United States
Environmental Protection
Agency
Municipal Environmental Research EPA-600/2-80-014
Laboratory March 1980
Cincinnati OH 45268
Research and Development
Lawrence Avenue
Underflow Sewer
System
Interim Report
Planning and
Construction
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into nine series. These nine broad cate-
gories were established to facilitate further development and application of en-
vironmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The nine series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4, Environmental Monitoring
5. Socioeconomic Environmental Studies
6. Scientific and Technical Assessment Reports (STAR)
7. Interagency Energy-Environment Research and Development :
8. "Special" Reports ;
9. Miscellaneous Reports
This report has been assigned to the ENVIRONMENTAL PROTECTION TECH-
NOLOGY series. This series describes research performed to develop and dem-
onstrate instrumentation, equipment, and methodology to repair or prevent en-
vironmental degradation from point and non-point sources of pollution. This work
provides the new or improved technology required for the control and treatment
of pollution sources to meet environmental quality standards.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
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EPA-600/2-80-014
March 1980
LAWRENCE AVENUE UNDERFLOW SEWER SYSTEM
I
Interim Report
Planning and Construction j
by
Louis Koncza
Donald H. Churchill
G. L. Miller
City of Chicago
Bureau of Engineering
Chicago, Illinois 60610
Grant No. 11020 EMD
Project Officers
Clifford Risley, Jr.
U.S. Environmental Protection Agency
Region V
Chicago, Illinois 60606
Richard P. Traver
Storm and Combined Sewer Section
Wastewater Research Division
Municipal Environmental Research Laboratory (Cincinnati)
Edison, New Jersey 08817 I
MUNICIPAL ENVIRONMENTAL RESEARCH LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OHIO 45268
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DISCLAIMER
This report has been reviewed by the Municipal Environmental
Research Laboratory, U.S. Environmental Protection Agency, and
approved for publication. Approval does not signify that the
contents necessarily reflect the views and policies of the U.S.
Environmental Protection Agency, nor does mention of trade names
or commercial products constitute endorsement or recommendation
for use.
ii
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FOREWORD
The Environmental Protection Agency was created because of
increasing public and government concern about the dangers of pol-
lution to the health and welfare of the American people. Noxious
air, foul water, and spoiled land are tragic testimony to the
deterioration of our natural environment. The complexity of that
environment and the interplay between its components require a
concentrated and integrated attack on the problem.
Research and development is that necessary first step in
problem solution and it involves defining the problem, measuring
its impact, and searching for solutions. The Municipal Environmental
Research Laboratory develops new and improved technology and sys-
tems for the prevention, treatment, and management of wastewater
and solid and hazardous waste pollutant discharges from municipal
and community sources, for the preservation and treatment of public
drinking water supplies, and to minimize the adverse economic,
social, health, and aesthetic effects of pollution. This publica-
tion is one of the products of that research; a most vital communi-
cations link between the researcher and the user community.
Many of our cities are faced with pollution problems associ-
ated with combined sewer overflows. Reduction or elimination of
combined sewer overflows into the receiving waters require some
kind of storage and treatment facilities at considerable costs,
particularly in large cities where land is scarce. Construction
of deep rock tunnels to serve as main outlets for the combined
sanitary and storm flow offers an attractive means of minimizing
this problem. The sewer, being below the river level, provides
storage and captures a large portion of the pollution from com-
bined sewers. The construction cost of such a tunnel system brings
some savings as compared to conventional surface sewers, because of
the use of modern tunnel boring machines and the elimination of
surface restoration costs. Moreover, the inconvenience to general
public by disruption of streets, utilities, sidewalks, etc. and
interference with commercial activity is completely avoided. This
report describes the planning, design and construction of such a
deep tunnel by the City of Chicago for their Lawrence Avenue
drainage basin.
Francis T. Mayo
Director
Municipal Environmental
Research Laboratory
1X1
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ABSTRACT
A new and bold concept in design of urban drainage systems
was developed as a step forward in the solution of combined
sewer overflow problems. A deep tunnel in bed rock about 200 to
250 feet (61 to 76 m) below the surface was designed and con-
structed for the Lawrence Avenue drainage basin in Chicago.
Utilization of modern tunnel boring machines made the project
economically competitive with conventional sewers while'reaping
additional benefits of ease in construction, no disturbance to
traffic and least inconvenience to public. In addition; the
tunnel sewer will serve as a reservoir totally capturing smaller
storms, and trapping a significant portion of the first;flush of
pollutants from larger storms. The entrapped pollutional load
will be pumped to a treatment plant through a pumping station to
be operated only at the end of the storm, for dewatering the
tunnel. The project is expected to reduce, to a large extent,
the combined sewer overflows to the waterways.
Hydraulic model studies were conducted at the St. Anthony
Falls Hydraulic Laboratory, Minneapolis, Minnesota, for the
design of dropshafts to convey wet weather flows from surface
sewers to the deep tunnel.
Pre-construction field measurements on the quantity and
quality of combined sewer overflows have already been collected
for a number of storms for 3 outfalls serving the Lawrence
Avenue drainage basin. Similar measurements will be taken after
the tunnel is in complete operation. Comparison of the results
will be documented in a final report to demonstrate the
effectiveness of this concept in reducing pollution to waterways
from combined sewer overflows.
This report is submitted in partial fulfillment of
Demonstration Grant No. 11020 EMD sponsorship of the
U.S. Environmental Protection Agency.
IV
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CONTENTS |
Foreword
'
Abstract . . • • ,.
List of Figures . , ;
Acknowledgements . .
Sections
I
I Conclusions
II Recommendations
.
i
III Introduction
The History of Tunneling in Chicago ! »
Started With Water Tunnels
Stormwater
The Intercepting Sewer System :. ,.
The Chicago Underflow Plan .
IV Lawrence Avenue Underflow Sewer System
General Description . t
Computer Studies
Summary of the Lawrence Avenue Sewer System
Federal Grant (EPA Grant No. 11020 EMD)
Page
iii
iv
vii
1
3
4
4
6
7
8
12
12
20
25
26
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Preparation of Contract Documents
Construction Progress
Contract No. 1
Monitoring Wells
Contract No. 2
Contract No. 2-A
Contract No. 2-B
Contract No. 3
Contract No. 4
Lawrence Avenue Testing Demonstration
Relationship of the Lawrence Underflow System
to the Tunnel and Reservoir Plan
Tunnel and Reservoir Plan
for the Chicagoland Area
Description
Present Award Program
Page
26
27
27
43
44
44
47
61
70
70
-71
72
72
75
VI
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LIST OF FIGURES
Number
III-l
III-2
III-3
IV-1
IV-2
IV-3
IV-4
IV-5
IV-6
IV-7
IV-8
IV-9
IV-10
IV-11
IV-12
IV-13
Page
Existing Water Tunnels Constructed in Rock 5
Flood and Pollution Problems 9
Flood and Pollution Control 10
Proposed Eastwood-Wilson Sewer System Location Map 13
14
Plan and Profile of Proposed Eastwood-Wilson
Sewer System
Lawrence Avenue Underflow Sewer System Location
Plan and Profile
Geologic Profile in Project Vicinity
Performance Comparison Table of Computer
Calculation Summary for Lawrence Underflow
vs Existing Conventional Sewers
18
19
Main Shaft
Tail Tunnel
Mining Machine
Cutter Head of Mining Machine
Control Section of.Mining Machine
Head Frame > 34
Machine Bored Section 38
Forms for 15'-6%"xl9'-5"(4.7mx5.9p) Concrete Lining 40
24
29
30
31
32
33
Vll
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Number Page
IV-14 Concrete Invert Finishing of Lining . 41
IV-15 Finished 15'-6h"xl9'-5" (4.7 m x 5.9 m) Section, 42
IV-16 Overall View - Model 50
IV-17 Exit Conduit Q = 300 cfs (8.5 m3/sec), ;
TW = 10 ft.(3m) 51
IV-18 Exit Conduit, Q = 300 cfs (8.5 m3/sec),
TW = 100 ft. (30.5 m) 52
IV-19 Exit Conduit, Q = 600 cfs (17 m3/sec),
TW = 10 ft.(3 m) l 53
IV-20 Exit Conduit, Q = 600 cfs (17 m3/sec),
TW = 50 ft. (15.2 m) 54
IV-21 Exit Conduit, Q = 600 cfs (17 m3/sec),
TW = 100 ft.(30.5 m) ,55
IV-22 Exit Conduit, Q = 600' cfs (17 m3/sec),
TW = .190 ft. (58 m) 56
IV-23 Vertical Shaft, Q = 600 cfs (17 m3/sec),
Effect of Air Slots 57
IV-24 Entrance Conduit, Q = 300 cfs (8.5 m3/sec), ;
TW = 225 ft.(68.6 m) 58
IV-25 Entrance Conduit, Q = 600 cfs (17 m3/sec), ;
TW = 190 ft.(58 m) 59
IV-26 Entrance Conduit, Q = 600 cfs (17 m3/sec),
TW = 225 ft. (68.6 m) 60
IV-27 Down Drill Rig for Drop Shaft 62
IV-28 Close Up View of Down Drill Cutter Head 63
IV-29 Cutting Through Overburden at Drop Shaft 64 '
IV-30 Down View of Drop Shaft Excavation 65
IV-31 Erecting Forms for Drop Shaft Boot 66
vzn
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Number
IV-32 Main Shaft Lining
IV-33 KSB Submersible Pump
V-l Tunnel and Reservoir Plan
Page
67
68
73
IX
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ACKNOWLEDGEMENTS
Acknowledgements are given to Harza Engineering Company of
Chicago, Illinois, with special mention to Dr. David S. Louie,
the Chief Hydraulic Engineer and Mr. W. T. Bristow, the Project
Manager, for all the consultation work done in connection with
the design of the Lawrence Avenue Underflow Sewer System.
Special thanks are given to the late Professor Alvin G.
Anderson, then Director of the St. Anthony Falls Hydraulic Lab-
oratory, Minneapolis, Minnesota, for his contributions and sug-
gestions during the hydraulic model studies for the dropshafts.
The assistance given by Mr.' Warren Q. Dahlin, Supervisor of the
model testing program at the Laboratory, was greatly appreciated.
Further thanks are given to Mr. Clifford Risley, Jr.,
Office of Research and Development, Region V, Mr. Richard Field,
Chief, and Mr. Richard P. Traver, Staff Engineer, Storm & Com-
bined Sewer Section, all of the U.S. Environmental Protection
Agency, for their cooperation and assistance.
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SECTION I
CONCLUSIONS
1. In planning new sewers for relief of existing sewer systems
in large metropolitan areas served by combined sewers, due
consideration should be given to utilize the storage in the
sewer system, either by lowering the sewer profile below the
level of receiving waters, or by some other means. This
could greatly reduce spilling of pollution to ;the receiving
waters by cutting down combined sewer overflows.
2. With the recently improved technology in the field of tunnel-
ing, a rock tunnel sewer, while being cost-competitive,
promises certain advantages over a large conventional open-
cut sewer. The former involves little interference with
traffic, parking and commercial activity, least inconvenience
to public, no hazards of accidental disruption-of the
numerous utility lines found in large cities and no costs of
surface restoration.
3. Drilled tunnels utilizing rock boring machines (moles) are
relatively smooth and need not be lined with concrete, if the
rock is structurally sound and impermeable to exfiltration of
polluted water into the aquifer. This would result in savings
in lining costs and also add to the tunnel storeige.
4. The air entraining dropshaft of the Type E-15, used for the
Lawrence Avenue System, was found satisfactory through hydrau-
lic model testing performed at the St. Anthony Falls Hydraulic
Laboratory, Minneapolis, Minnesota, for the purpose of drop-
ping wet weather flows some 200 to 250 feet (61 to 76 m) from
high level sewers to the deep tunnel. However, the sloping
crown of the air collection chamber requires huge excavations
with associated high costs, particularly for larger dropshafts
than those built for the Lawrence Avenue Underflow Sewer
System. Consideration should be given to reduce the size of
the air chamber by venting air through a separate shaft
wherever feasible. This was indicated by tests carried out
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later at the St. Anthony Falls Hydraulic Laboratory in con-
junction with development of dropshafts larger than 9 feet
(2.75 m) diameter for the Tunnel and Reservoir Plan for the
Metropolitan Sanitary District of Greater Chicago.
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SECTION II
RECOMMENDATIONS
As a result of construction problems encountered in the field and
additional hydraulic model studies undertaken in conjunction with
our work with the Sanitary District, several recommendations for
future "Underflow" sewers can be made as follows:
1. Specifications should require the use of a mole within all
practical size ranges.
2. The drop shaft structures and the pumping station and out-
fall should be included in the same contract as the rock
tunnel construction. This would give additional shafts for
ingress and egress, and thus, increase safety provisions. It
would give the Contractor a greater number of locations
where muck could be removed and would eliminate the inter-
ference of one Contractor with another.
3. The drop shaft structures should be simplified.
a. Provide for slip forming shafts from top to bottom and
thereby eliminate transition from inlet jinto circular
barrel. !
b. Reduce the size of the air collector at the bottom of
•the shaft. In this area, consideration should be given
to providing an additional smaller diameter shaft for
air release.
4. A scale model of the pumping station and outfall should be
provided by the designers as a check of the feasibility of
the design features (and thus reduce the possibility of
construction problems) and as an aid to prospective bidders.
5 The Contractor should be required to keep the floor of the
tunnel cleared of muck and debris. Also, a better drainage
system in the tunnel should be required. 3Cn this tunnel,
walking any great distance was extremely difficult because
of poor housekeeping.
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SECTION III
INTRODUCTION
THE HISTORY OF TUNNELING IN CHICAGO STARTED WTTH WATER
Chicago's first water tunnel was placed in service in
March, 1867. The 5 foot (1.5 m) diameter brick, tunnel, built in
clay, about 60 feet (18.3 m) below lake level, and extending
about 2 miles (3.2 km) into the lake to the Two Mile Crib intake
was designed to supply Lake Michigan water to the City's first
pumping station. it was considered a daring engineering project
for its time and brought international fame to the City of
Chicago. *
As the City grew and its water works system expanded,
^n1^0??1 fc^nelS Were built to new Piping stations. However,
many difficulties were experienced due to the poor soil condi-
tions encountered. in an attempt to eliminate the hazards in-
volved, City engineers resolved that, wherever feasible, future
tunnels would be constructed in rock.
The first tunnel built in rock was the Southwest Lake and
Land Tunnel, started in 1906 and completed in 1911 see
A?1^ J11"1: ThS depth varied from 102 feet (31 m) to 148 feet
(45 m) for the land portion; the remainder was 160 feet (49 m)
below lake level. ;
Mining in as many as six drifts was carried on simultane-
ously and progress varied in each. For the 14 foot (4 3 m)
section the peak performance rate recorded by any one heading
was 416 feet (127 m) in one month. «wng
The standard method of top heading and bench was used in
the raining operation. Blasting techniques left a lot to be
desired with large areas of overbreak occurring, and conversely,
considerable trimming was also required to permit construction
of the desired section. The specified minimum thickness 6f the
r?VinJ£g T?V2 ^ (3°-5 Cm)' 9 inch (23 cm> and:?
cm) for the 14 foot (4.3 m), 12 foot (3.7 m) and 9 foot
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(2.7 m) tunnels respectively, and as much as 1,114 lineal feet
(340 m) of the 14 foot (4.3 m) tunnel was lined in a month and
almost double that footage was obtained in the two smaller size
tunnels.
In mining the lake section of the tunnel, some stretches
of water-bearing rock were encountered. Our records do not in-
dicate what supports, if any, were required, but progress in one
drift dropped as low as 4 feet (1.2 m) mined in one month.
Water bled through the concrete lining and attempts at plaster-
ing the lining were in some cases almost futile.
As an example of the construction costs prevailing at that
time, the contract bid price for the 14 foot (4.3 m) tunnel,
complete with lining, was $79.00 per lineal foot ($260 per meter).
Today, there are 65 miles (104.6 km) of water tunnels in
service, or available for service, and of these,57 miles (92 km)
were constructed in rock. They vary in size from 9 foot (2.7 m)
to 20 foot (6.1 m), most of them are in the 12 to 16 foot
(3.6 to 4.9 m) range.
STORMWATER.
Modern sanitary engineering in Chicago began with!a cloud-
burst that dumped six inches (15.2 cm) of rain during a 24-hour
period August 2-3, 1885. At the storm's end, according;to con-
temporary accounts, the lake for miles off shore was "an
immense foul mass of wastes teeming with virulent bacteria."
The 1885 storm flushed pollution into the lake at'a rate
affecting the area to the water intakes. •
In those days before chlorination, the result was an
epidemic of cholera, typhoid and dysentery which proved fatal
to numerous victims.
A few days after the storm, a plan was drawn to protect
the health of Chicago inhabitants by reversing the flow of the
Chicago and Calumet rivers away from Lake Michigan and into the
Des Plaines River.
The Sanitary and Ship Canal was completed in 1900 and
hailed as an engineering wonder of the world.
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THE INTERCEPTING SEWER SYSTEM
The next step in the gigantic sanitation program involved
sealing off all wastes from Lake Michigan; it was accomplished
by constructing huge intercepting sewers 6 to 27 feet (1.8 to
8.2 m) in diameter. The intercepting sewers were linked to the
City's system of collecting sewers. By 1907 the basic system
had been completed and Chicago became the first Great Lakes city
to stop using the lakes as a receptor of it's normal domestic
sewage. '•
I
Because sanitation is a problem which extends beyond city
limits, the Metropolitan Sanitary District of Greater Chicago
(MSDGC) was established in 1889. The District was to provide
for the collection and disposal of sewage from Chicago proper
and the surrounding area and to prevent flooding by polluted
water. Today the District serves an area of 860 square miles
(2,227 sq. kms), 5,500,000 residents, and an industrial waste
load equivalent to 4,500,000 persons.
When the Metropolitan Sanitary District grew by later
annexations, other intercepting sewers were built along the lake
shore. The North Shore Channel was built to bring fresh water
from the lake at suburban Wilmette into the North Branch of the
river. The total cost of the construction of the canals, sewers,
locks, pumping stations and associated works of this drainage
system was $125,091,977.
But, while improved waste treatment methods could deal
with predictable problems, cloudbursts and flooding still re-
mained. I
The city's growth and multiplication of captured rainwater
volume long since have exceeded the sewer system's capacity. On
an average of 100 times a year, combined sanitary and storm
water sewers overflow and surge into the rivers at 640 different
points. Sometimes a mixture of stormwater and 'sewage backs up
into thousands of basements. Twenty-one times in 30 years,
flood gates of the Chicago and Calumet rivers have been opened
to keep them from going over their banks.
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THE CHICAGO UNDERFLOW PLAN
Recognizing the existence of many possible solutions to the
problems of flood control and water pollution abatement, offi-
cials of the State, the County; the Metropolitan Sanitary Dis-
trict of Greater Chicago, and the City of Chicago formed a Flood
Control Coordinating Committee.
After a thorough search of records and extensive investi-
gation, twenty-three separate alternatives were identified for
study. The system recommended was a composite of the several
Underflow Plan Alternatives and was outstanding in its relative
storage economy and simplicity and it was originally decided
that this system will include 120 miles (193 km) of tunnels
drilled principally through Silurian dolomite rock 150-300 feet
(45.7-91.4 m) below the city's streets. The tunneling will be
done underneath the rivers and the streets of the metropolis,
thus avoiding the costs of acquiring new and expensive rights-
of-way. Dropshafts leading to the tunnels will intercept the
flow in 5,000 miles (8,045 km) of sewers before it can reach the
640 overflow points that now line the metropolitan river-canal
complex. The tunnels will be drained by pumps associated with
three storage reservoirs, by far the largest, of which will be a
rock quarry 300 to 330 feet (91.4 to 100.6 m) deep. At maximum
performance the quarry will hold a 200 foot (61 m) depth of
water with a surface area 1,000 feet (305 m) wide and 2%:miles
(4 km) long. To prevent odors, aerating pumps will continually
agitate the wastewater prior to its being rationed out to sewage
treatment plants. During these waiting periods, solids will
settle to the quarry bottom and from time to time will be removed
for use as fertilizer. This primary containing basin will be
linked to the two smaller reservoirs, one of which is to be re-
served for use only during the rare periods'when downpours com-
parable to those experienced in the few peak hours of the worst
rainstorm in Chicago's history may strain the system's capacity.
*r
The tunnel and reservoir system will be a genuine flood con-
trol project as are the more customary dams and levees built by
the Corps. For the tunnel and reservoir system would do•more
than eliminate both high flow velocity and low water levels in
the Sanitary and Ship Canal; by breaking the force of a rainstorm
capturing the total rainfall, and later slowly releasing the
water at a steady rate, the system would level out the canal
flow while increasing the average water depth. See Figures III-2
and III-3.
8
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FLOOD AND POLLUTION PROB!.iJV4$
DRY WEATHER
CONDITION
Figure III-2 Flood and Pollution Problems
Diagrammatic illustration of the present conditions: Dry
Weather Condition - All dry weather flow is diverted into
the interceptor sewer, and from there to an MSDGC sewage
treatment plant. Average Rainfall - Some overflow is
discharged into the waterway (river or canal), but the
level is not high enough to affect basements or underpasses
Heavy Rainfall - The water level rises to a point where the
hydraulic gradient reaches high enough to flood basements
and depressed areas of the city.
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FLOOD AND POLLUTION CONTROL
INTERCEPTOR
SEWER
(To Treatment Plant)
Figure III-3 Flood and Pollution Control
Diagrammatic illustration of the conditions after the "Tunnel
and Reservoir Plan" is implemented: The water level is
controlled by TARP during heavy rainfalls, overflow of
combined sewage rarely discharges into the waterways and,
the hydraulic gradient during heavy rainfalls does not affect
basements and depressed areas. The heavy rainfall gradient
is indicated to show conditions before TARP.
10
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Completion of the Tunnel and Reservoir Plan is essential to the
success of the late Mayor Richard J. Daley's "Chicago 21" scheme
to stop deterioration of the central city and generate a vital
new life style for the next century. The scheme covers only
eleven square miles (28.5 sq. km)with a population of 165,000.
But in this 5 percent of its area is one-third of the total
valuation of the City's assessed property and 43 percent of all
jobs available in the metropolitan area. By cleaning up the
waterways that traverse the city, the Tunnel and Reservoir Plan
will facilitate "Chicago 21's" intent to beautify the Chicago
River environs so as to rival those of the Thames in London, the
Seine in Paris, and the Arno in Florence.
I
MSDGC can use its own bonding authority to obtain part of
the financing for the Tunnel and Reservoir Plan. Another part
can come from other bonds already approved by the State of
Illinois. But Federal appropriations guidelines set up in the
1972 amendments to the Clean Water Act of 1968 are clearly
applicable to the Tunnel and Reservoir Plan. By the year 1983,
the United States Environmental Protection Agency is charged
with providing for the purification of all the nation's waterways
to a degree that will encourage not only sailing, boating and
fishing but also swimming. MSDGCs analyses show that the Tunnel
and Reservoir Plan is the most reasonable and economical way to
meet the EPA requirements. The plan will benefit much more than
a single, lake, albeit one of the Great Lakes. The ability to
treat all, rather than only part of its sewage will enable any
city now discharging sewage effluent into rivers or lakes within
its boundaries to completely renovate its inner core.
•
The Lawrence Avenue Tunnel was the first section of the
Chicago deep tunnel to be constructed/and as such will be
described in detail in this report.
11
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SECTION IV
LAWRENCE AVENUE UNDERFLOW SEWER SYSTEM
GENERAL DESCRIPTION
Under the City of Chicago's Auxiliary Outlet Sewer Programs,
started in 1947, more than 230 miles (370 km) of new large
sewers have been constructed or are under contract at a total
cost of $203,000,000. The passage of the Sewer Bond Referendum
of July 7, 1977 will add another 23 miles (37 km) of sewers to
be constructed at a cost of $30,000,000. The remainder of the
City's present Five Year Capital Improvements Program provides
for the construction of an additional $116,000,000 of new
outlet sewers. When these sewers have been constructed all
community areas in the City will have received benefit.
In 1963, the City of Chicago's Five Year Capital Improvements
Program called for the construction of a new Auxiliary Outlet
Sewer System to provide relief from basement and underpass
flooding of an area bounded by the North Branch of the Chicago
River, Irving Park Road, Oriole Avenue and Devon Avenue. See
Figure IV-1. Preliminary hydraulic studies indicated that a
new trunk sewer in the vicinity of Wilson Avenue from the North
Branch of the Chicago River to Melvina Avenue with branches
extending north and south to intercept existing trunk sewers,
would provide the necessary flood relief.
This proposed sewer system was designated the Eastwood-Wilson
Avenue Sewer System and varied in size from a 2 barrel 13 ft.
(3.96 m) by 13 ft. (3.96 m) section at the lower end near the
River to a 7.5 ft. (2.29 m) circular section at its upper end.
This sewer was proposed to be built in five contracts, by
conventional methods, four by open cut construction and one by
earth tunnel under the Edens and Kennedy Expressways. See
Plan and Profile, Figure IV-2.
12
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Some measure of reduction in pollution, caused by the overflow
from combined sewers to the river, is provided by depressing
the outlet of the conventional auxiliary outlet siewers below
river level. The resulting storage thus produced is sufficient
to contain the runoff from frequently occurring small rainfalls
and thus preventing overflows to the river. The Eastwood-Wilson
Avenue sewer system would have equivalent storage volume below
low river water level of 0.07 inches (0.18 cm) spread over its
3620 acre (14.6xlObnT) direct tributary drainage area. This
would be equal to the runoff from a mass rainfall of approxi-
mately one quarter of an inch (0.63 cm) over this! entire area.
I
Because pollution abatement was of major concern .to engineers in
this field, consideration was given to lowering the profile to
increase the pool storage available in the downstream end of the
sewer and thereby reduce the frequency of overflows from this
combined sewer to the river. Lowering the profile would necessi-
tate pumping of sewage to the existing sanitary intercepting
sewer, increasing the overall cost. it would also require that
more of the construction be performed by earth tunnel method.
Recent development of earth mining machines has resulted in
lower bid prices in earth tunnel contracts. However, preliminary
soil investigations indicated that heavy primary steel lining
and occasional rock sections would negate the savings from the
use of such machines. Costs would greatly exceed; that of the
conventional open cut construction method.
I
j
The City of Chicago had obtained previous experience in building
large water tunnels in rock at an elevation of 100 feet (30.5 m)
to 200 feet (61 m) below the surface, i.e., the 6 mile tunnel
under Lake Michigan from the Central District Filtration Plant
to Wilson Avenue, a 4.6 mile (7.4 km) tunnel in 79th Street, and
the 3 mile (4.8 km) tunnel in Columbus Avenue. These tunnels
ranging in size from 12 feet (3.6 m) to 16 feet (4.9 m) were
constructed by the conventional drill and blast method.
I
I
Recent improvements of the rock mining machines (Moles) had
reduced the cost of tunneling in various kinds of rock materials
for large irrigation and hydroelectric projects throughout the
world. Preliminary cost estimates revealed that mining in rock
might be competitive with open cut methods.
Lowering the profile of the Eastwood-Wilson sewer over one
hundred feet into bed rock looked promising. Sanitary flow
would not normally, in dry weather periods, enter the tunnel
I
I
15
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and therefore would not be pumped on a continuous basis. Pump-
ing would be required, however, for dewatering of the tunnel to
the existing sanitary intercepting sewer in the post rainfall
period.
The City of Chicago's Department of Public Works retained the
services of a consulting engineering firm, Harza Engineering
Company, to study alternate methods of constructing the proposed
Eastwood-Wilson Auxiliary Outlet Sewer System. The studies
included a comparison of costs of constructing the sewer by open
cut and tunnels, the hydraulic feasibility of the system, the
maintenance and operating costs, and recommendations on the best
method to fit the City's needs.
Beginning November 1, 1966 the sewer project known as EASTWOOD-
WILSON was re-designated as the LAWRENCE AVENUE SYSTEM with
subsequent contracts prepared by the Harza Engineering,Company.
The principal sewer, Contract No. 1, was designed and built in
deep tunnel as recommended in the appraisal repprt prepared by
said firm.
A review of geologic data indicated that, along the proposed
route of the rock tunnel, the stratigraphic sequence would start
with an overburden of glacial drift varying in thickness of
Niagaran-Alexandrian rock lying above a formation of Maquoketa
shale. It was the Niagaran-Alexandrian rock strata which
warranted more information. Thirteen borings were taken along
the route to a depth exceeding 250 feet (76 m). The analysis of
these borings was studied with three elevation ranges in mind.
The upper range contained interbedded cherty and shaly dolomite
with some zones of reef material. If built in this range, the
tunnel would be located within 40 to 50 feet (12 to 15 m) of
depressions in the bedrock surface which was known to be
locally broken and fractured. It was thought that clay-filled
crevasses might be present as had been observed at quarries in
the Chicago region and as encountered in water tunnel rock
mining in nearby Wilson Avenue. Also, the weathered rock
occurring at the top of bedrock contained open joints and
solution channels and was known to be a high-yielding ground-
water aquifer.
If the tunnel were constructed in the middle range, it would
pass predominately through a porous dolomite believed to have
originated as a coral reef. "Driliability" tests of typical
core samples taken from the Lawrence Avenue borings brought
forth an opinion that the reef dolomite had a drillability of
16
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about 25% less than the other types of roclc tested.
The rock in the lower range was found to be principally shaly '
dolomitic limestone with strengths varying roughly from 10,000
to 30,000 psi (7xl06 to 21xl06 kgs/sq m), with the majority of
the readings spread between 19,000 and 23,000 psi (13.4xl06 and
16o2xl06 kgs/sq m). The rock at this lower level also presented
a uniformity of strata and was relatively free from interbeds.
I
These geologic characteristics, which are only stated in general
terms, were then related to costs and construction problems that
might be inherent to each level. Obviously, the more shallow
the tunnel, the greater the savings in shaft construction costs
and pumping requirements, both in original cost of the pumping
units and their operation. However, the porosity of the upper
level rock, with clay-filled crevasses and the possibility of
fractured rock zones could result in costly and hazardous con-
struction with the need for steel roof supports, as well as rock
bolts and wire mesh, and would require that a substantial con-
crete lining be installed,. Because of the negative features of
the higher level rock zone plus the necessity of crossing a
water tunnel located in the same stratum, it was decided to
locate the tunnel at a depth ranging from 250 feet (76 in) to
220 feet (67 m) below the surface. It was also believed that,
with the dense, uniform dolomite to be found at the accepted
level, any possibility of polluting the aquifer would be elimin-
ated and that as construction proceeded, evidence! would be
gathered and a determination made on the possibility that, where
mining was performed by machine, no lining would be required, or
at the most, a very thin lining for hydraulic reasons.
Where drill and blast methods were used for rock iexcavation, an
8-inch (20.3 cm) minimum lining was specified because of the
irregular surfaces typical of this procedure.
j
I
Harza's appraisal report recommended the construction of a lined
tunnel sewer in the Niagaran limestone formation japproximately
250 feet (76 m) under the surface of Lawrence Avenue. See
Figures IV-3 and IV-4. The rock tunnel would be excavated by a
tunnel boring machine. The Lawrence Avenue route was selected
because of the requirement of the mole to travel in nearly a
straight line. Because the tunneling would be so far below the
surface, traffic in that arterial street and commercial activ-
ities would not be interrupted, as would be the case with the
conventional open cut construction.
17
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UNDERFLOW PLAN
4t
•40
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•130
•140
•1*0
•HO
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••••HIOH-LEVEL FEEDER LINES
CITY OF CHICAGO
LAWRENCE AVENUE
UNDERFLOW TRIBUTARY
Figure IV-3 Lawrence Avenue Underflow Sewer System
Location Plan and Profile
18
-------
•H
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The main tunnel would be 12,800 feet (3091 m) long at 12 feet
(3.7 m) in diameter and 9,300 feet (2835 m) long at 17. feet
(5.2 m) in diameter. A branch tunnel in Harding Avenue extend-
ing, south from Lawrence Avenue to Berteau Avenue, a distance of
4,000 feet (1219 m) (formerly a new conventional branch line,
later lowered to be a rock tunnel) would also be 12 feet (3.6 m)
in diameter. Approximately 18,000 feet (5486 m) of new
conventional branch sewers would relieve the overloaded existing
sewers and convey the flow to the tunnel inlet shafts.; Ten
inlet shafts would be constructed to supply the tunnel: and one
30 foot diameter outlet shaft for the discharge of drainage.
The total storage in the tunnels and shafts would be about
4,000,000 cubic feet (113,280 m3) or about 0.30 of an inch
(0.8 cm) over the 3,620 acre (14.6xl06m) drainage area. This
storage would provide space for the runoff from rainfall
accumulation up to about 0.9 inches (2.3 cm) without overflowing
to the river.
The cost of the tunnels, shafts, high level collecting branch
sewers, pumping and ventilation facilities and the gate and
outfall structures was estimated at $12,334,000. This was
$2,000,000 less than the estimated $14,350,000 cost of the
conventional open cut method of construction. These estimates
were prepared in 1966. The Engineering News Record, Construc-
tion Cost Index at that time was about: ca 1019.
COMPUTER STUDIES
In order to analyze the Lawrence Avenue Underflow sewer system
under actual operating conditions, a mathematical model of the
system was simulated in a computer program developed by the City
of Chicago's Bureau of Engineering. Each hour of rainfall
during an entire year was analyzed. The amount of rainfall
along with the corresponding hourly code was recorded on
punched cards. The computer was programmed to determine the net
runoff from the impervious and pervious areas for each hour of
rainfall. For the impervious area, a small amount of Depression
storage was subtracted from the first hours of rainfall of each
storm to obtain the net runoff supply. On pervious areas,
depression storage and varying amounts of infiltration depending
on wet or dry antecedent conditions were subtracted from the
rainfall to determine the net runoff supply. The total runoff
was then calculated by weighing the net runoff supply from the
impervious and the pervious areas in accordance with the
imperviousness ratio of the tributary drainage area.
20
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A hydrograph with a mass equal to the net runoff ssup>ply was then
developed. The base of this hydrograph can be caairied for the
time of concentration of the tributary sewer system. The hydro-
graphs for adjacent hour periods having a net runoff supply
were then added together, somewhat similar to the method used in
summing the unit hydrographs in river hydrology„
Sanitary flow at a rate of 100 gallons (378.5 liters) per day
per capita was added to these runoff hydrographs* to obtain the
combined flow hydrographs for every rainfall period of the year.
For this study 0.01 cubic feet per second per acre (7.07xlO~4
cubic meter per second per hectare) was used as the sanitary
flow rate. This rate has been verified as a good approximation
for the quantity of sanitary flow by the U»S. Public: Health
Service studies on the Roscoe Street sewer system.
I
At each overflow point of the existing sewer system, it was
assumed that up to two times the dry weather flow would continue
to flow by the overflow weir and along its present route to the
treatment plant. The excess flow over and above two times the
dry weather flow overflows down into the tunnel system.
The sanitary flow at these overflow points is assumed to be
uniformly mixed in the total combined flow upstream of the
controlling weir. Four assumptions were set for the pollutional
load in the combined flow. These were as follows!:
l •>
1. Suspended Solids in Sanitary Sewage = j 114 mg/1
2. Suspended Solids in Stormwater Runoff = 227 mg/1
3. B.O.D. in Sanitary Sewage = 96 mg/1
4. B.O.D. in Stormwater Runoff = 17 mg/1
i
Data for sanitary sewage were taken from the Metropolitan
Sanitary District records of influent to the North Side Treat-
ment Works for the years 1958 and 1959. Data for storm flow
were taken from a report of Stormwater runoff measurement by
the Public Health Service for a test drainage area in Cincinnati,
Ohio. |
A graph of the storage volume was plotted against the water
surface elevation in the tunnel. This data was placed in the
computer with linear interpolation between sets of points. When
the volume of inflow to the tunnel exceeded the total storage
volume, the excess water was discharged to the river. Limita-
tions were placed on the maximum discharge flowing through the
system, since storms exceedincr the design capacity of the
21
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existing sewer system and the new tunnel system would cause
upstream basements to flood. This flooding would limit the
maximum discharge through the system. This eventuality was
provided for in the computer by flood routing procedures and
limiting the maximum discharge to 1500 cfs (42.48 m3 per second)
to cover a storm event with a return period of 5 years.
A set time after the last hour of rainfall of a storm period,
the dewatering pumps were turned on. The pumps were set at
48 cubic feet per second (1.36 m3 per second) which would
provide complete dewatering of the tunnel to the interceptor in
24 hours. :
The B.O.D. in the tunnel was assumed to be pumped to the
interceptor or to overflow to the river at the instantaneous
concentration in the system. The suspended solids were divided
into two parts, that which would remain in suspension and that
which would settle as a function of tunnel velocity. That
portion which remained in suspension was pumped during'dewater-
ing or overflow to the river at the instantaneous concentration
in the system. The volume of suspended solids that settled to
the bottom was assumed to be removed by flushing and pumping
after the tunnel was dewatered, or during large storms;when
high velocities occurred in the tunnel and scouring would cause
the settled solids to be washed to the river. A linear relation
between zero resuspension for zero velocity to 100% resuspension
for a velocity of 10 feet per second (3 m per second) was used.
The type-out of the computer program was as follows:
Column Description of Data
1. Time 'in hours from beginning of year.
2. Rate of rainfall for hour period.
3. Runoff in cubic feet per second from the drainage area.
4. Instantaneous elevation of water surface in tunnel.
5 . Volume of water in the tunnel, in cubic feet.
6. Discharge into the tunnel, in cubic feet per second.
7- Pumping rate to M.S.D. interceptor, in cubic
feet/secondo
8. Overflow from tunnel to river, in cubic feet/second.
9. Accumulation from first of year of suspended solids
to tunnel, in pounds.
22
-------
Column (contd)
Description of Data (cbntd)
10 Accumulation from first of year of B.O.D. to tunnel,
in pounds.
11 Accumulation from first of year of suspended solids to
river, in pounds. !
12 Accumulation from first of year of B.O.D. to river, in
pounds. i
13 Accumulation from first of year of suspended solids
pumped, in pounds. j
14 Accumulation from first of year of B^O.D. paimped, in
pounds.
In Columns 9 & 10, the suspended solids and B.O.D. overflowing
the weir to the tunnel can be assumed to be equivalent to the
spillage to the river of an existing sewer system of equivalent
drainage area. Therefore, comparing these columns', with
Columns 11 and 12 enables the determination of the! reduction in
suspended solids and B.O.D. for the drainage area with the
Lawrence Avenue tunnel system in place. \
\
Table I, see Figure IV-5, shows the results summarized for five
years of records using the rainfall as it occurred at Midway
Airport, U.S. Weather Bureau Gage for 1956 to 1960 inclusive.
23
-------
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24
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SUMMARY OF THE LAWRENCE AVENUE SEWER SYSTEM
A chronology of events leading up to the development of the
Lawrence Avenue Sewer Plan including the appraisal report by the
Bureau of Engineering's consultant, Harza Engineering Company,
and the electronic computer studies is presented.
The appraisal report recommended the Lawrence Tunnel Sewer with
indicated savings of $2,000,000 over the conventional open cut
method while providing all of the benefits of flood protection.
It minimized street disruption during construction and resulted
in less inconvenience to residents,-pedestrians, commerical
enterprises, parking, vehicular traffic and utilities» The
Underflow,Sewer would result in greater storage and provide for
less frequent overflows to the Chicago River. |
The computer studies summarized in Table I indicate an average
of the five years studied of 59 overflow periods for a total of
235 -hours for the existing sewers and would be reduced to 5
overflow periods for a total of 18 hours. This represents an
average of about 92 percent reduction in both the number of
overflow periods and the hours of overflow. The pounds of
suspended solids and B.O.D. discharged to the river would be
reduced by 73 and 78 percent, respectively.
Studies have indicated that combined sewers spill in the neigh-
borhood of 3% of the sanitary sewage to the receiving streams
during the course of the year. The above figures indicate that
with the Lawrence Avenue Underflow Sewer in operation, less
than 0.8% of the sanitary sewage pollutants would be discharged
to the North Branch of the Chicago River from its tributary
drainage area. Another way of stating this is to say that over
99% of the suspended solids and B.O.D. contained in sanitary
sewage would be delivered to the treatment plant for processing
before being discharged to the waterways.
In the pumping station contract, instrumentation was to be
provided to monitor the gate openings, the level of water in the
tunnel at all times, operation of the dewatering|pumps and auto-
matic sampling during spillages to the river. >
It was hoped that construction under the first contract would
demonstrate that the use of a hard rock mining machine or "mole"
to tunnel through the hard dolomitic limestone rock: in the
Niagaran strata was economically feasible and woiildl provide
data for future sewers of this type.
25
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FEDERAL GRANT (EPA Grant No. 11020 EMD)
Early in 1967, the Department of Public Works applied for a
Federal Demonstration Grant for the Lawrence Avenue Deep Tunnel
Sewer System. A grant offer of $1,500,000 was approved on
April 25, 1967, subject to the approval of final plans and
specifications for the project in addition to other conditions
and assurances.
It was considered to be a demonstration grant because no city in
the nation was currently using such a system, which would have
application in highly developed urban areas where- space for
surface storage is uneconomical. The portions of the project
which were eligible for grant participation, however,.were
limited to the rock tunnel sections and the pumping facility
under Contracts No. 1 and No. 3.
PREPARATION OF CONTRACT DOCUMENTS
Based on the findings of the appraisal report, the City's
Department of Public Works, retained Harza Engineering Company
to prepare contract documents for the Lawrence Avenue System.
The total cost of this consulting contract was $621,142000 which
included the appraisal report, reimbursable items, and services
provided in the design and preparation of contract documents for
the following contracts, construction of which were required to
complete the system as planned:
Contract No. 1 - Main Shaft and Rock Tunnels
Lawrence Avenue Monitoring Wells
Contract No. 2-A - High-Level Tunnels in Earth
Contract No. 2-B - Ten Drop Shafts
Contract No0 3 - Pumping Station and Outfall
Contract No. 4 - Additional High-Level Sewers .
26
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COBSTRUCTION PROGRESS
Contract No. 1
Contractor;
Bid Price;
Financing;
Location:
Contract
Description:
Main Shaft and Rock Tunnels
Joint venture of James McHugh Construction Company,
S.A. Healy Company, and Kenny Construction Company.
$10,792,094.00
22% of construction cost was paid from City's share
of Motor Fuel Tax Funds. Balance from Sewer Bond
Funds, and from Federal Funds.
In Lawrence Avenue from North Branch of the Chicago
River to Melvina Avenue, and in Harding Avenue from
Lawrence Avenue to Berteau Avenue. ;
I
16,638 feet (5,071 m) of 12'-0" (3.66 m) diameter
and 9,126 feet (2,782 m) of 17'-0" (5^18 m) diameter
concrete-lined sewer tunnels in rock; excavation of
approximately 250 feet (76.2 m) of main shaft of
29'-0" (8.84 m) in diameter in earth, excavation and
27'-o11 (8.23 m) in diameter in rock excaivation;
surface restoration; and all appurtenant and
collateral work.
Construction
Starting
Date;
Status;
November 6, 1967
Contract completed May 28,
1973
Construction Methods;
As a prebidding feature, DPW had in February of 1967 advertised
an invitation notice to inform prospective bidders; of the work
to be done under this contract. At the conference; that followed,
and which was attended by representatives of almost fifty
contracting, manufacturing and supply companies, it was indicated
by the City that consideration should be given to boring the rock
tunnels by machine if possible.
The low bidder on this project elected to use an existing rock
mining machine that could be made available in a short time but
whose^ cutting-face diameter was 13'-8" (4.17 m). His procedure
called for first mining the 17-foot (5.18 m) tunne|l with this
machine at the correct bottom elevation and then enlarging to
proper size by conventional drill and blast methods. By mining
27
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to the correct bottom elevation, trackage for his muck cars
could be installed and put into use as the heading advanced.
The,12-foot (3.66 m) finished diameter tunnel in Harding Avenue
and in Lawrence Avenue (west of Kildare Avenue) would also be
bored with this machine0 Both size tunnel sections would be
lined with a minimum 8" (20.3 cm) concrete lining as specified
in the contract documents 0
The Contractor started work by excavating the main shaft with
conventional methods. See Figure .IV-6. The top forty1feet
(12.2 m) of 29 foot (8.84 m) diameter shaft in over-burden was
supported by steel ribs and sheeting. The additional 215 foot
(65.5 m) depth of shaft, 27' (8.23 m) in diameter, was drilled
and blasted in a very short time. A tail tunnel, see Figure IV-7,
to accommodate muck car unloadings, was blasted for a distance of
73 feet (22.25 m) northeasterly from the shaft, and a 316 foot
(96.3 m) length of full-size excavation for the 17-foot (5.18 m)
tunnel section was shot out while waiting for the mining machine
to be deliveredo
The rock-mining machine, see Figures IV-8, IV-9 and IV-10, was
assembled in the tunnel and, for the next two months, tested
under actual operating conditions until the Contractor:was
satisfied that limestone of the hardness of 11,400 psi to
29,600 psi (SxlO6 kgs/m2 to 21xl06 kgs/m2) that was expected to
be encountered could be successfully bored by Machine. Several
types of conveyor set-ups were also tried during this time in an
attempt to find an efficient way of bringing the muck from the
cutting wheel to the cars. The excavated material as cut by the
machine resembled irregular chips of rock, no longer than 2"
(5.1 cm) on any side. A substantial amount of muck was too fine
in size to be scooped up by the machine and had to be washed out
from in front of the machine face.
The tunnel was properly ventilated as work progressed, and for
dust control, water was, sprayed on the rock face at the heading
at a rate of 40 gpm (151.4 1/m).
All tunnel excavation then stopped for 39 calendar days while
the Contractor erected his head frame and hoisting equipment,
see Figure IV-11, and performed other miscellaneous work. At
the end of May, 1968 full scale use of the mole began.
28
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29
-------
30
-------
31
-------
r^i^^r^"^ -"T^iC?,,^
32
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33
-------
Figure IV-11 Head frame and hoisting equipment at main shaft.
34
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Some facts concerning major equipment items used by the
Contractor, including the mining machine particulars, follows:
Mining Machine Data
Manufactured by:
Thrust of Machine
Drive of Machine No. 1
Drive of Machine No. 2
Operation Voltage
Make of Bits
Number of Cutters
Dia. of Cutterhead:
Machine No. 1
Machine No. 2
Length of Machine:
Assembly
Drawbar
Power Train
Auxiliary Power Train
TOTAL LENGTH
Tunnel Power Line
Conveyor System
Manufacturer
Muck Cars
Length of Train
Track Gauge
Locomotive s
Ventilation
Lawrence Mfg. Co. (Seattle, Wash.)
1,300,000 Ib. (589,680 kg). Maximum
5-125 hp. motors (126.75 hp - metric)
3-250 hp. motors (253.5 hp - metric)
480 Volts
Lawrence Mfg. Co0
29 Disc-Type with carbide inserts
13'-8" dia,
13'-9" dia.
Lawrence
(4.16 m) |in Lawrence Avenue
(4.19 m) in Harding and
19--11" (6.07 m)
15'-11" (4.85 m)
23'-7" (7.19 m)
25'-4" (7.72 m)
84f-9" (25.83 m)
4,160 Volts
Lawrence Mfg. Co. with a Goodyear
Belt 24" (61 cm) wide by 84' (25.6 m)
long ;
6 Cubic Yards (4.59 m3)
9 Cars
36-inch (91.4 cm)
10 Ton (9072 kg) Plymouth Diesel, 86 hp
(87.2 hp-metric)
28" (71 cm) Vent line
2-40 hp (40.56 hp-metric) Vent fans
made by the Joy-Axivane Co.-, 14,000
CFM (396 mVmin) each
(15.2 hp-metric fan at street level to
prevent any line back pressures.
Line & Grade Control
By Laser Beam
35
One 15 hp
-------
Factors Adversely Affecting Progress;
1. The basic and major problem which had delayed completion of
this contract, and the entire sewer system, had been the poor
performance of the original mole. The machine when working
properly could mine an average of about five lineal feet; (1.5 m)
of tunnel an hour. It was expected that the machine would be
out of operation during periods that the cutters had to be
replaced and normal maintenance performed. Many other malfunc-
tions had to be corrected, some of them several times. The
down-time reports include items such as bearing replacements,
replacing cutter 'guard, repairing hydraulic leaks, repairing
pilot cutter gear drive, disassembling hydraulic thrust system
and repairing drive shaft housing, repairing transformer at
Seattle plant, and many others.
The Contractor's "Critical Path Schedule" indicated an expected
average mining rate of 282 lineal feet (86 m) per week with the
mole, based on the claims of the manufacturer. After 49 weeks
of actual performance, the machine had averaged about 132 ft.
(40 m) per week and was completely worn out. The machine was
dismantled and removed from the job and, while awaiting delivery
of a new machine, the Contractor continued work by conventional
drill and blast methods.
The second machine was placed in operation December 1, 1969 in
Harding Avenue and later bored the Lawrence Avenue portion of
12-foot (3.7 m) tunnel. This machine bored an average of
better than 6 lineal feet (1.8 m) per hour and, when full scale
operation could be maintained, completed as much as 426 feet
(130 m) in one week,
2. When the first mining machine performed so poorly, the
progress of the tunnel work was definitely handicapped by the
fact that the only point of ingress and egress to the work was
through the main shaft0 This is a calculated risk with deep
tunnel work because of the high cost of excavating additional
work shafts and installing hoisting equipment.
It should be pointed out that two similar rock tunnels were
later contracted for by the Metropolitan Sanitary District
based on the information gained by our pioneering of the
Lawrence Ave. project. Each tunnel was bored by machine from a
single shaft and completed in rapid fashion. Each machine used
was by a different manufacturer than the ones tried on this
project.
36
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3. When the Contractor enlarged the 17-foot (5 ,.2 m) tunnel to
full size after drilling a 13'-8" (4.2 m) hole with the mole, he
did not trim his blasted section to suit the steel form to be
used in pouring the 8" (2003 cm) concrete lining„ Later while
the mole was excavating westerly in Lawrence Avenue, the lining
operations could also have been going on simultaneously, but
the muck train movements to the shaft interfered with the
trimming of these tight spots and as a result the concrete
lining operations stopped for nine months.
I
4. Strikes by both the operating engineers and the truck drivers
during the life of this contract also added to the Contractor's
problems.
Contract Modifications;
1. The original machine was difficult to steer and thus maintain-
ing line and grade was a problem. At the Contractor's request
the finished invert grade was revised to suit the actual grade
of tunnel as bored by the original mole for the first 6,128 feet
(1,868 m). The costs to revise the design of the drop shaft
structures because of this change were paid by the Contractor.
DEDUCTION = $12,250.00
2. Because of the excellent condition of the limestone rock in
which the tunnel is located, see Figure IV-12, It had been
decided that concrete lining of the machine-mined sections would
not be required. Restoration work in some areas, consisting of
rock bolts, wire mesh and guniting was performed. The
Contractor submitted an acceptable proposal to do the work.,
For Harding Av. Tunnel - ADDITION = $19,000.00
NOTE: By eliminating the concrete lining from these 12 ft.
(3o7 m) tunnel sections, and performing only corrective
work as stated, the total savings to the City was in
excess of 800 thousand dollars. in addition, the
elimination of the lining increased the storage
capacity of the system by about 580,000 cubic feet
(16,425 m3). I
3o Because of the Contractor's procedure in excavating the
original 17-foot (502 m) tunnel first by machine bore and then
enlargement by blasting, a substitute finished section was
designed. To achieve equivalent area, an egg-shaped section
resulted, with a 7'-6" (2.3 m) crown radius and
invert radius„ The maximum inside dimensions are .15'-6%" (4.7 m)
37
a 6'-0" (1.8 m)
-------
-------
in width, and 19'-5" (5.9 m) in height. See figures IV-13,
IV-14 and IV-15o There was no change in cost toj the City for
this modification.
4. Five time extensions were negotiated and apprpved. They were
for 482 days, 30 days, 120 days, 153 days and isb days.
5. Extra to perform tunnel restoration work in the Lawrence
Avenue portion of the machine-mined tunnel»
ADDITION = $87,000
ADDITION = $17,653
60 Tunnel inlet to the main shaft.
Other Items;
1. Contract Documents;
•
The length of tunnel actually excavated is less than that called
for in the proposal quantities because of the design and location
of the drop shaft structures <, This information was not known
when this contract was prepared and actually resulted in reducing
the final cost of the contract.
The radius of the tunnel curve at Milwaukee Avenue was increased
from 180' (54.9 m) to 500' (152*4 m) to accommodate the Contrac-
tor and to suit the length of the mining machine 1
l
2o State and Federal Requirements;
Because both Motor Fuel Tax Funds and Federal Grant money were
involved, the contract documents contained the inserts and
specifications required by the agencies concerned.
3. Traffic and Safety;
The only construction shaft was located on MSDC property and
therefore maintenance of vehicular traffic was not involved.
Safety regulations were documented in the specifications and
were adhered to by the Contractor.
4o Supervision of Construction;
i
Supervision was more than adequate and the complaints regarding
noise and vibration, which were to be expected where blasting
was performed, were handled with skill and understanding.
39
-------
.
i'^^Hi;^*,, ^jri,%'„'.«.!,'• js'iff L,,S ii,*-'"^^*:;*^"/'1'- '.« i ;.^w^ '^"--^wr^."
' '11"" '' '1'*"''11" !"" " lltv"
40
-------
41
-------
Figure
section
prior
shaft and pump sump
forming transition to main
42
-------
Recommendations;
1. Wherever possible, rock tunnel-type sewer systems should be
designed and constructed. Specifications should require the use
of a mole within all practical size ranges.
' i
2» The drop shaft structures should be included in the contract
with the rock tunnel construction. This would give additional
shafts for ingress and egress, and thus increased safety pro-
visions, but also would provide the Contractor with a greater
number of locations where muck could be removed.
I
3. The Contractor should be required to keep the'floor of the
tunnel cleaned of muck and debris. Also a better drainage system
in the tunnel should be required. in this tunnel, walking any
great distance was extremely difficult because of poor house-
keeping.
Contractor;
Bid Price;
Financing;
Location;
Monitoring Wells
Wehling Well Works, Inc.
$45,805o00 ; . ;
Sewer Bond Funds }
Just west of the southwest corner of Harding and
Wilson AvenueSo
Description & Purpose;
I
!
Three wells on 20-foot (6.1 m) centers were drilled to different
depths with 12 3/4" (32.4 cm) diameter casings in1 earth and 10"
(25.4 cm) bores in rocko These wells were installed so that the
necessary data could determine if the Lawrence Ave. Underflow
System has any objectionable effect on the Silurian aquifer and
on the Wilson Avenue water tunnel which crosses Harding Avenue
about 89 feet (27 m) above the sewer tunnel. These data consist
of water level measurement recordings, and sampling taken from
each well. , _
Contract Modifications; \
There^were no modifications or adjustments to final contract
quantities as the work was successfully completed without the
need to assess liquidated damages. [
Comments;
I
A small job of this type created no traffic problems and was so
specialized that it required customized plans and j specifications..
43
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Results To Date:
Since completion of the contract, results have been reviewed of
water level measurements, and of the samples which have been
taken on a monthly basis by personnel from the Bureau of Water,
no adverse effect on water quality or quantity has been noted.
The same frequency is to be maintained after the sewer system is
in operation except that additional measurements and samples will
be taken the day following any storm great enough to cause
pressurization of the tunnel.
As a separate study, the wells were also tested by the Illinois
State Water Survey in order to determine horizontal and vertical
permeabilities of this aquifer.
Contract No. 2
High-Level Tunnels in Earth and Drop Shaft Structures
Problems Encountered With Contract No. 2
Bids for Contract No. 2 of this system were received on
October 3, 1969 but were rejected as too high because the low bid
of three received exceeded by 31.5% the estimate prepared by
Harza Company. The contract in part called for the ten drop
shaft structures to be constructed without disturbing the work
being performed in the rock tunnel and making connections to the
completed tunnel later.
The work originally proposed under Contract No. 2 was then split
into two contracts by the City's Department of Public Works with
construction of the drop shaft structures to be delayed until
after the rock tunnel excavation was completed. This would be
Contract 2-B. The balance of the proposed work was put into
Contract 2-A and re-bid. The wisdom of this procedure was proven
when the low bids for 2-A and 2-B combined totaled $389,305.00
less than the original No. 2 bid.
Contract NQo 2-A
Hiqh-Level Tunnels in Earth
Contractor; Reliance Underground Construction Company, Inc.
Bid Price; $2,393,645.00
Financing; 52% of construction cost paid from City's share
of Motor Fuel Tax Funds. Balance from Sewer
Bond Funds.
44
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Location;
Contract
Description;
Estimated Cost
of Revising
City-Owned
Utilities;
Construction
Starting
Date;
Status;
In Menard Avenue from Lawrence Avenue to Berteau
Avenue; in Melvina Avenue from Lawrence Avenue to
Gunnison Street; in Moody'Avenue from Gunnison
Street to Strong Street to Mobile Avenue to
Foster Avenue; and in Argyle Street from Mobile
Avenue to Nagle Avenue.
700 feet (213 m) of 5'-0" (1.5 m) diameter, 1,310
feet (399 m) of 6'-0" (1.8 m) diameter, 3,910 feet
(1192 m) of 6'-6" (1.98 m) diameter, 1,540 feet
(469 m) of 8'-6" (2.6m) diameter, and 960 feet
(293 m) of 9'-6" (2.9m) diameter earth tunnel;
270 feet (82 m) of 12-inch (30.48 cm) diameter
vitrified clay pipe; one monolithic concrete drop
inlet structure; three monolithic concrete side
weir inlet structures; three junctions; twelve
drop pipe connections; manholes; catch basins;
surface restoration; and all appurtenant and
collateral work.
$53,947.41
March 16, 1970
I
All construction work completed June 1, 1972
Construction Methods
The tunnel sections were excavated with a Caldwell earthmining
machine, equipped with hydraulic jacks to expand steel ribs and
lagging against the earth sides as mining progressed. The
contract, as bid on, specified five sizes of tunnel but per-
mission was given to the Contractor to construct only two sizes
namely 9'-6" (2.9 m) and 6'-6" (2.0 m) finished diameter after
reinforced concrete lining was poured. Where a larger-size sewer
than specified was constructed, there was no additional cost to
the City and the expense of revising the contract plans where
required was paid by the Contractor.
Shafts for most of the connections were excavated with a vertical
boring machine. With a 50-foot (15.2 m) high rig arid an adjust-
able cutter, shafts varying from 8 ft (2.4 m) to 20 ft (6.1 m)
in diameter were drilled.
45
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ADDITION = $11,525.00
DEDUCTION =$23,043.24
The concrete tunnel lining was placed by pumping concrete into
the tunnel and around a collapsible, portable steel forni 70 feet
(21.3 m) in length.
Temporary bulkheads were placed in all structures connecting to
existing sewers to prevent water and sewage from entering the
finished work from that source. Provisions were made under
Contract No. 3 to remove these bulkheads when the system was
ready to be put into operation.
Contract Modifications:
1. Revisions were required to some of the contract plans because
the Contractor constructed larger tunnel sections than proposed.
This was done at his expense. DEDUCTION = $2,500.00
2. Four time extensions were negotiated which totaled 328
calendar days. The last extension of 171 days was required
because the remaining surface restoration awaited suitable
weather.
3. Surface restoration item.
4. Adjustment to Final Contract Quantities
General;
in the 25 years that the Auxiliary Outlet Sewer Program has been
in existence, the City of Chicago's Department of Public Works
has gained vast experience in the design, and supervision of
construction, of sewers of this type.
Traffic requirements were worked out in advance with the Bureau
of Street Traffic, coordination was maintained with public and
private utilities, State Highway requirements (for Motor Fuel
Tax fund approval) were met, City codes and ordinances were
followed, public protection and safety were stressed, and in the
case of this contract, 65 bid items were included in the proposal.
It should not be surprising, therefore, that there were no
inadequacies to report in any of the areas aforementioned.
Recommendations that have been received through the years were
incorporated in the Plans and Specifications. The biggest
factor in earth tunneling was to prevent movement of the
surrounding earth and thus keep settlement to a minimum so that
adjacent facilities were not damaged. Strict requirements to
prevent settlement were included in our Specifications and
enforced by the Department of Public Works' engineers who
supervised the construction.
46
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Contract No. 2-B
Ten Drop Shafts
Contractor; Rock Road Construction Company
Bid Price: $3,415,688.00
Financing;
Location:
2
3
4
5
6
7
8
9
10
Contract
Description;
52% of construction cost was paid from City's
share of MFT Funds. Balance from Sewer Bond Funds.
Ten Drop Shaft Structures located at:
1. Harding Avenue & Berteau Avenue
Harding Avenue & Mpntrose Avenue
Lawrence Avenue & Harding Avenue
Lawrence Avenue & Drake Avenue
Lawrence Avenue & Kildare Avenue
Lawrence Avenue & Kilbourn Avenue
Lawrence Avenue & Laramie Avenue
Lawrence Avenue & Long Avenue
Lawrence Avenue & Menard Avenues
Lawrence Avenue & Melvina Avenue
In addition to the above ten structures; three drop
inlets? six side weir inlets; drain connections and
all other appurtenant and collateral work.
Estimated Cost
Of Revising
City-Owned
Utilities: $93,032.86
Construction
Starting
Date;
Status;
February 28, 1972
All construction work completed October 13, 1974.
Design;
During the design of "these drop shaft structures, the services
of the University of Minnesota, St. Anthony Falls Hydraulic
Laboratory, were obtainedo Studies were made wi-|th models to
determine; the sizes of the shafts in relation to the quantities
of flows entering from the. high level sewers, ai.r entrainment,
the removal of the entrained air in the air collector in the boot
of the structure and the dividing wall and deflectors as well as
water surge conditions.
47
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Model Studies;
The, Lawrence Avenue Sewer System consists of a large deep;tunnel
for temporary storage of the surface runoff fed to it by a
series of drop shafts placed at intervals along the axis of the
tunnel. Each drop shaft was designed to handle a variable
discharge, the peak value of which was different for each drop
shaft. As the volume of runoff increases, the tailwater eleva-
tion will change from zero to a maximum governed by overflow
facilities. The objective of the research was to investigate
the nature of the .flow in the drop shafts and to examine various
alternative designs suggested by the results of the studies„
The essential purpose of the drop shaft is to transport water
from one elevation and energy content to a lower elevation and
lower energy content. Its function, then, is to dissipate the
energy of the incoming flow in the course of its passage down
the drop shaft to its new elevation and new flow pattern.. If
the drop shaft runs full, the energy change may be accomplished
by friction along the wall of the drop shaft so that its ;energy
at the bottom of the shaft is equal to that of the outflowing
water«, When the drop shaft is partially full, the change in
energy is accomplished by impact of the falling water on the
bottom of the shaft. For variable discharges, this change of
energy is accomplished by a combination of boundary friction and
impact o
In a system involving drop shafts of the height required by the
Lawrence Avenue Sewer System, dissipation of energy by boundary
friction alone required that the diameter be relatively small
and that the flow velocities be quite high. It also requires
that the drop shaft run full for all discharges that must be
handled. For larger diameters and lesser velocities, the full
flow condition can be attained in several ways. It is possible
to maintain full flow to drop shafts for all discharges by using
a valve at the bottom of the shaft. Full flow for a range of
discharges could also be attained by introduction of air in
varying amounts into the flow so that the water bulk will be
increased sufficiently to fill the drop shaft. From the
hydraulic point of view, use of a valve at the foot of the drop
shaft is rather attractive, but it would have the disadvantage
of being located far underground in the outlet tunnel and would
require special instrumentation so that the valve opening could
be governed by the inflow discharge. In addition, the valve
would be subject to possible damage by sediment and other debris
transported through the system. In the second alternative, that
48
-------
is, the introduction of air into the flow, all obstructions to
the flow and the necessity of moving parts would be eliminated,
but the problem involving the development of a homogeneous
mixture of air and water for all discharges in the drop shaft
will probably be more difficult. Also, the design will have to
provide for entrainment of proper quantities of air during the
fall, its separation from the water and collection at the bottom,
and its removal before being carried into the tunnel.
Because of the advantages that appear to be inherent in the air
entraining type of drop shaft and because of experiences gained
in previous studies of such drop shafts, the investigations for
the Lawrence Avenue Sewer System were directed towards further
development of such structures. Figures IV-16 through IV-26
show the results of experiments on several alternative systems
which involve the entrainment of air in the drop shaft and the
removal of this air from the flow at the bottom.
The development of the Type E-15 drop shafts consisted of
successive tests of modifications of the basic structure. By
observing the functioning of each design, changes ;were intro-
duced which appeared to offer improved functioning. By this
means the final arrangement was reached. The Type E-15 drop
shaft will effectively remove entrained air before; it reaches
the downstream tunnel for all discharges up to itss capacity and
for all tailwater elevations above the crown of the downstream
i
tunnel.
The sloping crown of the air collector is very important in order
to effectively remove entrained air. It was also demonstrated
by these tests that the slope of the air collector' s crown vshould
not be reduced, but an increase in slope would be beneficial to
its operation. These experiments indicate that a slotted divider
wall is more effective than a solid divider wall. If a slotted
divider wall is used, then deflectors are necessary to deflect
the flow away from the slot to provide the pressure distribution
that permits air to be drawn into the flow and distributed over
the cross-section. Of the deflectors tested, it cippears that the
largest deflector was the most effective, both from the point of
view of air distribution and safety from damage by foreign bodies
that might be carried by the flow. ;
49
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Figure IV-16 Overall View - Model
The drop shaft model was fabricated of a
transparent plastic so that the flow
patterns could be observed. The photo-
graph shows a model slightly different
from Type E-15 but is included here to
demonstrate the relative size of the
model and its characteristic features.
50
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Figure IV-17 Exit Conduit, Q=30Q cfs, TW=10 ft..
C8.5m3/sec.), (3m)
This photo shows that for 300 cfs and a low tailwater of 10 ft-
the air collector is effective in removing the air.
51
-------
Figure IV-18 Exit Conduit, Q=300 c£s, TW=100 £t.
(8.5m3/seci), (30.5m) ;
For higher tailwaters such as shown in this photograph,where
the elevation is 100 ft. the Type E-15 can easily remove
the air from the flow. ;
52
-------
Figure IV-19 Exit Conduit, Q=600 cfs, TW=10 ft.
(17m3/sec.), (3m)
For a discharge of 600 cfs and the tailwater maintained at
10 ft. the Type E-15 successfully removes the air from the
flow.
53
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Figure IV-20 Exit Conduit, Q=600 cfs, TW=50 ft.
(17m3/sec.), (15.2m)
When the tailwater has been raised to 50 ft. the entrained
air quickly rises to the top of the air collector so that
none can escape into the downstream tunnel.
54
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Figure IV-21 Exit Conduit, Q=600 cfs, TW=100 £t.
C17m3/sec.) , (30.;5m)
For a tailwater o£ 100 ft. the air collector is still effective
in removing air.
55
-------
Figure IV-22 Exit Conduit, Q=600 cf s , TW=190 £t.
(17m3/sec.), (58m)
For a discharge of 600 cfs and a tailwater at 190 ft. the
entrained air has been considerably reduced and the air
collector can easily remove it from the flow so that none
escapes into the downstream tunnel.
56
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Figure IV-23 Vertical Shaft, Q=600 cfs, Effect
of Air Slots
-\. —_- »
(17m5/sec.)
This photograph shows a discharge of 600 cfs. through the
structure with a deflector over the air slots. The flow is
homogeneous and no water escapes through the slots into the
air vent.
57
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Figure IV-24 Entrance Conduit, Q=300 cfs, TW=225 ft.
(8.5m3/sec.), (68.6m)
When the discharge is 300 cfs with the tailwater at 225 ft,
incoming tunnel runs only partly full but there is no air
entrainment. The drop shaft is full and the pressure
difference between inlet and outlet is relatively small.
(Shown for Type E-,17, E-15 flow patterns are identical at
this tailwater).
the
58
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Figure IV-2 5 Entrance Conduit, Q=600 cfs, TW==190 £t.
(17m3/sec.), (58m)
When the tailwater is 190 ft. which is somewhat below the
elevation of the incoming tunnel, the discharge of 600 cfs
slows smoothly around the inlet and into the drop shaft
proper. As it flows into the drop shaft, air is entrained
and mixed with the water. The pressures in the incoming
tunnel are atmospheric and the water surface represents the
hydraulic gradeline.
59
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Figure IV-26 Entrance Conduit, Q=60J) cfs, TW=225 ft.
(17m3/sec.), (68.6m)
When the discharge is 600 cfs with the tailwater at 225 ft.,
the flow characteristics are essentially unchanged from when
the flow is 300 cfs.
60
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Construction Methods:
During the construction of this Contract, work also was proceed-
ing on Contracts No<> 1 and No. 3 by another Contractor which
caused some conflict. The excavation of the drop shaft struc-
tures was accomplished by the raise bore method through the
rock and by the down drill cutter machine through the overburden.
See Figures IV-27, IV-28, IV-29 and IV-30. The form work for
the concrete connecting section from the main tunnel to the drop
shaft boot is shown in Figure IV-31.
Contract Modifications:
lo Relocation of existing sewers around drop shaft structures.
ADDITION == $6,227.90
2. Restore existing 15-inch sewer in Laramie Avenue through no
fault to Contractor. ADDITION == $7,935.50
3. Five time extensions were approved for a total of 407 days.
4. Additional manhole added. ADDITION -~ $295.00
5. Final Contract Quantity adjustment. DEDUCTION = $30,376.30
Contract No. 3
Pumping Station and Outfall
Joint venture of James McHugh Construction Company.
S.A. Healy Company, and Kenny Construction Company.
$1,977,000.00
52% of construction cost was paid from City's share
of Motor Fuel Tax Funds„ Balance from Sewer Bond
Funds, and from Federal Funds.
Lawrence Avenue at North Branch of Chicago River.
\ Pumping facilities; outfall structure; yard area;
Contractor
Bid Price:
Financing;
Location;
Contract
Description;J main shaft concrete lining; a discharge line to the
M.SoD.C. interceptor; the removal of existing
temporary brick, concrete and wooden bulkheads; the
construction of brick weirs; and the performing of
all appurtenant and collateral work.
Construction
Starting
Date; April 17, 1972
Construction Status;
Figure IV-32 shows main shaft features installed following
placing of the concrete lining prior to installation of the
elevator.
Figure IV-33 shows one of the submersible pumps.
61
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Figure IV-27 Down drill rig at the drop shaft at Lawrence Ave
and Menard Ave. for drilling through the over-
burden prior to rock drilling by the raise-bore
method.
62
-------
Figure IV-28 Close up view of the down drill cutter head for
drop shaft excavation.
63
-------
64
-------
65
-------
Figure IV-31 Erecting form work for the concrete connecting
section from main tunnel to the drop shaft boot.
66
-------
(0
0
J>
o
o
rt fl
f-i o
-P -H
bOi— I
fl >H
•H 03
rt -P
•H tfl
rH fl
•H
0 o
^1 -H
O -P
P! c«
o >
u 0
rH
bO O
s
•H O
w o
•H
•P (I
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nJ
•H
rt ft
•H
ni P
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0
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-------
Figure IV-33
Submersible Pumps
Manufactured in Germany by the
KSB Pump Company. Pumps were
designed for installation and
removal while the Main Shaft
is filled with water.
Characteristics:
(each of four)
Rated Capacity 5,000 GPM
(315 I/sec.)
228 Feet
(69.5 m)
535 HP
(542.5 lip-metric)'
1,180 RPM
15 Ft.(4.6 m)
28,000 Pounds
(12,700 Kg)
Rated Head
Rated Power
Rated Speed
Height
Weight
68
-------
As of Feb. 1979, the contract work was 96o65% completed. Pump
failures had occurred due to infiltration or intrusion of water
into the upper chamber of the junction boxes which caused
considerable delays. This was believed to have been caused by
water absorption through the power cable jacket after long
periods of submergence or through faulty junction boxes.
Although the cables were installed per specifications, it became
necessary to research new cables which now have testing labora-
tory approval.
I
The use of Okonite control cables now requires larger diameter
reels and gear modifications in gear boxes to operate the reels.
This problem is currently being resolved. ;
Contract Modifications:
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17,
18.
Revision of electrical work in the control chamber.
ADDITION = $1,702.00
Domestic water supply change. ADDITION = $3,680.24
Furnishing and placing four pump discharge diffusers.
ADDITION
Heating system for pump supply line. ADDITION
Additional reinforcement steel for baffle walls.
ADDITION
Replacement of blown terminal boxes. ADDITION
Starter-fuses (spare parts). ADDITION
Miscellaneous protection devices. ADDITION
Modification of 14-inch ball valves. ADDITION
Grate modification to clear hoisting chains.
ADDITION
Disposal of debris for bulkhead removals.
ADDITION
Plywood covers at main shaft (freeze prevention).
ADDITION
Replacement of manhole covers for Outfall
= $5,161.29
= $189.62
= $311.08
= $50,125.00
= $3,426.89
= $1,108o68
= $948.75
= $3,162,50
= $5,325.34
= $2,173.50
Structure (36-inch-double openings). ADDITION
Crane charges for Pump removals. ADDITION
Pumping Costs. ADDITION
New Cables - Okonite, power & control. ADDITION
Modifications for new cable reels. ADDITION
Five time extensions have been approved as of April,
a total of 973 days.
$612.38
$4,606.70
$3,474.60
$73,729.00
$20,013.00
1978 for
69
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Contractor;
Bid Price:
Financing;
Location:
Contract
Description:
Construction
Starting
Date;
Status:
Contract No. 4
Additional High-Level Sewers
Jay-Dee Contractors, Inc.
$2,644,875.00
Sewer Bond Funds
In Drake Avenue from Lawrence Avenue to Argyle
Street; in Long Avenue from Lawrence Avenue to
Montrose Avenue; in Melvina Avenue from Lawrence
Avenue to Eastwood Avenue to Narragansett Avenue
to Montrose Avenue; and in Strong Street from
Moody Avenue to Austin Avenue to Higgins Avenue.
3,930 feet (1198 m) of 6'-0" (1.8 m) diameter and
4,610 feet (1405 m) of 5'-0" (1.5 m) diameter earth
tunnel; 1,245 feet (379 m) of 60-inch (152.4 cm)
diameter reinforced concrete pipe; one monolithic
concrete drop inlet structure; three monolithic
concrete side weir inlet structures; eight drop
pipe connections; manholes, catch basins, surface
restoration; and all appurtenant and collateral
work.
May 1, 1974
All construction work completed June 30, 1975.
Contract Modifications;
1. The Contractor proposed to construct the Drake Avenue branch
by the jacking-tunneling machine method. This allowed the City
the advantage of minimal street replacement and traffic disrup-
tion for a credit of surface restoration items. See Modification
No. 3. ADDITION = $27,340.00
2. Spot welding of air vent gratings to frames. (Vandalism pre-
vention). ADDITION = $143oOO
3. Total adjustment to Contract. DEDUCTION = $47,852.81
LAWRENCE AVENUE TESTING DEMONSTRATION
The entire Lawrence Avenue System did not receive flow until the
outfall and pumping station included in Contract No. 3 were
completed and the pumps were installed.
In accordance with our agreement for Federal (USEPA) Demonstra-
tion Grant Funds an extensive testing program must be undertaken
with samples taken of storm overflows from sewers of and
influenced by the Lawrence Avenue System to demonstrate its
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performance.. Sampling and testing for the pre-operation
condition has been completed.
The sampling and testing for the post-operation condition will
be conducted when the Pumping Station is fully operational.
This work will consist of testing for the following;' Biochemical
Oxygen Demand, Chemical Oxygen Demand, Dissolved Oxygen,
Settleable Solids, Suspended 'Solids, Fecal Coliform, Organic
nitrogen, Ammonia nitrogen and Spectroanalysis for metals. The
results of this sampling and testing program will be covered in
the Phase II, Final Report.
RELATIONSHIP OF THE LAWRENCE UNDERFLOW SYSTEM
TO THE TUNNEL AND RESERVOIR PLAN
The Metropolitan Sanitary District of Greater Chicago is now
constructing segments of the Tunnel and Reservoir Plan (TARP).
This system is comprised of a series .of rock tunnels and
reservoirs. The tunnels are approximately 250 feet (76 m) below
the surface and are designed to capture combined sewer flows,
which presently overflow to the river during times of storm,
and convey them to storage reservoirs for containment until
capacity is available at the treatment plants.
When the Mainstream Section of the TARP is in operation, the
pumping station of the Lawrence Avenue System will be a branch
of the entire waterway flood and pollution control system. The
capacity of the Lawrence System to handle combined sewer over-
flows will then be increased. This is significant because the
rock tunnels of the Lawrence System can then be used as an out-
let for flows originating from areas beyond its currently
designed drainage area of 3600 acres (1457 hectares). It is
recommended that the maintenance and operation of the Lawrence
Avenue System be undertaken by the Metropolitan Sanitary
District of Greater Chicago who have personnel qualified to
handle pumping stations of this type. In addition, the system
will eventually be a direct connection to the District's Tunnel
and Reservoir Plan.
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SECTION V
TUNNEL AND RESERVOIR PLAN FOR
THE CHICAGOLAND AREA
DESCRIPTION
The Tunnel and Reservoir Plan (TARP), currently under
construction by the Metropolitan Sanitary District of Greater
Chicago (MSDGC), has been selected from fifty-one considered
proposals as the most cost-effective method which will prevent
combined sewer overflows to the waterways, except for the
recurrence of the three largest storms of record, and will
eliminate backflow from the waterways to Lake Michigan. During
spills from these events, the flows would be relatively clean
since the highly-polluted, "First Flush," would be captured by
TARP during the early stages of rainfall.
TARP is actually made up of 125 miles (201 km) of tunnels
including their related collector systems, an aquifer protection
system, two on-line reservoirs, three terminal (retention)
reservoirs, and treatment facilities. See Figure V-l.
Based on currently available or anticipated funding,
construction has been divided into four separate systems,
viz; Mainstream, Calumet, Main(Lower) Des Plaines, and Northwest
(Upper) Des Plaines. For the Mainstream and Calumet Systems,
Stage 1 construction is primarily for pollution control and
Stage 2 is primarily for flood control. Stage 2 construction
will follow as Federal funding becomes available.
Mainstream System
The combined sewer overflows from about 60 percent of the
study area are captured by the Mainstream tunnels and conveyed
to storage reservoirs. A collector system with drop shafts is
used to collect the runoff from- the overflow outlets and divert
it to the tunnels. Basically, the system provides a free
draining outlet for some 20 communities, portions or all of
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TUNNEL AND RESERVOIR PLAN
Figure V-l Tunnel and Reservoir Plan
Tunnel and Reservoir Plan as proposed by the Metropolitan
Sanitary District of Greater Chicago.
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which are located in the affected service area. However, system
design does permit spillage in the North Shore and Main.Chicago
areas, but only if the most severe storms of record were to
recur. The rate and volume, though, are controlled so that the
spillage does not become a source of damage or pollution.
Sufficient in-line storage is provided to avoid spillage in the
area tributary to the North Branch of the Chicago River upstream
of the North Shore Channel.
Some 56 miles (90 km) of Mainstream tunnels and extensions
are required! to convey the overflows to the terminal reservoir
near the existing West-Southwest treatment plant. Plans call
for the reservoir to be located in a commercial quarry about
2 miles (3.2 km) south and west of the plant. This reservoir
will provide storage of 82,000 acre-feet (10,115 hect-m). In
addition, an on-line underground reservoir adjacent to the
existing North Side treatment plant has been provided. It
controls only in-line back up and permits the use of smaller
sized tunnels in the northern reaches of the Mainstream Tunnel.
The room and pillar construction method will be used to create
this 2,900 acre-foot (358 hect-m) storage area in the rock
strata underlying the plant.
Calumet System
The Calumet system is not interconnected with the Mainstream
system. It is an independent system serving some 14 communities,
totally or in part. Slightly over 36 miles (58 km) of tunnels
are needed to capture the overflow from a watershed that amounts
to about 24 percent of the study area. The tunnels are sized
to permit limited spillage to the Calumet River and Calumet-Sag
Channel. However, spills will not be allowed into that portion
of the Little Calumet River upstream of its junction with the
Calumet-Sag Channel. The flows are conveyed to a terminal
reservoir, also located in a commercial quarry. This quarry is
located in Thornton, Illinois, several miles away from the
Calumet treatment plant and will provide 39,000 acre-feet
(4,811 hect-m) of storage. Part of the proposed tunnel system
serves as an interconnector between the reservoir and treatment
plant. The excavated rock will be stockpiled in the quarry and
eventually incorporated in the future sales of aggregate lime-
stone and for other uses.
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Main (Lower) Des Plaines System
The excess overflow from the 19 communities interconnected
with this tunnel system will be conveyed to the terminal
reservoir that serves the Mainstream system, located near the
West-Southwest treatment plant. No spillage will be permitted
from the over 23 miles (37 km) of main-line tunnels and
extensions. The applicable water quality standards,, not the
in-stream capacity, require this design constraint. Approxi-
mately 13 percent of the study area is located in the tributary
watershed.
,i
Northwest (Upper) Des Plaines System
This system will intercept sanitary and combined sewage flows
arising within the Upper Des Plaines (O'Hare) Basin and divert
these flows to the O'Hare Water Reclamation Plant (OHWRP) for
treatment. The project includes all or parts of the communities
of Arlington Heights, Buffalo Grove, Des Plaines, Elk Grove
Village, Mount Prospect, Rolling Meadows and Wheeling and
unincorporated areas in parts of the Townships of Elk Grove,
Maine, Northfield, Palatine and Wheeling. Current plans call
for the installation of 7.7 miles (12.4 km) of main-line tunnels
and extensions. The tunnels are sized to prevent any spillage
to the waterways of the excess runoff from the communities
interconnected to the system. Water quality standards and
in-stream capacity applicable to the receiving watercourses,
Weller Creek and Feehanville Ditch, preclude any spillage. Also
included in the system are two reservoirs: (1) an 850 acre-foot
(105 hect-m) on-line surface reservoir at the upper end of the
tunnel system; and (2) a terminal reservoir with some 2,700
acre-feet (333 hect-m) in storage capacity. Co-located with the
terminal reservoir will be a new treatment plant. This plant
will be used to process the flows from the surrounding, rapidly
expanding suburban area. This action will help relieve the
overload to the North Side plant which currently handles these
flows.
PRESENT AWARD PROGRAM
The Tunnel and Reservoir Plan is the largest tunneling
program in the history of the metropolitan Chicago cirea. The
MSDGC has already awarded contracts for 47 miles (75.6 km) of
rock tunnels ranging in diameter from 9 feet (2.7 m) to 33 feet
(10.1 m), 137 drop shafts from 4 feet (1.2 m) to 18 feet (5.5 m.)
in diameter and the associated connecting structures,totalling
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a bid price of $733,403,475. Additional contracts for an
estimated cost of $376,679,924 will be advertized before the
end of 1979. The breakdown for each area is given below.
Mainstream System
Contracts have already been awarded for 21.4 miles (34.4 km)
of lined rock tunnels and 9.8 miles (15.8 km) of unlined
tunnels 13 feet (4.0 m) to 33 feet (10.1 m) in diameters and
112 drop shafts with finished diameters varying from 4 feet
(1.2 m) to 18 feet (5.5 m) and depths varying from 200 feet
(61 m) to 266 feet (81 m) for a total cost of $543,633,595.
These cover the first stage tunnels from 59th Street, near the
proposed storage reservoir site, to Wilmette Harbour on the
north end. Contracts have also been awarded for 128 structures
connecting existing outfalls to the Shaft-tunnel system from
Damen Avenue to Addison Street for a total of $46,094,860.
Construction work to be advertized by the end of 1979,
for an estimated cost of $303,134,488 includes 6 miles (9.7 km)
of lined tunnel and 2.4 miles (3.9 km) of unlined tunnel from
10 feet (3 m) to 33 feet (10.1 m) in diameter, 3 drop shafts,
4 feet (1.2 m) to 9 feet (2.7 m) in diameter, 82 connecting
structures and a pumping station.
Calumet System
A contract for $79,256,370 has been awarded for 9.2 miles
(14.8 km) of unlined rock tunnels varying from 9 feet (2.7 m)
to 21 feet (6.4 m) in diameter and 17 drop shafts with finished
diameters 5'-8" (1.7 m) to 15' (4.6 m) and depths varying from
249 feet (76 m) to 331 feet (101 m). This covers the section
from Crawford Avenue to the Calumet sewage treatment plant.
The award program for the next year includes a pumping station
for $53,400,000 and some 27 connecting structures at an
estimated cost of $20,145,436.
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Des Plaines System (Including both Upper and Lower)
All work for the Upper Des Plaines System is already under
contract including: construction of 6»6 miles (10.6 km) of
lined rock tunnels varying from 9 feet (2.7 m) to 20 feet (6.1 m)
in diameter, 1.1 mile (1.8 km) of a 5 foot (105 m) diameter
earth tunnel, 8 drop shafts, varying from 5 feet '(1.5 m) to
9 feet (2.7 m) in diameter, 130 feet (40 m) to 150 feet (46 m)
deep and connecting structures at some 29 locations. The
contract price of tunnels and shafts is $59,820,000 and that of
the connecting structures is $4,598,650.
No work is contemplated for the Lower Des Plaines system
before 1980.
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
. REPORT NO.
EPA-600/2-80-014
3. RECIPIENT'S ACCESSION NO.
. TITLE AND SUBTITLE
LAWRENCE AVENUE UNDERFLOW SEWER SYSTEM
Interim Report
Planning and Construction
5. REPORT DATE
March 1980 (Issuing Date)'
6. PERFORMING ORGANIZATION CODE
. AUTHOR(S)
8. PERFORMING ORGANIZATION REPORT NO.
Louis Koncza, Donald H. Churchill, and G. L. Miller
i. PERFORMING ORGANIZATION NAME AND ADDRESS
City of Chicago, Department of Public Works
Bureau of Engineering, Water and Sewer Programs
320 North Clark Street
Chicago, Illinois 60610
10. PROGRAM ELEMENT NO.
1BC822, SOS 31. Task #06
11. CONTRACT/GRANT NO.
11020 EMD
12. SPONSORING AGENCY NAME AND ADDRESS
Municipal Environmental Research Laboratory--Cin.,OH
Office of Research and Development
U.S. Environmental Protection Agency
Cincinnati, Ohio 45268 ___^
13. TYPE OF REPORT AND PERIOD COVERED
Interim 1966-1978
14. SPONSORING AGENCY CODE
EPA/600/14
15.SUPPLEMENTARY NOTES -Supplement to EPA-11020 02/71 "Deep
Project Officers: Clifford Risley, Jr., (312) 353-2200,
Traver, (201) 321-6677, FTS '340-6677
Tunnels in Hard Rock"
FTS 353-2200; and Richard P.
16. ABSTRACT
A new and bold concept in design of urban drainage systems was developed as a step
forward in the solution of combined sewer overflow problems. A deep tunnel in bed
rock about 200 to 250 feet (61 to 76!;jn) below the surface was designed and constructed
for the Lawrence Avenue drainage basin in Chicago. Utilization of modern tunnel bor-
ing machines made the project economically competitive with conventional sewers while
reaping additional benefits of ease in construction, no disturbance to traffic^and
least inconvenience to public. In addition, the tunnel sewer will serve as a reservoir
totally capturing smaller storms, and trapping a significant portion of the first flush
of pollutants from larger storms. The entrapped pollutional load will be pumped to a
treatment plant through a pumping station to be operated only at the end of the storm,
for dewatering the tunnel. The project is expected to reduce, to a large extent, the
combined sewer overflows to the waterways.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b. IDENTIFIERS/OPEN ENDED TERMS
COSATI Field/Group
Drainage, Water pollution, Surface water
runoff, Runoff, Storm sewers, Overflows,
Combined sewers, Tunneling (excavation),
Tunneling machines, Flood control,
Excavating equipment, Underground storage,
Reservoirs
Deep tunnels, Drop
shafts, Hydraulic
modeling, Combined
sewer overflows,
Inline storage
13B
18. DISTRIBUTION STATEMENT
RELEASE TO PUBLIC
19. SECURITY CLASS (ThisReport)
UNCLASSIFIED
21. NO. OF PAGES
• 88
20.!
his page)
22. PRICE
EPA Form 2220-1 (Rev. 4-77)
78
ft U.S. GtfKRNMENTPRINTING OFFICE: 1980 -657-146/5642
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