Presentation 6th Workshop Chicago - 08!03!2010

6th International Workshop on Concrete in the Americas
Load Transfer at Existing República

Station During Construction of São Paulo
Subway Line 4 – Yellow
Dr. Nelson Lúcio Nunes
Civil Design Department
São Paulo Subway Company
SUMMARY
 SÃO PAULO – GENERAL INFORMATION

 SÃO PAULO SUBWAY SYSTEM
 LINE 4 – YELLOW
 REPÚBLICA STATION CONCEPT FOR LINE 4
 DESIGN MODELING FOR LOAD TRANSFER
 EXECUTIVE SEQUENCE FOR LOAD TRANSFER AND TBM DRAGGING
 INSTRUMENTATION OF TRANSFER LOADS
Load Transfer at Existing República Station During Construction of São Paulo Subway Line 4 – Yellow
SÃO PAULO – GENERAL INFORMATION
São Paulo Metropolitan Area
Brazil
São Paulo State
São Paulo Metropolitan Area - Pop.: 16,3 M

Area: 8051 km²
City of São Paulo – Population: 11 M

Area: 1509 km²
Downtown
Chicago – Population: 2,8 M
Area: 606 km²
City of São Paulo
DOWNTOWN SÃO PAULO
SÃO PAULO SUBWAY SYSTEM
SÃO PAULO SUBWAY SYSTEM – 2010
Present:
Total length: 62,3 km
Stations: 56
Passengers: 3,3 Million / day
LINE 1 – Blue
LINE 3 – Red
LINE 2 – Green
LINE 4 – Yellow
(Under Construction)
LINE 2 Extension
(Under Construction)
LINE 5 – Lilac
Line 5 – Future Extension

(Design Under Development)
Logo ACI
LINE 4 – GENERAL FEATURES

 Total Length = 12,8 km
Shield tunnels = 6,4 km
NATM tunnels = 5,5 km
Cut and Cover tunnels = 0,9 km
Surface = Maintanance Yard 111.400 m2
 Number of stations = 11
Cut and Cover: 3 (Faria Lima, Fradique Coutinho and
República)
NATM: 8 (Vila Sônia, Morumbi, Butantã, Pinheiros, Oscar
Freire, Paulista, Higienópolis and Luz)
 Some numbers
Passengers: 900.000 per day (Ridership estimated for 2012)
24 trains with 6 cars each
Republica Station
REPÚBLICA STATION
CONCEPT
FOR LINE 4
Line 3
(Operating) República
Square
Existing Station Line 4

(Built in 1982) (Under Construction)
Block for Line 4

Built in 1982
Block for Line 4

Under Construction
Single NATM Existing Block
Tunnels
Single NATM
Tunnels
Hilton Shaft Existing

New Block 24 de Maio Shaft
Block
ORIGINAL CONCEPT:
•Tunnel Boring Machine Arrives at Hilton Shaft
• TBM is disassembled at Hilton Shaft
• TBM is assembled at 24 de Maio Shaft
• TBM departures from 24 de Maio Shaft
Single NATM Existing Block
Tunnels
Single NATM
Tunnels
Hilton Shaft Existing

New Block 24 de Maio Shaft
Block
ORIGINAL CONCEPT:
• Construction of Shafts demands detours and street
interdictions, causing severe traffic jams and disturbing
neighborhood
• Conception abandonned.
Existing Block
Block 5
New Block (Existing)
NEW CONCEPT:
• Tunnel Boring Machine arrives at Station
• TBM is dragged through Station
• TBM depatures from Station
• Shafts are not necessary
SÃO PAULO LINE 4 TUNNEL BORING MACHINE
• Earth Pressure Balance
• Outer diameter: 9,50 m
• Inner diameter: 8,43 m
• 30 m Tunnel / day
SITUATION FOR LINE 4 WITH
12 13 14 15 15A
ORIGINAL CONCEPT:
LEVEL A - ROOF
CENTRAL PLATFORM
TWO SINGLE TRACKS

LEVEL B
NATM NATM
LEVEL C - LINE 4 PLATFORM Tunnel Tunnel
LEVEL C
11
LEVEL D
LEVEL E - LINE 3 PLATFORM
LEVEL E
SITUATION FOR LINE 4 WITH NEW
CONCEPTION:
12 13 14 15 15A
LEVEL A - ROOF
DOUBLE TRACK SHIELD TUNNEL
TBM ARRIVES AT STATION
DRAGGING OF TBM LEVEL B
LEVEL C - LINE 4 PLATFORM
Tunnel LEVEL C
Boring
Machine
11
COLUMNS ON THE LEVEL D
TBM WAY
????
LEVEL E
TBM ARRIVING AT REPUBLICA STATION (NEW BLOCK)
SHIELD TUNNEL FROM TBM ARRIVED AT STATION
WHAT IS NECESSARY TO DRAG TBM
THROUGH EXISTING STATION ?
• BUILD NEW COLUMNS
• TRANSFER LOADS FROM EXISTING COLUMNS TO NEW
ONES
• DEMOLISH EXISTING COLUMNS
• DEMOLISH CENTRAL PLATFORM
• DEMOLISH LEVEL C SLAB
• DRAG TBM THROUGH STATION
• REBUILD LEVEL C SLAB
• BUILD NEW PLATFORMS
WHAT IS NECESSARY TO DRAG TBM
THROUGH EXISTING STATION ?
• BUILD NEW COLUMNS
THE CHALLENGE:
• TRANSFER LOADS FROM EXISTING COLUMNS TO NEW
TO PERFORM ALL THESE
ONES
STEPS WITHOUT
• DEMOLISH EXISTING COLUMNS
INTERRUPTING LINE 3
• DEMOLISH CENTRAL – 59,000
PLATFORM
OPERATION
PEOPLE
• DEMOLISH LEVEL AT STATION PER
C SLAB
DAY
• DRAG TBM THROUGH STATION
• REBUILD LEVEL C SLAB
• BUILD NEW PLATFORMS
DESIGN MODELING FOR LOAD TRANSFER
DESIGN AND ANALYSIS MODELING
• Software: SAP 2000 (Computers & Structures, Inc.)
• Staged Construction Analysis
• Considers overlaping effects in structures
• Each Stage considers accumulated effects in structure
until last stage
• Load Transfer and TBM dragging: Nine Stages of
Structural Modifications
• Staged Construction Outputs:
• 3D Perspective Graphical Displays
• Force Diagrams and Stress Contours
3D
6th Perspective Display
International Workshop of 1stinStage
on Concrete the Americas
3D
6th Perspective Display
International Workshop of 2ndin Stage
on Concrete the Americas
FORCE DIAGRAMS
A
STAGE 2 - AXIS C :
B INTRODUCTION OF NEW
STRUCTURES (COLUMNS AND
STEEL BEAMS AT LEVELS A and
B)
FORCE DIAGRAMS
Aa
AFTER STAGES 3 AND 4 – AXIS C
B 3 - PARTIAL LOAD TRANSFER

FROM EXISTING COLUMNS
BETWEEN LEVELS A and B
4 - DEMOLITION OF COLUMNS
C BETWEEN LEVELS A and B
FORCE DIAGRAMS

B
5 - COMPLETION OF LOAD
TRANSFER FROM EXISTING
COLUMNS BETWEEN LEVELS B
and D
C 6 - DEMOLITION OF COLUMNS
BETWEEN LEVELS B and D AND
PARTIAL DEMOLITION OF LEVEL
D C STRUCTURE
FORCE DIAGRAMS
A
B 7 - RECONSTRUCTION OF LEVEL
C STRUCTURES AFTER TBM
DRAGGING.
8 - INPUT OF LIVE AND

PERMANENT LOADS, AS WELL
C
LOADS FROM LINE 3 AND LINE 4
TRAINS.
D
EXECUTIVE SEQUENCE FOR LOAD TRANSFER
AND TBM DRAGGING
12 12A 13 14 14A 15 15A
LEVEL A - ROOF
CONSTRUCTION 3 3
OF NEW
COLUMNS LEVEL B
3 3
• CONSTRUCTION
OF FUNDATION
LEVEL C
BLOCKS,
INCLINED
PILLARS AND
3 3
TIE MEMBERS
LEVEL D
2
2
2
LEVEL E
TIE MEMBER
INCLINED PILLAR
12 12A 13 14 14A
15 15A
LEVEL A - ROOF
LEVEL B
ASSEMBLING OF STEEL
BEAMS WHICH WILL
LIFT EXISTING
STRUCTURES BETWEEN
LEVELS A & B LEVEL C
LEVEL D
LEVEL E
TRENCHES WHERE BEAMS
WILL BE POSITIONED
PREPARING STEEL BEAMS TO BE LIFTED
LIFTING OF LEVEL A STEEL BEAMS
VERTICAL TENDONS DUCTS
LEVEL A SLAB
LOAD TRANSFER VERTICAL TENDONS
NEW COLUMN EXISTING COLUMNS

CONCRETE COVER
12A 13 14 14A
12 15 15A
LEVEL A - ROOF
LEVEL B
6 7
PARTIAL LOAD
TRANSFER TO NEW LEVEL C
COLUMNS, BY
PRESTRESSING OF 8
VERTICAL TENDONS,
WHICH LINKS LEVEL D
EXISTING CONCRETE
STRUCTURE TO STEEL
BEAMS ASSEMBLED AT
LEVEL A
LEVEL E
CONCRETE COVER
12A 13 14 14A
12 15 15A
LEVEL A - ROOF
LEVEL B
DEMOLITION OF EXISTING
COLUMNS AT AXES 13
AND 14, BETWEEN 9
8
9
9
LEVELS A and B
LEVEL C
10
LEVEL D
LEVEL E
LOAD TRANSFER VERTICAL
TENDONS
DEMOLITION OF EXISTING COLUMN BY DIAMOND WIRE SAW CUTTING

CONCRETE COVER
12A 13 14 14A
12 15 15A
LEVEL A - ROOF
LEVEL B
9 9
9
LEVEL C
10 Assembling of level B steel

beams at axes B, C and D
LEVEL D
LEVEL E
PREPARING STEEL BEAMS FOR LIFTING
LIFTING OF STEEL BEAMS
JACK
JACK BASE JACK BASE
STEEL BEAM POSITIONED OVER CORBELS

ASSEMBLING OF JACK BASE FINISHED
POT BEARING
CORBEL
JACK BASE JACK BASE

CONCRETE COVER
12A 13 14 14A
12 15 15A
LEVEL A - ROOF
LEVEL B
9 9
9
LEVEL C
10
LEVEL D
execution of load transfer

from existing columns at LEVEL E - LINE 3 PLATFORM
the axes 13 and 14 for new LEVEL E
columns at axes 12A and

14A
25690
50 POT BEARING
SUPPORT CORBEL
100
920
50
D
P.T
920
CONCR
6376 3700 5280 4385 5949
ETE BE
50
PLAN
AM FAC
200
E
SECTION
1700 ou 1840
CONCRETE FILLING UNDER SLAB JACK

EXISTING SLAB
700
EXISTING BEAM
970
20
STEEL BEAM STEEL BEAM
130
SHEET STIFFENER 25.0
PLATE 25.0 x 450

200 200
PS 450 x 450 x 31.5 x 25 PLATE STIFFENER 25.0
1700 ou 1840

EXISTING SLAB
700
EXISTING BEAM
970
20
130
PLATE 25.0 x 450

200 200
Jack action over concrete

structure near to existing
columns
1700 ou 1840

EXISTING SLAB
700
EXISTING BEAM
970
20
130
PLATE 25.0 x 450

200 200
Reaction over steel

beams
STEEL BEAM
JACK
STEEL WEDGE
JACK BASE
CONCRETE COVER
12A 13 14 14A
12 15 15A
LEVEL A - ROOF
LEVEL B
LEVEL C
12
LEVEL D
Demolition of existing
columns at axes 13 and 14, LEVEL E - LINE 3 PLATFORM
between levels B and D.

LEVEL E
CONCRETE COVER
12A 13 14 14A
12 15 15A
LEVEL A - ROOF
LEVEL B
LEVEL C
12
LEVEL D
Demolition of existing
boarding platform at level
C and part of slab and
beams of this level, at

LEVEL E
T.B.M. Clearance area.
CONCRETE COVER
12A 13 14 14A
12 15 15A
LEVEL A - ROOF
LEVEL B
LEVEL C
12
LEVEL D
Construction of Tunnel
Boring Machine dragging
cradle.
LEVEL E
DEMOLITION WORKS
LEVEL B STEEL BEAMS
EXISTING COLUMNS CUT OFF
TBM
LEVEL C DEMOLISHED
TBM WAITING CONSTRUCTION OF DRAGGING CRADLE

CONSTRUCTION OF DRAGGING CRADLE
DRAGGING CRADLE FINISHED
DRAGGING CRADLE FINISHED
CONCRETE COVER
12A 13 14 14A
12 15 15A
LEVEL A - ROOF
LEVEL B
DRAG OF
TUNEL BORING MACHINE LEVEL C
13
LEVEL D
Dragging of Tunnel Boring

Machine
LEVEL E
TBM DRAGGING
TBM SHIELD TBM BACKUP
LEVEL D SLAB
UNDERPINNING
LINE 3 PLATFORM
UNDERPINNING OF LEVEL D SLAB DURING PASSAGE OF TUNNEL

BORING MACHINE
CONCRETE COVER
12A 13 14 14A
12 15 15A
LEVEL A - ROOF
LEVEL B
17
TOP OF
16
RAILHEAD
LEVEL C
Disassembling of Tunnel
Boring Machine dragging LEVEL D
cradle
Reconstruction of slabs and

beams of the level C. LEVEL E - LINE 3 PLATFORM
LEVEL E
Constructiion of new
platforms at level C.
RECONSTRUCTION OF LEVEL C SLAB AND PLATFORMS
CONCRETE COVER
12A 13 14 14A
12 15 15A
LEVEL A - ROOF
LEVEL B

TOP OF
RAILHEAD
LEVEL C
LEVEL D
LEVEL E
INSTRUMENTATION OF TRANSFER LOADS
ISTRUMENTATION
• VIBRATION WIRE STRAIN GAGES
• Arc Weldable Strain Gage
• Concrete Embedment Strain Gage
• Fiber Optic Rebar Strainmeter
• Temperature Strain Gages
• IMPLEMENTATION AND OPERATION
• LPC LATINA (BRAZIL)
• EQUIPMENT
• GEOKON, Inc. (New Hampshire – USA)
• SOFTWARE
• Vista Data Vision database - Vista Engineering (Iceland)
SG "ST
VIBRATING WIRE STRAIN GAGE
C
P SETTLEMENT
PI CONTROL
ST "ST
TEMPERATURE STRAIN GAGE
SB "ST
FIBER OPTIC REBAR STRAINMETER
D
85
PILARES EXISTENTES
Arc Weldable Strain Gage
Concrete Embedment Strain Gage Fiber Optic Rebar Strainmeter
Data Acquisition:
10 Multiplexers
2 Dataloggers
2 Computers
AUTHORS
• São Paulo Subway Company
• Civil Conception Department
• Roberto Yazbek Junior (Coordinator)
• Danton Soares Junior (Supervisor)
• Nelson Lúcio Nunes (PhD, Specialized Engineer) – SPEAKER
• Rafaelle Tiboni Fioranelli (MsE, Civil Design Engineer)
• Helder José Ribeiro Soares (Civil Design Engineer)
• Line 4 Construction Department
• Alberto Benedito de Lima Junior (Chief )
• Sérgio Renato de Arruda Leme (Coordinator)
• Yasushi Uema (Senior Engineeer)
• Via Amarela Consortium
• Walter de Almeida Braga (PhD Senior Structural Designer )
• João Rocha (Senior Structural Designer )
• Milton Carvalhal (Construction Coordinator )
THANK YOU
OBRIGADO
GRACIAS
Visit us:
www.metro.sp.gov.br
www.viamarela.com.br
www.ibracon.org.br

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6th International Workshop on Concrete in the Americas

Load Transfer at Existing República

 SÃO PAULO – GENERAL INFORMATION

6th International Workshop on Concrete in the Americas

6th International Workshop on Concrete in the Americas

São Paulo Metropolitan Area - Pop.: 16,3 M

City of São Paulo – Population: 11 M

6th International Workshop on Concrete in the Americas

Line 5 – Future Extension

LINE 4 – GENERAL FEATURES

6th International Workshop on Concrete in the Americas

6th International Workshop on Concrete in the Americas

Existing Station Line 4

Block for Line 4

Block for Line 4

Hilton Shaft Existing

6th International Workshop on Concrete in the Americas

Hilton Shaft Existing

6th International Workshop on Concrete in the Americas

6th International Workshop on Concrete in the Americas

• Earth Pressure Balance

• Outer diameter: 9,50 m

• Inner diameter: 8,43 m

6th International Workshop on Concrete in the Americas

TWO SINGLE TRACKS

LEVEL E - LINE 3 PLATFORM

TBM ARRIVES AT STATION

DRAGGING OF TBM LEVEL B

LEVEL C - LINE 4 PLATFORM

COLUMNS ON THE LEVEL D

6th International Workshop on Concrete in the Americas

6th International Workshop on Concrete in the Americas

6th International Workshop on Concrete in the Americas

6th International Workshop on Concrete in the Americas

6th International Workshop on Concrete in the Americas

B 3 - PARTIAL LOAD TRANSFER

6th International Workshop on Concrete in the Americas

AFTER STAGES 5 AND 6 – AXIS C

6th International Workshop on Concrete in the Americas

8 - INPUT OF LIVE AND

6th International Workshop on Concrete in the Americas

6th International Workshop on Concrete in the Americas

LEVELS A & B LEVEL C

LEVEL E - LINE 3 PLATFORM

LOAD TRANSFER VERTICAL TENDONS

NEW COLUMN EXISTING COLUMNS

LEVEL C - LINE 4 PLATFORM

LEVEL E - LINE 3 PLATFORM

DEMOLITION OF EXISTING COLUMN BY DIAMOND WIRE SAW CUTTING

10 Assembling of level B steel

LEVEL E - LINE 3 PLATFORM

JACK BASE JACK BASE

STEEL BEAM POSITIONED OVER CORBELS

JACK BASE JACK BASE

execution of load transfer

the axes 13 and 14 for new LEVEL E

columns at axes 12A and

CONCRETE FILLING UNDER SLAB JACK

SHEET STIFFENER 25.0

PLATE 25.0 x 450

CONCRETE FILLING UNDER SLAB JACK

SHEET STIFFENER 25.0

PLATE 25.0 x 450