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Tunnel Construction 101

On-Demand Training:
Tunnel Construction 101

Recorded: September 30, 2025

Overview Agenda Instructors
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Gain a clear understanding of one of civil engineering’s most challenging projects with EUCI’s Tunnel Construction 101 online course, designed for construction professionals eager to master the fundamentals of tunnel building. From utility tunnels to cross-state projects, underground infrastructure shapes the future of urban infrastructure using automation, manpower, and advanced materials. This course delivers a practical introduction to the core principles of tunnel construction and how advances in this specialized industry are making the process faster, safer, and more efficient.

EUCI’s Tunnel Construction 101 course will provide insights into topics such as how to determine the need and feasibility of a tunnel project, breaking down the design of the tunnel, and the numerous elements required to begin and execute a tunnel construction project.

This course is ideal for anyone currently in the field of tunnel construction including engineers, project managers, geologists, and those entering the industry. Register today to gain in-depth knowledge and up-to-date information about this specialized industry.

Learning Outcomes

  • Review the basics of tunnel construction from what tunnels are used for, where they can be located, and how much they cost
  • Discuss the planning aspects of the process - Information gathering and developing and assessing options before moving into the design phase
  • Discover the multiple steps of project design for tunnels including geotechnical investigation and reports as well as construction, cost, and risk assessments
  • Assess procedures for contractor outreach and getting bids for the project
  • Detail the various steps that must be performed during a tunnel construction project
  • Review the key considerations that must be kept in mind throughout the construction period

Register

This is a recorded session - no instructor interaction is available. Recordings do not qualify for continuing education credits. Recordings will expire 30 days from date of purchase and sharing, downloading or copying of the recording in any way is strictly prohibited and will result in the termination of your license.

PURCHASE THIS RECORDING:

Recording license(s)$ 895.00 each

Agenda

8:45 AM - 9:00 AM

Log In & Welcome

12:30 - 1:30 PM

Lunch Break

9:00 AM - 5:00 PM

Course Timing

Project Planning and Geotechnical Risk Identification

Explore how the unique challenges of subsurface variability drive early tunnel planning, feasibility, risk analysis. Examine how geotechnical investigations, groundwater dynamics, and seismic risks affect project alignment, constructability, and long-term performance. Real-world examples illustrate how early missteps can result in costly redesigns and project delays.

  • Differences in lifecycle and risk profile: tunnels vs. surface infrastructure
  • Defining project needs, functional requirements, and spatial constraints
  • Geotechnical hazards and uncertainty management:
    • Transitions between soil and rock strata
    • High water tables and dewatering system design considerations
    • Fault zones, active seismic regions, and discontinuities
  • Planning-level corridor analysis and alignment optimization
  • Geotechnical data collection: borings, CPT, LIDAR, geophysical methods
  • Integrating subsurface data into conceptual design frameworks
  • Tools for ground condition modeling
  • Decision-making, scenario planning and contingency reserves
  • Bridging the gap between planning and preliminary design

Tunnel Design: Excavation Strategies, Ground Support, and Engineering Detail

Discover design approaches tailored to complex ground conditions, groundwater inflows, and structural requirements. Learn how design engineers match excavation and ground support methods to site-specific geotechnical conditions while accommodating permanent infrastructure needs such as utility interfaces and ventilation systems.

  • Selecting and procuring experienced tunnel design consultants
  • Optimization of alignment and shaft portal locations using GIS and 3D modeling
  • Excavation Method Selection and Technical Considerations:
    • Earth Pressure Balance (EPB) and TBMs: pressure balance and spoil conditioning
    • Hard rock TBMs: cutterhead design and rock mass classification
    • Drill-and-Blast: vibration control and tunnel geometry implications
    • SEM/NATM: sequential excavation, shotcrete application, and convergence monitoring
    • Cut-and-Cover: utility conflict mitigation and traffic management
  • Development of Geotechnical Baseline Reports (GBR) and Data Reports (GDR)
  • Ground support strategies:
    • Interaction of shotcrete, lattice girders, and segmental linings
    • Pre-support systems for unstable or loose ground
  • Space proofing techniques for fit-out, ventilation, access, and maintenance
  • Design of inflow barriers, grouting strategies, and groundwater control
  • Vibration, settlement, and third-party structure protection
  • Preliminary design deliverables: drawings, reports, and engineer cost estimates
  • Stakeholder coordination and utility agency input integration

Procurement and Bidding for Tunnel Construction

Learn how to develop technically sound bid packages and navigate the procurement of specialty tunneling contractors. Explore how to balance cost competitiveness with qualifications, risk allocation, and realistic schedule forecasting.

  • Understanding the tunneling contractor market and regional capabilities
  • Procurement models:
    • Design-Bid-Build
    • Construction Manager/General Contractor
    • Design-Build and Progressive Design-Build
  • Bid document development: technical specifications, GBR inclusion, and risk allocation
  • Overseeing pre-bid RFIs and managing geotechnical clarifications
  • Applying value engineering alternatives without compromising design integrity
  • Analyzing bids: unit cost realism, qualifications, and contingency handling
  • Notice to Proceed (NTP) preparation and contractor onboarding

Tunnel Construction Execution: Methods, Mitigation, and Monitoring

Explore the intricacies of underground construction, with a focus on sequencing, logistics, instrumentation, and active mitigation of construction-phase risks. Emphasis will be placed on managing mixed ground conditions, TBM operation, and ensuring quality under constrained urban or remote conditions.

  • Pre-construction setup: mobilization, laydown areas, and shaft excavation
  • Procurement of TBMs and specialized tunneling equipment
  • Material logistics: segment delivery, spoil removal, and site safety
  • Ventilation and life safety planning:
    • Temporary and permanent ventilation schemes
    • Real-time air quality monitoring and confined space protocols
  • Construction sequencing:
    • Bypass tunnels, cross passages, emergency egress coordination
    • Managing interface with surface infrastructure
  • Instrumentation and monitoring:
  • Mixed-face tunneling and cutterhead wear in variable strata
  • QA/QC systems for segmental lining, grouting, and backfill
  • Delay mitigation: TBM maintenance, face instability, labor constraints
  • Utility protection and community impact minimization
  • Transition to commissioning, systems testing, and fit-out phases

Managing Cost and Time Overruns in Tunnel Projects

Tunnel projects frequently exceed budget and schedule due to unforeseen ground behavior, contractor availability, and site logistics. Learn how to identify root causes and use tools such as contingency modeling, risk registers, and proactive management to mitigate disruption.

  • Drivers of overruns:
    • Incomplete geotechnical data
    • Inexperienced or undersized contractor teams
    • Shaft access limitations and constrained work hours
  • Advanced cost estimating practices and risk-adjusted budgets
  • Scheduling techniques for uncertainty
  • Incorporating change management protocols into contract language
  • Use of risk registers: identification, tracking, and mitigation response
  • Claims avoidance: collaborative contract structures and dispute resolution mechanisms

Lessons Learned

Enjoy a recap of key technical insights and explore the future of tunnel project delivery. Highlights include common pitfalls, successful strategies, and innovations including digital twins, AI-powered monitoring, and TBM data analytics.

  • Key differentiators of tunnel projects vs. other civil infrastructure
  • Top risk areas and how successful projects address them
  • Geotechnical diligence as a project foundation
  • Defining tunnel project success: KPIs and benchmarks
  • Trends in tunnel delivery:
    • Real-time instrumentation dashboards
    • Predictive maintenance for TBMs
    • Virtual design and construction (VDC) for underground works
  • Preparing interdisciplinary teams for tunnel complexity

Closing Remarks

Instructor

Samuel (Sam) Swartz has over 27 years of engineering experience on major tunnel design projects at Delve Underground. He is the Tunnel and Underground Practice Lead for the Midwest Region, and Chief Quality Officer. Sam has served as project manager and design lead on a number of large tunneling projects for water, wastewater, transportation, and power projects, including planning, preliminary design, final design, and design support during construction. He has worked on tunnels with finished diameters from a few feet to over fifty feet. Sam has been a Task Lead for both Tender and Final Design for design-build projects and other alternative delivery procurements. His technical knowledge encompasses geotechnical assessment of ground conditions and risks for soft ground and rock tunneling, design of primary and final tunnel linings with a particular focus on segmental lining design for tunnel boring machine (TBM) drive tunnels, analysis of settlements above tunnels and development of mitigation measures and geotechnical instrumentation, microtunneling, and methods of ground improvement. Sam has worked on projects throughout most major cities across the West and East Coasts, the Midwest, Texas, and Oklahoma in the US; British Columbia, Ontario, and Alberta in Canada; Melbourne, Sydney, and Perth in Australia; and Auckland, New Zealand.

Sam Swarz

Tunnel and Underground Practice Lead for the Midwest Region, Chief Quality Officer

Delve Underground