Madrid: Biggest Tunnelling Worksite in the WorldMadrid's regional autonomous government, through its transport infrastructure department MINTRA, is implementing during the 2003-2007 term the biggest ever metro expansion in its history. This expansion consists in constructing 80.8 new kilometres of conventional metro and tramway systems, of which 53.1 km are metro lines and 27.8 km tramway lines, and 79 new stations.The expansion programme will take the metro to districts of the city that are still not served by mass transit lines (in particular Villaverde, La Elipa, Hortaleza, Pinar de Chamartin, Alameda de Osuna, Montecarmelo and Carabanchel Alto), extending existing lines and building new stations on lines already in service. In addition, various schemes in this expansion plan will anticipate the demand in new areas, not only witnessing phenomenal urban growth north of the capital (tramway to Sanchinarro and Las Tablas) but also south ot it (Ensanche de Vallecas).But the metro network will be extended beyond the borders of Madrid, thanks to the north metro line, aka Metronorte, that will provide mass transit service to the municipalities of Alcobendas and San Sebastian de los Reyes; the east metro line, or Metroeste, that will do the same though the Henares corridor and put San Fernando and Coslada closer; and the new tramway system, with lines to Pozuelo de Alarcon and Boadilla del Monte. Therefore, the network can already be considered as a regional metro. Click here. The total budget amounts to EUR4,879 million, of which EUR3,049 million for civil works, EUR21.4 million for design and EUR86 million for technical assistance. The construction methods are a combination of 10 EPB TBMs (for 63.8% of the 80.8 kilometres), the Madrid traditional mining method (6.4%), diaphragm walls (29.5%), false tunnel (0.3%) and surface construction (14%). As of 16th March, 2006 74% of the TBM-driven sections was completed (29,463 m), 80% of the sections built with the Madrid traditional mining method (3,164 m), 71% of the diaphragms walls (13,087 m) and all the sections at grade. Seven of the 10 TBMs are Herrenknecht machines, there are also two Mitsubishi-NFM Technologies and one is a Lovat. Click here.Three of the 10 TBMs operated by the regional government are new. They have been nicknamed 'Metromachine', 'Chotis' and 'Guster'. They have been made by German TBM maker Herrenknecht (respectively machines S-280, S-295 and S-302). The remainder of the fleet is composed of machines which previously worked on previous metro extensions in the past. On 19th and 21st July, 2005 'Carpetana' and 'Verne', two other Herrenknecht machines (S-272 and S-274) were put in operation. The first machine will take Line 5 to Alameda de Osuna. This is the TBM that already completed the extension to Line 1 until Ensanche de Vallecas. 'Verne', which was brought to Madrid from Oporto in Portugal where it was used to build the light rail system, is working to link up Line 1 and Line 4 in Pinar de Chamartin, which will be the departure point of the tramway line to north Madrid.'Metromachine' and 'Chotis' are being used to tunnel the Metronorte line since May and June 2005. The first EPB shield progresses from San Sebastian de los Reyes while the second machine started from Ciudad de las Comunicaciones heading north. The two shields will meet in Alcobendas. A third machine, christened 'Madriladora', is working on the north metro line (Herrenknecht S-276). It was previously used on Metrosur (Line 12 south of Madrid) and commenced to burrow Madrid's subsoil in September 2005 from a start shaft in Ciudad de las Comunicaciones. Click here. Visit www.herrenknecht.comIn Coslada is the start box from where, in June and July 2005, 'Rompearenas' and 'Mascastiza' commenced Metroeste, the east metro line, that will connect San Fernando de Henares from La Peineta. Both machines worked in the past on the Metrosur line. The first is a Lovat (previously known as 'Cibeles') and the second is another Herrenknecht (machine S-278). Visit www.lovat.comTo extend Line 3 to Villaverde, 'Guster' is at work driving section Legazpi-San Cristobal heading to Villaverde Alto, and 'La Adelantada' is excavating the next stretch San Cristobal-Villaverde Alto, heading to Madrid to reach Legazpi station. The latter machine is a Mitsubishi-NFM Technologies. Visit www.nfm-technologies.com'Excavolina' will take the metro to PAU de Carabanchel. It was the last TBM to be put at work on 17th October, 2005. It is the NFM Technologies TBM that completed the Atocha-Nuevos Ministerios stretch on the second suburban rail tunnel between Atocha and Chamartin railway stations. Another TBM seconded 'Excavolina' to excavate that tunnel. The first machine was launched from Atocha in June 2004 and ended its 4.5 km drive on 27th July, 2005 while the second began in June 2005 from the Chamartin launch box and ended its 2.5 km section on 7th December, 2005. They both came out in Nuevos Ministerios. In June and July 2005, 10 TBMs were working in Madrid's subsoil in a crazy race to build the new metro and suburban rail lines. Eight of these machines were working on metro lines and two on the second suburban rail tunnel between Atocha and Chamartin. Click here and here. Extension of Line 1 from Congosto to Ensanche de VallecasEnsanche de Vallecas is a new urban centre, southeast of Madrid, where increased housing densities will see the construction of a total of 26,046 housing estates and the arrival of 80,000 new residents. This is a 100% increase of the current population in the district.The full length of the section is 3,105 metres with three stations, of which 2,611 metres built by TBM and 494 metres with diaphragm walling. The project design was awarded to Incoydesa. The constructor is Ferrovial. The work supervision is carried out by Incoydesa and Ingenieria Basica, and quality control by Geocisa.The TBM was launched on 20th September, 2004 and it arrived at destination on 3rd May, 2005. That concluded the first major tunnel of the 2003-2007 extension programme. The TBM, dubbed 'Carpetana', erected 1,734 concrete rings. Its advance speed reached 14 metres per day to excavate through gypsum rock, a predominant type of material in the area characterized by an average hardness and great resistance to fragmentation due to its fiber-like structure.The total budget is EUR257.6 million. Construction started in May 2004 and the extension is programmed to be commissioned in September 2006. Visit www.incoydesa.com, www.ferrovial.com and www.geocisa.com 'Excavolina' breaks through Line 11 extension on 7th March, 2006 in Madrid. Extension of Line 1 from Plaza de Castilla to Pinar de Chamartin and Line 4 from Parque de Santa Maria to Pinar de ChamartinThis scheme aims at extending Line 1 and Line 4 from their northern terminal stations (respectively Plaza de Castilla and Parque de Santa Maria) to a new interchange station in the Pinar de Chamartin district, thus forming a loop. Two more stations will be added to Line 1, with service to the Chamartin interchange. On the other hand, Line 4 will receive two new stations and be extended up to Pinar de Chamartin, where interchange with Line 1 and the tram line to Sanchinarro and Las Tablas will be provided. The project has been divided in two sections: Plaza de Castilla-Chamartin interchange (1,978 m and the interchange station) and Chamartin interchange-Parque de Santa Maria (4,784 m and three stations). The existing subway station in Chamartin on Line 10 will be part of a big interchange hub, where will meet two metro lines (1 and 10), a bus station and the suburban rail station operated by RENFE, the Spanish railway operator. The works began in October 2004 and entry in service is scheduled for January 2007.For section Plaza de Castilla-Chamartin, Aepo designed the project, Ferrovial is building the line, Prointec supervises its construction and a JV formed by Azierta, Geoteyco and Aepo controls the quality of works. 1,258 metres of the 1,977 metres are built using Madrid's traditional tunnelling method and 719 metres is diaphragm wall work. The budget totals EUR188.3 million. Visit www.aepo.es, www.prointec.es and www.geoteyco.es Section Parque de Santa Maria-Chamartin has an overall length of 4,784 m, with three stations and the Pinar de Chamartin interchange. Aepo also designed the project. Sacyr is the builder, Geoconsult is the work supervisor and a JV between Iberinsa and Cemosa is in charge of quality control. The section is constructed by means of the TBM named 'Verne' (3,076 m), diaphragm walls (891 m) and, from Plaza de Castilla to the Chamartin interchange, the local traditional method of excavation (816 m). The 8.7 m-diameter TBM started up on 19th July, 2005. As of 16th March, 2006 it had placed 1,386 of the 1,719 segmental rings. The total investment amounts to EUR310.5 million. Visit www.gruposyv.com, www.geoconsult.es, www.iberinsa.es and www.cemosa.esExtension of Line 2 from Ventas to La ElipaThe section has a comprehensive length of 1,613 metres. This extension, and its station, were designed by Ginprosa. OHL is using the traditional method of Madrid (1,148 m) and slurry wall excavation (465 m). Eptisa supervises the construction and Payma Cotas is responsible for quality control. The spending bill totals EUR95 million. Construction began in October 2004 and the section will open in the autumn of 2006.129 miners are using the so-called 'pick and shovel' method, Madrid's traditional mining method, to excavate the section. By many ways, their hard work is similar to mining. The method is also known as traditional method, Belgian method and even Madrid method. It is a manual method. Miners use picks and a pneumatic shovel at a depth of about 25 metres, progressing at a daily rate of 2.5 metres. They work in three shifts of eight hours. At the moment, approx. 750 metres of tunnel has been completed. A few days ago, they even beat their record, with 17.5 metres tunnelled in one week. The station is almost finished and the last level is being excavated. View photos here. Visit www.ginprosa.es, www.ohl.es, www.eptisa.es and www.paymacotas.comExtension of Line 3 from Legazpi to Villaverde AltoThe line is extended underground by 8,704 metres towards the south and the doorstep of Getafe, where a future connection with the Metrosur line 12 is foreseeable. There will be six new stations. The design was completed by Iberinsa. FCC executes the works and Typsa monitors the construction. The quality control checks are undertaken by Euroconsult.Two TBMs are digging 6,817 metres whereas 1,305.5 metres consist of diaphragm wall boxes with internal reinforced concrete walls and slabs and 581.5 metres are built with the Madrid method. 'Guster', a 9.4 m-diameter TBM, commenced its work on 19th May, 2005. As of 16th March, 2006 the machine had still to install 208 of the 2,658 rings of segments. The machine was then progressing at a rate of 23 rings per day. 'La Adelantada' began drilling on 5th May, 2005. Its diameter is identical. At the same date, it had still to install 384 of the 1,328 rings. The machine was then working at a rate of 16 daily rings.The total cost amounts to EUR475.8 million. Construction commenced in October 2004 and the line will be inaugurated in March next year. Visit www.fcc.es, www.typsa.es and www.euroconsult.esExtension of Line 5 from Canillejas to Alameda de OsunaThis is a 2,417 m-long extension, with two new stations. Inocsa is the designer. Ferrovial is working under the supervision of Aepo while quality is verified by Euroconsult and Icaes. A TBM excavated 2,016.5 metres and diaphragm walls have been built on 400.5 metres. 'Carpetana', the TBM which before completed the extension of Line 1 to Ensanche de Vallecas, began this second drive on 21st July, 2005 and ended on 7th December, after lining the tunnel with 1,342 rings of prefabricated segments.The project is budgeted at EUR189.7 million. Construction began in October 2004. Opening to commercial operation is expected for October 2006. Visit www.inocsa.es and www.icaes.esMetroeste - East Extension of Line 7 from Las Musas to Coslada and San Fernando de HenaresThis scheme is intended to give access to La Peineta where future urban facilities will be developed, to supply service to Coslada and San Fernando de Henares and to offer a new alternative to the suburban rail service to get to Madrid. The extended Line 7 will add eight stations. It is scheduled to be put in service in February 2007.Construction has been divided in various sections: Las Musas-M-40, M-40-Coslada and Coslada-San Fernando de Henares. Euroestudios designed the projects and supervises the construction. Intemac is the quality control supervisor of the first two sections.The first section has a length of 1,300 m and one new station. Sacyr is at work since September 2005 using diaphragm walls and top down construction. The total cost is EUR162.7 million. Visit www.euroestudios.es and www.intemac.esThe next two sections from the M-40 ring road to Coslada (4,136 m) and from Coslada to San Fernando (6,651 m) are built by Dragados since October 2004 and should be concluded this spring. The first of the two sections is a TBM-driven dual-track tunnel. The first tube is 1,996 m long and the second spans 2,094 m. There is also 75 metres of diaphragm wall tunnels. 'Rompearenas', a 7.4 m-diameter Lovat TBM, started the north tunnel on 20th June, 2005. It broke through last 24th October. The machine went back to work in the south tunnel on 22nd November, 2005 and finished it on 13th March, 2006. The total investment for this section amounts to EUR110.4 million. Click here. The second section also includes the construction of six stations and a transport interchange with the suburban line in Coslada. The project design was entrusted to Euroestudios, the work supervision to Proser and quality control to SGS Tecnos. The total cost is EUR372.2 million. 5,823 metres are constructed with a Herrenknecht TBM and 827 metres using diaphragm wall excavation. 'Mascastiza' began its job on 5th July, 2005. As of 16th March, 2006 366 of the 1,464 segmental rings had been placed, which represented a daily average of nine rings. Visit www.grupoacs.com and www.proser.esMetronorte - North Extension of Line 10 from Fuencarral to San Sebastian de los ReyesThe scope of the new Metronorte line is focused on the northernmost zone of Madrid's metropolitan area, including the municipalities of Madrid, Alcobendas and San Sebastian de los Reyes. Metronorte is a 16 km regional transport line with 11 stations, four of which in the capital (Tres Olivos, Montecarmelo, Las Tablas and Ciudad de las Communicaciones), four in Alcobendas (Poligono Industrial, Diversia, Baena de Castro and Parque de Extremadura) and three in San Sebastian de los Reyes (Universidad Popular, Plaza de Toros and Dehesa Vieja). A EUR760 million spending will be required. Building was initiated in October 2004. Metronorte will be a reality sometime between February and April 2007. It will give service to 184,000 users. Three TBMs began working simultaneously last summer. Click es/109.The first, dubbed 'Metromachine', started on 16th June, 2005 in San Sebastian de los Reyes to bore section 2B. It features a diameter of 9.4 metres and a weight of 486 tonnes. At 16th March, 2006 there was still 918 of the 2,355 rings of segments to be placed. Its average daily performance to date is 17 rings. Out of the 4,969 metres of tunnel, 4,293 metres are excavated with this TBM, 469 metres using diaphragm walls and 207 metres at ground level. This section includes four of the eleven stations: three in San Sebastian de los Reyes and another one in Alcobendas. Prointec designed the project. OHL constructs the section. Geocisa manages the construction and Eptisa checks the quality.The tunnel will connect with the one driven by two other EPB shields, which started to work from Las Tablas, one to connect with Line 10 to Madrid and the other one progressing towards Alcobendas. These sections are 1B and 1C-2A, each being built by Acciona Infraestructuras. Visit www.acciona-infraestructuras.comSection 1B (4,624 m) has three stations. The designer is Typsa. Supervision of the works is by Intemac. A JV of Euroestudios and Proyec is responsible for quality control. Total investment in the project is EUR270.8 million. The length bored by the TBM stretches 3,734 metres while 890 metres have been built sinking diaphragm walls. Since it commenced working on 29th September, 2005 'Madriladora' had installed 366 rings of segmental lining as of 16th March, 2006 which is an average of 18 rings per day. Section 1C-2A, of 5,578 m of length with three stations, has been designed by Typsa and Prointec. Sener manages the works and their quality is controlled by CIESM and Labiker. Almost all of the length (5,221 m) is bored by a TBM whereas slurry walls were put in place on just 357 metres. The TBM named 'Chotis', of 9.4 m of diameter, began to work on 29th June, 2005. As of 16th March, 2006, it had placed an average of 15 daily rings. The money invested totals EUR207.7 million. Visit www.sener.esSection 1A is a short 566 m-long section, including a station, built by the Metronorte JV set up by Teconsa, Obrum and Arias Hermanos Construcciones. Slurry wall excavation is used. Tycsa was involved in the project design. Iberinsa manages the construction and the Cecomartos-Cones-Tecinco JV controls quality. Visit www.teconsa.net, www.tycsa.es, www.cecomar.com and www.cones.esExtension of Line 11 from Pan Bendito to CarabanchelExtending to the south Line 11 requires a 2,708 m tunnel and three new stations (Avenida de los Poblados, Casco Historico de Carabanchel and PAU de Carabanchel). Design work was completed by Intecsa-Inarsa. Dragados is the building company, Ineco supervises the construction and a JV between Sergeyco and Progeotec controls the good quality of works. The civil works began in October 2004. 'Excavolina', a 9.4 m-diameter Mitsubishi-NFM Technologies TBM, holed through on 7th March, 2006. In little less than five months, the TBM has excavated the 2,149 metres of line that separate Pan Bendito from the last station of the line. Slurry wall excavation has been adopted for a 559 m section.In November 2006 in principle, this extension of Line 11 will be ready. About 50,000 residents from Carabanchel will be able to take the metro in their district. The regional government has allocated EUR172.3 million for the extension of the line. Visit www.intecsa-inarsa.es, www.ineco.es, www.sergeyco.com and www.progeotec.esStationsOther schemes include the cut-and-cover construction of three new stations (on lines 6, 8 and 10) and the rehabilitation of the stations on Line 3.The new Arganzuela station on Line 6, between Legazpi and Mendez Alvaro stations, will be 183 metres in length. Epsa designed the project. Comsa and Ortiz Construcciones are the constructors. Inocsa is in charge of managing the works and Geocisa of the quality control. The budget is EUR51 million. The station is foreseen to open in December 2007. Visit www.comsa.com and www.ortiz-construcciones.comCimsa and Constructora San Jose are constructing the new 126 m-long Pinar del Rey station on Line 8 between Colombia and Mar del Cristal stations. Epsa also designed the project, Geoteyco follows up the construction and Geocisa verifies the quality. The cost is EUR39.8 million. The station is expected to be ready for December 2006. Visit www.grupo-sanjose.comThe new Aviacion Espanola station (132 m of length), on Line 10, is being built between Colonia Jardin and Quatro Viento stations. MINTRA designed the project. Begar Construcciones y Contratas builds it. LV Salamanca Ingenieros is in charge of work supervision and Euroconsult checks the quality. The total cost is EUR29.7 million. The station would open in December this year. Visit www.begar.es and www.lvsalamanca-ingenieros.esDaily ridership on Line 3 exceeds 260,000 users. EUR319 million has been allocated for its complete refurbishment, jointly financed by the regional government and the city of Madrid. Inaugurated in 1936 with a route of 1.4 km, the line spans 6.2 km between Moncloa and Legazpi serving 11 stations. This line has reached its limit of capacity and this situation would worsen when the new segment to Villaverde opens. In June 2004 a plan for structural refurbishment was initiated, consisting in lengthening the platforms from 60 to 90 metres and introducing new trains. In addition, a new tunnel will shorten by 200 metres the distance from Arguelles to Moncloa, where a large transport interchange is constructed, which will give the possibility to extend the line up to Cuatro Caminos in the future.ADIF will contribute EUR21 million to rehabilitate Embajadores station and its connection to the suburban lines.Tramway LinesAs part of the ongoing programme to expand public transport in metropolitan Madrid, the regional government has initiated for the first time the construction of tram lines as a complementary solution to the conventional metro network, in the eastern municipalities of Pozuelo de Alarcon and Boadilla del Monte and the northern districts of Sanchinarro and Las Tablas. Construction began in December 2004 and opening is programmed for the spring of 2007. These new lines will extend the network and serve populations living in the outskirts of Madrid, adopting a technical solution that has proved its effectiveness in many European cities. Click es/121.The east tramway line project will bring the subway system closer to Pozuelo de Alarcon and Boadilla del Monte thanks to two new lines built at surface level and below ground, which comprise a total of 25 stations and two interchanges. Both will start at Colonia Jardin, where an interchange will be completed to give travellers on this new transport service to get on Line 10 of the metro. From that new transportation hub, both tramway lines will share the same tracks before branching off at the intersection of highways M-502 and M-511. The first will head north taking the direction of Pozuelo de Alarcon whereas the second line will serve Boadilla, running to the west. Building commenced in February 2005 and commissioning is anticipated for March 2007.The Colonia Jardin-Pozuelo de Alarcon line has an overall length of 8,680 metres, 13 stations and an interchange. Ineco designed the line. OHL received the construction contract. Intraesa inspects its building and the Eurocontrol-Icaes JV oversees the quality. 4,661 metres is built at grade and 4,019 metres with slurry wall construction. The total cost will be EUR151.7 million. Visit www.intraesa.com and www.eurocontrol.esThe Colonia Jardin-Boadilla del Monte line stretches 13.7 km, with 13 stations and an interchange. Sener was in charge of the project design. The constructors are AZVI, Constructora San Jose and Elsan. Grusamar supervises the works whereas quality control has been commissioned to a JV made up of Cecomartos and Cones. 1,761 metres of diaphragm walls are cut off, 160 metres is built with the traditional method of Madrid and 11,778 m at street level. The total financial package is EUR210.5 million. Visit www.azvi.es, www.elsan-pacsa.com and www.grupoelsamex.com/grusamarThe objective of the tramway line to the north of Madrid is to create a new line which, starting from the new interchange station in Pinar de Chamartin where metro lines 1 and 4 will converge, connects with the new Metronorte line in Las Tablas. The new tram line to Sanchinarro and Las Tablas will be highly functional, supplying service to 40,000 inhabitants. Its construction has been divided in two sections, both designed by Proser.The first section has a length of 2,531 metres and five stations. The construction companies are Comsa and Ortiz Construcciones. Idom, in partnership with EIS, supervises construction. A JV formed by Azierta, Geoteyco and Aepo ensures the project quality. The contractors have opted for the diaphragm wall method on 1,581.5 metres and surface tracks for 949 metres. EUR120.8 million will be spent. Visit www.idom.esThe second section, 2,864 m in length, will serve four stations. The construction contract has been awarded to Corsan-Corviam, who builds 2,035 m of slurry cutoff walls to place the line underground and 829 m of track at street level. Gestion Integral del Suelo supervises the works and the Iberinsa-Cemosa JV controls the quality. This section will cost EUR141.5 million. Visit www.corsan-corviam.esConclusionThe 2003-2007 expansion plan of the mass transit system implemented by the Madrid regional autonomous government, is a clear leap forward which will diversify, structure and extend the network, in many cases beyond the city borders. When completed and fully opened, the plan will improve dramatically urban mobility and life quality in a region that moves forward more and more every day towards improved well-being. Click es/17. Visit www.metromadrid.es and www.madrid.org/However, these gigantic underground works are not the only ones underway in Madrid. To enhance the M-30 ring road, the world's two biggest EPB shields are working to bore the south bypass of the M-30 between Arganzuela and the A-3. Each machine, 15.2 m in diameter for a weight of 2,600 tonnes, is excavating one of two parallel tunnels. Their approximate cost is EUR40 million each. Click es/104, here and here. Visit www.munimadrid.es Lastly, transport interchanges are also under construction, partly underground, in Principe Pio, Plaza Eliptica and Plaza de Castilla. Click es/123. 14/06.