Tunneling Technology for Future Highways

Steven, I.; Majtenyi, Joan E. · 1985 · ROSA P / United States. Department of Transportation. Federal Highway Administration

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Summary

This report summarizes the Federal Highway Administration’s (FHWA) research program, Project 5B, "Tunneling Technology for Future Highways," conducted between 1971 and 1982. The initiative was motivated by projections of a sharp increase in transportation tunnel construction, particularly in urban areas where tunneling offered an environmentally sensitive alternative to surface expansion. A 1968 National Research Council report recommended a federally funded program to reduce costs and improve excavation speed, leading to a coordinated Department of Transportation effort. The FHWA’s specific objectives focused on minimizing construction, operation, and maintenance costs while addressing environmental, safety, and aesthetic concerns. The program was structured around four primary tasks: cut-and-cover tunneling, site investigation, ground movement prediction and control, and highway environmental criteria. The research methodology involved administrative contracts, in-house studies, and Highway Performance and Research (HP&R) studies supported by state and federal funds. The FHWA collaborated with other agencies through the Interagency Committee on Excavation Technology and engaged industry leaders via DOT-Industry Council meetings. Technical accomplishments were categorized into state-of-the-art reviews, techniques accepted abroad but not widely in the U.S., and experimental methods. Specific studies analyzed cost systems, classical ground control theories, prefabricated elements, slurry trench walls, tiebacks, and grouting. Site investigation research aimed to develop accurate subsurface technologies to prevent cost overruns caused by unforeseen conditions. Ground movement studies focused on analytical techniques for estimating earth movements and evaluating stability, while environmental research addressed air pollution, lighting, traffic operation, and driver behavior. Key findings highlighted the cost-effectiveness and technical advantages of specific construction methods. Research demonstrated that diaphragm walls were more watertight and caused less earth movement than conventional sheeting, making them suitable for both temporary and permanent structures. A detailed cost analysis by Jacobs Associates evaluated 176 construction situations, providing data on labor, equipment, and material costs for various support systems. Studies on slurry walls indicated that while generally more expensive than classical methods, they offered significant savings in areas with high water tables or historic sites, potentially saving millions in projects like the Washington D.C. Metro System. Ground control research provided theoretical frameworks for designing support walls and recommended improved analytical methods, including finite element analysis, to predict wall stability and ground movement. The report concludes that the state-of-the-art in tunneling was significantly advanced despite severe funding constraints, with actual expenditures falling far short of the recommended $111 million. The FHWA program culminated in 1976, after which funding steadily declined. The authors recommend continued implementation of research results and increased training activities to diffuse innovative design ideas to state and federal agencies and private industry. They emphasize that while the reports provide valuable guidelines and references, they should not be used as rigid "cookbooks," as engineering requires judgment based on specific site conditions. The study underscores the importance of accurate site investigations and optimized construction techniques to manage costs and environmental impacts in future highway tunnel projects.

Key finding

Slurry walls used as permanent earth support in the Washington D.C. Metro System redesign could have saved an additional $2 million compared to temporary use, while providing superior watertightness and environmental compatibility.

Methodology

review

Provenance

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