Projects

Following are descriptions of my work on a few of the more than 100 tunneling projects I have been involved with over the years.   

ALTO MAIPO HYDROELECTRIC PROJECT - Alto Maipo, Chile

Details: The project employes four hard rock tunnel boring machines (TBMs), two Herrenknecht and two Robbins TBMs, ranging in diameter from 4.1 to 6.9 m. I was initially engaged by the project owner to assist the owner's engineers with monitoring and improving TBM performance on the project.  I am now employed as an expert witness for the owners, working with their attorneys and other expert witnesses in a dispute with one of the contractors.

SR99 HIGHWAY TUNNEL - Seattle, WA USA

Details: The SR99 tunnel was excavated by a 17.45 m diameter Earth Pressure Balance Machine (EPBM).  At the time it was purchased, it was the largest TBM in the world.  I was retained by the TBM manufacturerer, Hitachi Zosen, to assist with various aspects of machine design and operation review, as well as root cause failure analysis.  I am now working as an expert witness in a legal dispute between the project owners, the contractors and other parties.  I am working in coordination with Hitachi Zosen's attorneys and other expert witnesses.

KEMANO COMPLETION PROJECT - British Colombia, Canada

Details: I was retained by the project owners, Rio Tinto, to work with their team as a TBM subject matter expert to review the technical equipment specifications, construction methods, sequences and schedules contained in the tenders made by the two pre-qualified contractors.  I participated with the owners and their engineers to create a comprehensive risk register.  I worked with the team and the selected contractor to review the technical specifications of the hard rock Herrenknecht single shield TBM, and attended the first design review meeting at Herrenknecht's factory.

PANDO HYDROELECTRIC PROJECT - Volcán, Panama

Details: The project employed two shielded Lovat EPBMs to excavate tunnels for 52 MW and 32 MW, run of river hydroelectric plants.  The schemes are sequentially located on the same river. One of the TBMs completed its tunnel without undue issue.  After much delay, the other machine was removed from the tunnel before the tunnel was completed and the contractor removed from the project.  I was retained by the owner of the project to provide a report on the probable root cause for the TBM and contractor's failure to complete the tunnel.

CATERPILLAR TUNNELING (LOVAT) - Toronto, Canada

Details: A USA based contractor made a claim against Caterpillar for damages due poor performance of the contractor's TBM on a project.  Caterpillar felt the claim was frivolous in that Caterpillar had only provided a few parts to the contractor, per the contractor's specifications, and that the TBM in question was not a Caterpillar TBM nor had it been rebuilt by Caterpillar.  Caterpillar retained my services to provide expert testimony regarding TBM design, performance, performance estimating, rebuilding practices, as well as disc cutter performance and cost estimating.

LOCKBOURNE INTERMODAL EXTENSION - Columbus, OH, USA

Details: I was retained as a third party, independent consulting engineer, as required by the project owner, to review and report on the design of the TBM main bearing and articulation seal systems.  I reviewed the designs for fit, finish, materials, lubrication systems, sub-supplier experience, etc.  The review resulted in some small modifications to the originally proposed design.

PARRAMATTA RAIL LINK - Sydney, Australia 

Details: The project required two, 7.2 m diameter, hard rock tunnel boring machines with a unique backup system design that allowed pouring of a concrete road bed as the machines advanced, all while being serviced by rubber tired vehicles (RTV's or MSV's).  I was personally responsible to liaise with the contractor during the design and manufacture phase, with the machines being manufactured in Newcastle, Australia.  I led the site assembly effort of the two TBMs and five conveyor systems, in coordination with the contractor, as well as commissioning and startup of all equipment.  The machines set a world record for production. 

CHATTAHOOCHEE SEWER TUNNELS - Atlanta, Georgia, USA 

Details: The project required two, 5.6 m diameter, hard rock tunnel boring machines, boring through primarily very hard granite.  I was the liaison with the contractor throughout the design, manufacture, delivery, commissioning and operation of the TBMs.  I was on the job site for a few days per month, working with the contractor to maximize machine performance and resolve any claims or conflicts. 

KARGI HYDROELECTRIC PROJECT - Turkey 

Details: I was responsible for the modification and refurbishment of this 10 m diameter, double shield TBM.  The machine was modified and refurbished in Spain and the USA.  I managed the transportation of the machine to the job site.  I coordinated with the job site field service personnel to assist in the on-site, first time assembly of the machine and its commissioning. 

SVARTISEN HYDROELECTRIC PROJECT - Arctic, Norway 

Details: This project employed five Robbins hard rock TBMs, from 3.5 m to 10 m diameter, for an enormous hydroelectric project.  I was on site for the commissioning and launch of the two, first-ever, Robbins High Performance TBMs fitted with 19 inch cutters (Robbins' HP-TBMs).  I stayed on the jobsite for several months at the startup working with the contractor and Robbins engineers and service personnel to maximize performance of the TBMs and the new 19 inch cutters. 

ENGLISH CHANNEL - FRENCH SIDE UNDERSEA TUNNELS - Sangatte, France 

Details:  I was the on-site mechanical engineer on the French side of the project, supporting the 100% Robbins service tunnel machine as well as the 50/50% Robbins-Kawasaki running tunnel machines.  The machines were Earth Pressure Balance machines, boring primarily through chalk, with water pressures at times reaching as high as 8 bar.