragm
works at Al- Ahram station is concluded from the tender document volume 6. The

DATA
reference geotechnical data shall be the performed boreholes and the idealized soil
parameters. Figure 6-1 shows the geological sections of the soil at Al-Ahram
station. The logs for the two preformed boreholes BHDD27-BH65 are in Annex A.
 BC 40
SchlitzwandfräseTrench Cutter
 THE ARAB CONTRACTORS
‫أجزاء الماكينة‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
 THE ARAB CONTRACTORS
‫أجزاء الماكينة‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
 THE ARAB CONTRACTORS
‫أجزاء الماكينة‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
 THE ARAB CONTRACTORS
‫أجزاء الماكينة‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
 THE ARAB CONTRACTORS
‫أجزاء الماكينة‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
 THE ARAB CONTRACTORS
‫أجزاء الماكينة‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
 THE ARAB CONTRACTORS
‫أجزاء الماكينة‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
PROCEDURES OF EXECUTION
(Diaphram walls and slurry walls)
 THE ARAB CONTRACTORS
‫خطوات التنفيذ التفصيلية‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
 THE ARAB CONTRACTORS
‫خطوات التنفيذ التفصيلية‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
 THE ARAB CONTRACTORS
‫خطوات التنفيذ التفصيلية‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
 THE ARAB CONTRACTORS
‫ملخص مراحل التنفيذ‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
PROBLEM OCCURRENCE
(2021/11/09)
 THE ARAB CONTRACTORS
‫بداية المشكلة‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT

THE MAIN PROPLEM

DURING EXCAVATION WORKS IN PANEL (13) IN (2021/11/09) AT (15:23) ,THE DESANDER UNIT STOPPED
WORKING AND THE CUTTER OF THE MACHINE STUCK BENEATH THE SOIL LAYERS AT THE DEPTH OF
(43 M) AND THE CABLES OF THE MACHINE WAS UNABLE TO LIFT THE CUTTER FROM THE SOIL .
 THE ARAB CONTRACTORS
‫أسباب المشكلة‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT

REASON OF THE PROPLEM

• The excavation was on faster rates than the ordinary rates.

• The machine cut 43 meters in 2 hours giving a highly amount of excavated materials.
• The excavation rate was (35 cm\minute) and the ordinary rate for the excavation is (15 cm\minute)
• The distance (43m) to be cut on ordinary rate would have taken 4.5 hour
• This leads the suction system into Failure and has stopped working , and the cutter was trapped.

The normal Rate screen

 THE ARAB CONTRACTORS
‫المحاولة األولى إلنقاذ القاطع‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT

Explanation of 1st trial

Steps of Rescue.
1. Move main hydrofraise away from the
trench, so rescue one can be vertical to the
panel
2. Make rescue panel Infront of the main
panel using secondary hydrofraise till depth
= 50 meter from current ground level .(as-
shown in drawings)
3. Remove the Cutter of secondary hydrofraise
& install air lift pipe ,through main panel
and start to pump air through the air lifter
4. Any filled soil above cutter shall be moved
to the rescue panel, Meanwhile the main
hydrofraise lift up the Stuck cutter from the
panel smoothly (low rate)
5. After lifting cutter & air lift pipe, the two
panels shall be concreting using sand
immediately .
 THE ARAB CONTRACTORS
‫نتائج المحاولة األولى‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT

Results of 1st trial

1. The cutter was still stuck between soil

layers
2. The cables unable to lift the cutter due to
the Heavy loads of Soil combined with
Cutter
3. Study an alternate method (2nd trial)
 THE ARAB CONTRACTORS
‫المحاولة الثانية إلنقاذ القاطع‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT

Explanation of 2nd trial

Steps of Rescue.
1. Move the main hydrofraise away from the
trench, so the rescue one can be vertical to
the main panel
2. Make excavation for two rescue panels at the
two sides using secondary hydrofraise till
depth = 50 meter from current ground level .
3. Install air lift pipe through the main panel
and start to pump air through the air lifter
4. Any filled soil layers above the cutter shall be
removed to the rescue panel, Meanwhile the
main hydrofraise lift the trapped cutter from
the panel smoothly (low rate)
5. After lifting cutter & air lift pipe, the three
panels shall be concreting using stabilized
sand immediately .
 THE ARAB CONTRACTORS
‫نتائج المحاولة الثانية‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT

Results of 2nd trial

1. The cutter was still stuck between soil layers

2. The cables of the fraise unable to lift the
cutter due to the Heavy loads of Soil
combined with Cutter
3. Study an alternate method (3rd trial)
 THE ARAB CONTRACTORS
‫المحاولة الثالثة إلنقاذ القاطع‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT

Explanation of 3rd trial

Steps of Rescue.

1. Using Expert Divers in this trial in order to dive

through the rescue panels
2. The Divers Attach the Cable wires from the
Crawler Crane to the Cutter (recovering eyes).
3. Lift up the cutter using the hydrofraise and
Crawler Crane Cables to give an additional
Lifting Power.
 THE ARAB CONTRACTORS
‫نتائج المحاولة الثالثة‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT

Results of 3rd trial

1. The suction pump and the cable wire that carry

the cutter damaged during the process .
2. the cutter still stuck underneath the soil layers
without any movement.
3. Failure of lifting up the Cutter using Crawler
Crane
 THE ARAB CONTRACTORS
‫المحاولة النهائية إلنقاذ القاطع‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT

Explanation of 4th trial

Steps of Rescue.
1. Evacuate the Road surrounding the panel
for (6 hours period).
2. Start the excavation works for the new
rescue panel behind the main panel
3. Install the new frame to lift the cutter at
the center of the main panel
4. Start the process of lifting the stuck cutter
using the hydrofraise and the Cable wires
attached to the crawler crane which
installed by Divers and the additional
installed Truss frame.
 THE ARAB CONTRACTORS
‫الرسومات التنفيذية للهيكل المعدنى‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT

ELEVATION - VIEW

SIDE-VIEW
TOP-VIEW
 THE ARAB CONTRACTORS
‫نتائج المحاولة النهائية‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT

Results of 4th trial

The method Managed to lift the cutter up from the soil layers successfully IN (2022 / 1 / 3)
PROCEDURES OF FINAL TRIAL
 THE ARAB CONTRACTORS
‫اجراءات إخالء الطريق‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
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‫تصنيع الهيكل المعدنى بالورش‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
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‫نقل الهيكل المعدنى الى الموقع‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
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‫تركيب الهيكل المعدنى بالموقع‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
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‫عملية تحضير معدات الغطس و التأكد من األمن و السالمة‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
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‫عملية إنزال الغطاسين‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
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‫عملية إنزال الغطاسين‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
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‫عملية إنزال الغطاسين‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
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‫تجهيز المعدات لعملية السحب‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
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‫أثناء عملية السحب‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
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‫بداية ظهور القاطع أثناء عملية السحب‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
 THE ARAB CONTRACTORS
)2022-01-03( ‫خروج الجسم الكلى للقاطع‬ OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
 THE ARAB CONTRACTORS
OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT
 ‫‪THE ARAB CONTRACTORS‬‬
‫‪OSMAN AHMED OSMAN & CO.‬‬
‫‪TUNNELS AND SLIPFORMS DEPARTMENT‬‬

‫إعداد‬
‫الوحدة الھندسية بإدارة األنفاق و الشدات المنزلقة‬
‫‪ENGINEERING UNIT - TUNNEL & SLIPFORM DEPARTMENT‬‬

‫نائب مدير االدارة ‪-:‬‬ ‫مدير االدارة ‪-:‬‬

‫م – إيمان فاروق فهمي‬ ‫م – محمد إبراهيم فودة‬

‫‪ENG – EMAN F . FAHMY‬‬ ‫‪ENG – MOHAMED E . FOUDA‬‬

‫مهندسي االعداد ‪-:‬‬ ‫مدير الوحدة الهندسية ‪-:‬‬

‫) ‪(ENG – AYMAN M. GAMIL‬‬ ‫م – أيمن محمد جميل‬ ‫م – أحمد عادل ناصر‬

‫م – محمد نبيل عبد الفتاح )‪(ENG – MOHAMED NABIL‬‬ ‫‪ENG – AHMED A . NASSER‬‬
 THE ARAB CONTRACTORS
OSMAN AHMED OSMAN & CO.
TUNNELS AND SLIPFORMS DEPARTMENT

Thank you