An Overview of TBM Tunnelling in Turkey and

An Overview of TBM Tunnelling in Turkey and Middle East Özgür Savaş Özüdoğru E-Berk Tunnelling & Foundation Tech. 21. 08. 2012 Colorado School of Mines

CONTENTS • • • A quick overview of E-Berk Project details in Turkey Upcoming projects in Turkey Project details in the Middle East Selected planned major tunnelling projects in the M. E. • Selected major tunnelling projects under way in the M. E. • Conclusion

A Quick Overview of E-Berk • Founded in 2002 as subsidiary of Ozudogru Group of Companies. • Located in Ankara with 8000 m² manufacturing and heat treating closed facility. • Offices are located in Istanbul, England Qatar (from October 2012). • All kind of TBM cutters has been producing such as cutter ring, single and double disc cutter, ripper, bucket, knife and any kind of cutter with tungsten carbide. • Cutterhead modification, TBM overhaul and site assembly. • 20 projects has been finished in Turkey and exports increased to 12 different countries such as Russia, Poland, India, Bulgaria, Saudi Arabia, Azerbaijan, Australia, Israel, and so on.

Metro transportation is an indispensible issue for solving traffic problem for metropolitan areas. Therefore, every year metropolitan municipalities spend a lot of money for metro tunnel construction from their budget. For example, Istanbul Metropolitan Municipality (IMM) has been spending approximately 45 % of its investment budget for metro and transportation projects in last year's.

Depending on the ratio of the population of human beings, clean water supply and waste water disposal projects is becoming more importance. Within this scope, General Directorate of State Hydraulic Works has also been spending approximately 20 % of its investment budget which is about 1 billion USD to clean and waste water tunnel project.

PROJECT DETAILS IN TURKEY

ANADOLU RAY – Kadikoy Kartal Metro Project Location: İstanbul, TURKEY Contractor: YAPI MERKEZI-DOGUSYUKSEL-YENIGUN Joint Venture Lenght of Tunnel: 12331 m Type of TBM: Herrenknecht EPB Diameter of TBM: 6, 57 m Number of Cutter Disc in Cutterhead: 26 single cutter disc 6 double cutter disc Ground Condition: Clay, sand, gravel deposit, shale, limestone, fault Single Disc Cutter Ring Hub Shaft Twin Disc Cutter Cutting Knife

DSI Blue Tunnel Project (Turkish Republic Ministry of Environment and Forestry) Location: Konya, Turkey Contractor: İLCİ Joint Venture Lenght of Tunnel: 17034 m Type of TBM: SELI Double Shield Diameter of TBM: 4, 2 m Removable Twin Disc Single. Disc Scraper Support Wedge Type

ISKI Istanbul European Side 2 nd Part Waste Water Tunnel Project Location: Silivri- İstanbul, Turkey Contractor: NAS INS. Lenght of Tunnel: 8674 m Type of TBM: Herrenknecht EPB Diameter of TBM: 3, 82 m Double Disc Scraper Knife Cutter Bucket Housing Chisel Single Disc Cutter

ISKI Istanbul European Side 3 th Part Sea Water Tunnel Project Location: Cayırbasi Ayazaga, Turkey Contractor: DEPAR INS. Lenght of Tunnel: 5000 m Type of TBM: Herrenknecht Hardrock TBM Diameter of TBM: 3120 m Over Cutter Scraper Bucket Disc Cutter Bucket

ISKI İstanbul European Side 4 th Part Waste Water Tunnel Project Location: Istanbul European Side İLCİ OZGUN Joint Venture Lenght of Tunnel: 9254 m Type of TBM: Herrenknecht EPB Diameter of TBM: 4, 6 m Twin Ripper Twin Disc Double Disc TBM Backup Equipments Knife Cutter

Istanbul BASAKSEHIR-IKITELLI Metro Project Location: Istanbul GULERMAK-DOGUS Joint Venture Lenght of Tunnel: 5350 m Type of TBM: 2 LOVAT EPB, 1 Herrenknecht EPB Diameter of TBM: Each 6. 5 m Twin Ripper Twin Disc Cutter Single Disc TBM Backup Equipments Knife

General layout of ongoing metro projects in Istanbul

Istanbul OTOGAR-KIRAZLI Metro Project Location: Istanbul GULERMAK-DOGUS Joint Venture Lenght of Tunnel: 5500 m Type of TBM: 1 Herrenknecht EPB 1 Lovat EPB Diameter of TBM: Each 6. 5 m Twin Ripper Twin Disc Cutter Single Disc TBM Backup Equipments Knife

Istanbul MARMARAY Project Location: Istanbul TAISEI-GAMA-NUROL Joint Venture Lenght of Tunnel: 9360 m Type of TBM: 2 HITACHI ZOHEN, 1 JTSC EPB Diameter of TBM: Each 7. 0 m Single Disc Type 1 Single Disc Type 2

MELEN Project - Istanbul Location: Istanbul, Mosmetrostroy, Engeocom, Alke and STFA Joint Venture Lenght of Tunnel: 5500 m Type of TBM: Herrenknecht EPB Diameter of TBM: 6. 15 m Twin Disc Cutter Single Disc Scraper Bucket

Istanbul-Ankara High Speed Rail Project, Kosekoy Tunnel Location: Bilecik-Kosekoy, Cengiz, Ictas, Belen Joint Venture Lenght of Tunnel: 6100 m Type of TBM: Herrenknecht Single Shiled Diameter of TBM: 13. 77 m Double Disc Scraper Knife Cutter Bucket Housing Twin Disc Single Disc Cutter

ANKARA WATER II. MERHALE PROJECT-GEREDE Location: Gerede, Kolin Limak Joint Venture Lenght of Tunnel: 31600 m Type of TBM: 3 Herrenknecht Double Shiled Diameter of TBM: 5. 40 m Twin Disc Cutter Bucket Single Disc Cutter

ISTANBUL METRO PROJECT, USKUDAR-UMRANIYE Location: Istanbul, Dogus Const. Lenght of Tunnel: 22100 m by TBMs, 18700 m by NATM Type of TBM: 3 Herrenknecht Double Shiled Diameter of TBM: 6. 30 m Double Disc Scraper Knife Cutter Bucket Housing Twin Disc Single Disc Cutter

SURUC TUNNEL PROJECT Location: Sanliurfa, Ilci Const. Lenght of Tunnel: 17185 m Type of TBM: SELI Double Shiled Diameter of TBM: 7. 80 m Double Disc Scraper Knife Cutter Bucket Housing Twin Disc Single Disc Cutter

ANKARA METRO PROJECTS Under construction metro projects

• Ankara Metro (M 2, Kizilay-Çayyolu) - 16. 6 km total length, 3. 7 km by TBM and 2. 9 km by NATM. • Ankara Metro (M 3, Batikent-Torekent) - 16 km total length, 2 km by TBM and 6. 6 km by cut and cover. • Ankara Metro (M 4, Tandoğan-Kecioren) - 9. 2 km total length, 4. 2 km by TBM and 3 km by NATM.

KARGI HEP PROJECT Location: Kargi-Corum, Gulermak Heavy Ind. Co. Lenght of Tunnel: 11800 m Type of TBM: Robbins Double Shiled Diameter of TBM: 10. 00 m Twin Disc Cutter Single Disc Cutter Scrapper

YAMANLI HEPP PROJECT Location: Adana, Enerji. Sa-NTF Const. Lenght of Tunnel: 7900 m Type of TBM: Robbins Double Shiled Diameter of TBM: 4. 40 m Double Disc Cutter Scrapper Twin Disc Cutter Single Disc Cutter

DOGANCAY HEP PROJECT Location: Adana, Enerji. Sa Atac, Hinteregger Joint Venture Lenght of Tunnel: 6900 m Type of TBM: Herrenknecht Double Shiled Diameter of TBM: 4. 20 m Double Disc Cutter Bucket Twin Disc Cutter Single Disc Cutter

KARAKUZ DAM and HEP PROJECT Location: Adana, Alarko-Altek Const. Lenght of Tunnel: 11000 m Type of TBM: 2 CAT Double Shiled Diameter of TBM: 3. 00 m Double Disc Cutter Bucket Twin Disc Cutter Single Disc Cutter

UPCOMING PROJECTS • - OVIT Tunnel Project; City : Rize Contractor : Makyol Const. Length : 30 km (2 x 15 km) Diameter : 12. 50 m excavation Machine Type : 2 Gripper TBM 1850 m Raise Boring with 6 m diameter for ventilation shafts

• - Silvan Tunnel Project; City : Diyarbakır Contractor : Yertas, Kayaoglu Joint Venture Length : 20. 5 km (2 x 10. 25 km) Diameter : 7. 9 m excavation Machine Type : Double Shield TBM (Herrenknecht) • - Babakaya Tunnel Project; City : Diyarbakır Contractor : Unal Akpınar Const. Length : 10. 4 km (2 x 5. 2 km) Diameter : 7. 9 m diameter Machine Type : Double Shield TBM (CAT)

• - Beylerbeyi Wastewater Tunnel Project, City : Istanbul Contractor : Unal Akpinar Const. Length : 4680 m Diameter : 3. 2 m excavation Machine Type : Single shiled • - Zeytinburnu Wastewater Tunnel Project, City : Istanbul Contractor : Unal Akpinar Const. Length : 4500 m Diameter : 3. 2 m excavation Machine Type : EPB

• Dogancay Tunnel Project (Ankara-Istanbul High Speed Rail Project); - City : Bilecik (Vezirhan-Kosekoy) - Length : 7. 4 km - Diameter : 13. 80 m excavation - Machine Type : EPB (expected) • - Bagbası Tunnel Project; City : Konya Contractor : Ilci Constr. Length : 18 km Diameter : 5. 2 m excavation Machine Type : Double shiled TBM

• Bosphorus Crossing Tunnel Project; - City : Istanbul, under the bosphorus - Contractor : Yapi Merkezi and SKEC-Samwhan. Hansin-Namkwang-Kukdong Joint Venture - Length : 3. 34 km - Diameter : 13. 70 m excavation - Machine Type : Herrenknecht Slurry TBM

PROJECT DETAILS IN MIDDLE EAST

As it is know that the Middle East market has quite big value of construction industry. About 80 per cent of the projects involving tunnelling are in the transport sector, including metro schemes in Cairo, Abu Dhabi, Baku, Tehran, Tel Aviv, Doha, Riyadh and Kuwait. Urban transport projects often for tunnelling as underground lines minimise disruption to the existing buildings and infrastructure of cities. More than $279 bn-worth of projects with a tunnelling element are currently planned or under way in the Middle East.

With $76. 2 bn of new projects and extensions to existing lines planned in the Gulf and North Africa, the urban rail sector is set to offer significant opportunities for contractors in the region. If we have a look at tunnelling industry, we have seen that there are many projects which are under way and planning to built.

Selected Planned Major Tunnelling Projects

• Kuwait Metro Project, Ø Sector: Rail Ø Cost : 7 billion USD Ø Scope : 160 km metro network Ø Client : Partnerships Technical Bureau Ø Country : Kuwait Ø Expected Tunnelling : TBM Ø Tender Issue Date: Jul-12

• Inner Doha Resewerage Scheme, Ø Sector : Water Ø Cost : 2, 5 billion USD Ø Scope : Interceptor tunnel Ø Client : Public Works Authority (Ashghal) Ø Country : Qatar Ø Expected Tunnelling : TBM Ø Tender Issue Date : Dec-12

• King Faisal Tunnel, Ø Sector: Road Ø Cost : 500 million USD Ø Scope : 2. 5 km underpass beneath King Faisal highway Ø Client : Ministry of Public Works Ø Country: Bahrain Ø Estimated Tunnelling : Cut and cover Ø Tender Issue Date : Jan-13

• Etihad Rail Phase 3, Ø Sector : Rail Ø Cost : 2, 5 billion USD Ø Scope : Final section of 1, 200 km network to Fujairah and Oman border Ø Client: Etihad Rail Ø Country: UAE Ø Estimated Tunnelling: Drill and blast Ø Tender Issue Date: Jan-13

• Oman National Railway, Ø Sector : Rail Ø Cost: 2, 5 billion USD Ø Scope : 1, 370 km network, starting with 230 km line from Muscat to Sohar Ø Client: Ministry of Transport Ø Country: Oman Ø Estimated Tunnelling : Drill and blast Ø Tender Issue Date : Apr-13

• Mecca-Taif Road Tunnel, Ø Sector : Road Ø Cost : 533 million USD Ø Scope : 11 km road tunnel Ø Client : Al-Tareek Investment & Development Company Ø Country : Saudi Arabia Ø Estimated Tunnelling : Cut and cover Ø Tender Issue Date : Apr-13

• Abu Dhabi Metro, Ø Sector : Rail Ø Cost : 7 billion USD Ø Scope : 131 km network under Abu Dhabi, mainly tunnelled Ø Client : Ministry of Transport Ø Country : UAE Ø Estimated Tunnelling : TBM Ø Tender Issue Date : Jun-13

• Cairo Metro Line 4 , Ø Sector : Rail Ø Cost : 2, 6 billion USD Ø Scope : 24 km metro linking Giza and Grand Museum to city centre Ø Client : National Authority for Tunnelling Ø Country : Egypt Ø Estimated Tunnelling : TBM Ø Tender Issue Date : Aug-13

• Cairo Metro Line 3 Phase 3 , Ø Sector : Rail Ø Cost : 1 billion USD Ø Scope : 16. 6 km, mainly underground, extending current Line 3 Ø Client : National Authority for Tunnelling Ø Country : Egypt Ø Estimated Tunnelling : TBM Ø Tender Issue Date : Third quarter 2012

• Baghdad Metro Project, Ø Sector : Rail Ø Cost : 3 billion USD Ø Scope : 39 km city centre metro network Ø Client : Baghdad Municipality Ø Country : Iraq Ø Estimated Tunnelling : TBM Ø Tender Issue Date : Dec-13

• Tehran Metro Lines 8, 9 and Express Lines, Ø Sector : Rail Ø Cost : 10 billion USD Ø Scope : 179 km expansion of existing system by 2025 Ø Client : Tehran Metro Company Ø Country : Iran Ø Estimated Tunnelling : TBM Ø Tender Issue Date : First quarter 2018

• Al-Hayer Wastewater Project, Ø Sector : Water Ø Cost : 100 million USD Ø Scope : Two 37 km 3, 000 mm wastewater tunnels Ø Client : National Water Company Ø Country : Saudi Arabia Ø Estimated Tunnelling : TBM Ø Tender Issue Date : Bids under evaluation

Selected Major Tunnelling Projects Under Way

• Abu Dhabi Road Tunnels Project, Ø Sector : Road Ø Cost : 817 million USD Ø Scope : Three road tunnels and two flyovers improving road access to Port Zayed Ø Status : Under construction Ø Country : UAE Ø Client : Abu Dhabi Municipality Ø Proposed Completion Date : May-12

• Qatar Education City Utilities Tunnel, Ø Sector : Water Ø Cost : 184 million USD Ø Scope : 9 km utility tunnel for Education City services Ø Status: Under construction Ø County : Qatar Ø Client : Qatar Foundation Ø Proposed Completion Date : May-12

• Dammam University Tunnel Project, Ø Sector : Road Ø Cost : 66 million USD Ø Scope : 30 km connection between university and hospital Ø Status : Under construction Ø Country : Saudi Arabia Ø Client : Ministry of Higher Education Ø Proposed Completion Date : Oct-13

• Riyadh Road Tunnels, Ø Sector : Road Ø Cost : 55 million USD Ø Scope : Two road tunnels in Riyadh Ø Status : Under construction Ø Country : Saudi Arabia Ø Client : Riyadh Municipality Ø Proposed Completion Date : Apr-14

• Muharraq Wastewater Treatment Project, Ø Sector : Water Ø Cost : 250 million USD Ø Scope : New facility including 20. 9 km gravity sewer Ø Status : Under construction Ø Country : Bahrain Ø Client : Muharraq STP Company Ø Proposed Completion Date : Oct-14

• Abu Dhabi Step, Ø Sector : Water Ø Cost : 1, 6 billion USD Ø Scope : 41 km water storage tunnel Ø Status: Under construction under three tunnelling packages Ø Country : UAE Ø Client : Abu Dhabi Sewerage Services Co. Ø Proposed Completion Date : Dec 2014

• Etihad Rail Project, Ø Sector : Rail Ø Cost : 11 billion USD Ø Scope : 1, 200 km network including six tunnels Ø Status : Phase 1 under construction Ø Country : UAE Ø Client : Etihad Rail Ø Proposed Completion Date : Jan-18

• Azer Korpu Baku Metro Project, Ø Sector : Rail Ø Cost : 600 million USD Ø Scope : Under Construction, 12200 m length in total with 6. 5 m 2 EPB (1 Herrenknecht, 1 Robbins) Ø Country : Azerbaijan Ø Proposed Completion Date : 2015

• Tel Aviv – Jeruselam High Speed Rail Project, Ø Sector : Rail Ø Scope : Under construction, 21000 m length in total, 1 Herrenknecht EPB and 2 double shiled with 10. 3 m diameter. Ø City : Tel Aviv Ø Proposed Completion Date : 2015

• Tel Aviv Metro Project, Ø Sector : Rail Ø Cost : 12 billion USD Ø Scope : Under construction, 23 km Red Line with 6. 5 m diameter, 35 km Green Line with 6. 5 m diameter Ø Country : Israel Ø Client : Metropolitan Mass Transit System Ltd. Ø Proposed Completion Date : 2017

CONCLUSION According to growing population and increasing economic opportunities in rapidly developing countries, especially infrastructure investments in are gaining more and more importance. In this context, local administrations have been planing to invest more for metro, rail, road, clean and waste water tunnel projects as it is seens in this presentation. As one of the companies that related in TBM industry , we would like to be also one of the solution partners for each single project.

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