A tunnel boring machine ( TBM ), also known as a "mole" or a "worm", is a machine used to excavate tunnels . Tunnels are excavated through hard rock, wet or dry soil, or sand , each of which requires specialized technology.
126-834: The Kaimai Tunnel is a railway tunnel through the Kaimai Range in the North Island of New Zealand. Since it was opened in 1978, it has held the title of longest tunnel , at 8.879 kilometres (5.517 mi), in New Zealand, assuming this distinction from the previous title holder, the Rimutaka Tunnel . It is part of the Kaimai Deviation, which was constructed to bypass the old route of the East Coast Main Trunk Railway through
252-540: A 10-year turnaround plan for the rail industry. This was accompanied by significant government investment in KiwiRail of over $ 2.1 billion during the period 2008 to February 2017. In May 2017, the government announced a further $ 450 million capital injection and that KiwiRail would be subject to a further significant review. The plan has been significantly undermined by the Christchurch earthquakes of 2010 and 2011,
378-480: A 9 km tunnel (essentially what ended up being the Kaimai Deviation). The budget for such an option was expected to be at least NZ$ 10.5 million. It was felt that there was still sufficient capacity on the existing line, and that the idea should be reviewed when demand required it. Local interests were not satisfied with the 1958 report, and continued to prevail upon the government for action. In 1960,
504-533: A bore of 5.95 m (19.5 ft) to 6.4 m (21 ft) diameter, which provided for future electrification. The TBM had over 2,000,000 lb (910 t) of thrust. 666,000 ft⋅lb (903 kJ) of rotation torque and a muck handling capacity 85 cu ft (2.4 m) a minute. Despite concerns about starting at the western portal with the TBM, it was considered to be the better option to alleviate problems with drainage that would ensue otherwise because of
630-616: A boring diameter of 6.67 m (21.9 ft). The medium was water saturated sandy mudstone, schistose mudstone, highly weathered mudstone as well as alluvium. It achieved a maximum advance rate of more than 345 m (1,132 ft) per month. The world's largest hard rock TBM, known as Martina , was built by Herrenknecht AG . Its excavation diameter was 15.62 m (51.2 ft), total length 130 m (430 ft); excavation area of 192 m (2,070 sq ft), thrust value 39,485 t, total weight 4,500 tons, total installed capacity 18 MW. Its yearly energy consumption
756-655: A deputation met with the Minister of Railways in order to impress upon him the importance of a replacement for the existing route, and as a result, a Commission of Inquiry was established in August 1962 to investigate "Improved Access by Land to the Port of Tauranga and Bay of Plenty". During the commission's hearings in October, submissions from 38 individuals and groups were heard and 261 pages of evidence submitted. In conclusion,
882-411: A leading shield that advances with the cutting head and a trailing shield that acts as a gripper. The two shields can move axially relative to each other (i.e., telescopically) over a limited distance. The gripper shield anchors the TBM so that pressure can be applied to the cutter head while simultaneously the concrete lining is being constructed. In hard rock with minimal ground water, the area around
1008-675: A lunch stop at Matamata, Prime Minister Robert Muldoon greeted the assembled crowd and boarded the train. The next stop was Hemopo, where a crowd had assembled. They were addressed by Piako County Council Chairman Mr. Thomas, the MP for Piako Mr. Jack Luxton and the Minister of Railways the Hon. Colin McLachlan . Then the Prime Minister gave a speech and unveiled a plaque paying tribute to
1134-627: A national network connecting major centres in New Zealand was never realised. Despite the abolition of the provinces in 1876, parochial interests often overcame national interests, and the government approved and built many branch lines to lightly populated hinterlands, instead of prioritising interprovincial main trunks. As a result, a number of routes first proposed by Vogel in 1870 were still not complete by 1920. Bush tramways were usually privately owned light railways , usually for logging operations. Usually built with light tracks and light-weight rolling stock, bush tramways were usually connected to
1260-542: A nationwide network linking major centres, especially during the Vogel Era of railway construction following the abolition of the provinces. Narrow gauge of 3ft 6in (1,067mm) was adopted nationally. Bush tramways or light industrial railways sprang up connecting to the national network as it expanded. Railways became centrally controlled as a government department under the names New Zealand Government Railways or New Zealand Railways Department (NZR), and land transport
1386-616: A new rail hub complex in Hamilton and another planned for Mosgiel . In 2019, the government began a "Future of Rail" review, and in December 2019 released a draft New Zealand Rail Plan, outlining changes to the rail transport industry. The draft plan proposes a number of major changes, the most significant being future funding of the rail network through the National Land Transport Fund (NLTF). The final plan
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#17327973234921512-435: A plug to form in the screw. The cutter head is filled with pressurised slurry, typically made of bentonite clay that applies hydrostatic pressure to the face. The slurry mixes with the muck before it is pumped to a slurry separation plant, usually outside the tunnel. Slurry separation plants use multi-stage filtration systems that separate spoil from slurry to allow reuse. The degree to which slurry can be 'cleaned' depends on
1638-427: A result, it was felt that further investigations into the idea were justified. Rock samples were submitted to the manufacturers (Jarva Company) for an assessment of the suitability of the machines for the tunnel project. It was felt that such a machine would be able to handle the eastern end of the tunnel, but that the western end could pose problems if the rock was found to be too fractured. The Jarva tunnelling machine
1764-484: A rotating drum with metal tines on its outer surface, or a rotating circular plate covered with teeth, or revolving belts covered with metal teeth. However, these TBMs proved expensive, cumbersome, and unable to excavate hard rock; interest in TBMs therefore declined. Nevertheless, TBM development continued in potash and coal mines, where the rock was softer. A TBM with a bore diameter of 14.4 m (47 ft 3 in)
1890-402: A single cylindrical shield after the cutting head. A permanent concrete lining is constructed immediately after the shield, and the TBM pushes off the lining to apply force to the cutter head. Because this pushing cannot be done while a next ring of lining is being constructed, the single-shield TBM operates in alternating cutting and lining modes. Double Shield (or telescopic shield) TBMs have
2016-472: A small pilot tunnel, later being enlarged to the final size. It was at this time that the only lives were lost on the project. A cave-in, caused by a high ground water level, resulted in the loss of four lives. The rescue operation was able to save eight other workers who were trapped with those that perished. Tunnelling resumed after a delay of several months, and by 1971 the TBM was ready to commence work. A three-month trial period had been allocated to assess
2142-818: A speed and safety not previously possible. The Channel Tunnel , the Thames Water Ring Main , sections of the London Underground , and most new metro tunnels completed in the last 20 years worldwide were excavated using this method. EPB has historically competed with the slurry shield method (see below), where the slurry is used to stabilize the tunnel face and transport spoil to the surface. EPB TBMs are mostly used in finer ground (such as clay) while slurry TBMs are mostly used for coarser ground (such as gravel). Slurry shield machines can be used in soft ground with high water pressure or where granular ground conditions (sands and gravels) do not allow
2268-486: Is a 24.01 kilometres (14.92 mi) line between Waharoa and Apata , including several major cuttings, embankments and viaducts, while the tunnel makes up 8.879 kilometres (5.517 mi) of this distance 5.625 kilometres (3.495 mi) from the Apata end of the line. It had 26.5 mi (42.6 km) of new track, including yards at Waharoa, 15 bridges and over 2,000,000 cu yd (1,500,000 m) of earthworks and
2394-556: Is a division of KiwiRail that maintains and upgrades the rail infrastructure and is responsible for the control of the network (i.e. train control and signalling). Other rail operating companies using the rail network include Auckland One Rail and Transdev Wellington , who operate suburban services in Auckland and Wellington respectively, and Dunedin Railways , who operate tourist trains out of Dunedin . KiwiRail released in 2010
2520-546: Is a smaller equivalent to a general tunnelling shield and generally bore tunnels of 1 to 1.5 meters (3.3 to 4.9 ft), too small for operators to walk in. Behind all types of tunnel boring machines, in the finished part of the tunnel, are trailing support decks known as the backup system, whose mechanisms can include conveyors or other systems for muck removal; slurry pipelines (if applicable); control rooms; electrical, dust-removal and ventilation systems; and mechanisms for transport of pre-cast segments. Urban tunnelling has
2646-472: Is due to open in late 2025 at the earliest. Light rail networks are planned for Auckland , Wellington , and Christchurch. Advocacy group Greater Auckland proposed the Regional Rapid Rail initiative in 2017, including tilt trains with a maximum speed of 160 km/h. This network would provide passenger services linking Auckland with Hamilton , Tauranga and Rotorua . In December 2018,
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#17327973234922772-544: The 2016 Kaikōura earthquake , Pike River Mine disaster , coal price collapse, coal miner Solid Energy going into voluntary administration in 2016 and major motive power issues with the new DL class of locomotives. Nevertheless, significant improvements in freight volumes have followed (other than with coal). Two of KiwiRail's major customers, Mainfreight and Fonterra , also invested heavily in rail-related infrastructure. Mainfreight allocated $ 60 million for investment in new railhead depots, while Fonterra invested $ 130m in
2898-468: The Alps , Maus had it built in 1846 in an arms factory near Turin . It consisted of more than 100 percussion drills mounted in the front of a locomotive-sized machine, mechanically power-driven from the entrance of the tunnel. The Revolutions of 1848 affected the funding, and the tunnel was not completed until 10 years later, by using less innovative and less expensive methods such as pneumatic drills . In
3024-765: The Capital Connection between Wellington and Palmerston North , the Northern Explorer between Auckland and Wellington , the Coastal Pacific between Picton and Christchurch , the TranzAlpine between Christchurch and Greymouth , and Te Huia between Hamilton and Auckland Strand . Dunedin Railways operates tourist trains out of Dunedin , with frequent services on part of the former Otago Central Railway line and occasional services north from Dunedin to Palmerston. This service
3150-576: The Government of New Zealand committed funding to reintroducing a five-year trial rail service, named Te Huia , between Papakura in southern Auckland to Hamilton, starting in 2020. As a result of the COVID-19 pandemic in New Zealand , the Te Huia service had been delayed commencing operations to sometime after 3 August 2020, changed from its initial announced opening date of March 2020. In 2020,
3276-711: The Karangahake Gorge (part of which has been preserved as the Goldfields Railway ). In the first half of the 20th century, the disadvantages of the East Coast Main Trunk route through the Karangahake and Athenree gorges became starkly apparent. The capacity of the line was constrained by several factors; its length, severe grades of up to 1:50, sharp curves of up to 6 chains radius, and light 55 lb per yard rail which prohibited
3402-634: The Mersey River . The Hudson River Tunnel was constructed from 1889 to 1904 using a Greathead shield TBM. The project used air compressed to 2.4 bar (35 psi) to reduce cave-ins. However, many workers died via cave-in or decompression sickness. During the late 19th and early 20th century, inventors continued to design, build, and test TBMs for tunnels for railroads, subways, sewers, water supplies, etc. TBMs employing rotating arrays of drills or hammers were patented. TBMs that resembled giant hole saws were proposed. Other TBMs consisted of
3528-444: The TranzAlpine , Coastal Pacific and Northern Explorer . Dunedin Railways also operate tourist trains out of Dunedin , and a number of heritage operators run charter specials from time to time. Urban passenger rail services exist only in Auckland and Wellington . Rail in New Zealand has received significant and ongoing government investment since re-nationalisation in 2008, with the two urban rail systems being upgraded. In 2021,
3654-587: The Waihou River . A bank of around 35 ft (11 m) crosses the flood plain at the start of a 1:300 grade to and through the tunnel (though 1:324 at the western portal of the tunnel and 323 through the tunnel) crossing the Gordon-Okauia road, on Bridge 41, to a passing loop at Hemopo. The eastern approach has two bridges over the Whatakao Stream. Bridge 42, 3 m (9.8 ft) from
3780-666: The Wellington Province ) were in London to negotiate the retention of Imperial British forces then in New Zealand fighting the New Zealand Wars . They were also tasked with investigating a uniform railway gauge for New Zealand. In 1870, James Macandrew MHR called for another select committee to investigate the need for a law to require one uniform railway gauge for the entire colony. Information from Featherston and Dillon Bell reached Wellington in August 1870, and
3906-484: The 12 miles (19 km) between Napier and Hastings but some were replaced by a New Zealand Railways Road Services bus in 1926, and soon they ceased altogether. Worker's concession tickets had been introduced in 1897, initially for the Wellington-Hutt service, and extended next year to Auckland, Christchurch and Dunedin (and then between Westport and Waimangaroa). A 1979 NZR report "Time for Change" said that
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4032-664: The 1930s they ran from Christchurch to Springfield on the Midland Line, and into the 1950s overnight between Christchurch and Dunedin. On the North Island Main Trunk they ran during the day while the expresses ran at night. On the Okahukura-Stratford Line they lasted to the early 1970s. In the 1950s and 1960s, most provincial routes had railcar and locomotive-hauled passenger services. In 1965, 25 million passengers travelled by rail; by 1998
4158-430: The 1:300 ascending grade from west to east. Also, the tunnel was to terminate at the eastern end on a viaduct over the Whatakao Stream which had yet to be built. Construction of the tunnel started at the western end on 15 January 1969 with the excavation of the approach cutting which reached 25 m deep at the portal. A layer of alluvial material at the tunnel face meant that this section had to be excavated by hand, first as
4284-465: The 667 km line reduced truck volumes on the route by around 120 per day. A 2008 study by the Ministry of Transport predicted that by 2031 rail freight volumes would increase to 23 million tonnes per annum or 70% on the 2006–2007 financial year. In 2018 the same report found freight levels had increased by 17% between 2007 and 2012. As of 2023, there are only five long-distance passenger routes:
4410-650: The Auckland Regional Council was granted slots for it to contract the operation of suburban passenger trains. Auckland railway stations not already local council-owned were transferred to Auckland Regional Transport Network Limited (ARTNL), owned by the Auckland territorial authorities, which was merged with the Auckland Regional Transport Authority (ARTA), a subsidiary of the Auckland Regional Council (ARC). With
4536-607: The Bay of Plenty had ceased in 1967 with the final running of a post- Taneatua Express 88 seater railcar service; the lengthy and time-consuming route that the tunnel replaced was part of the reason this railcar service had ceased to be viable. It was not until 9 December 1991 that regular service to the Bay of Plenty was re-introduced. Named the Kaimai Express after the tunnel, it ran between Auckland and Tauranga until its cancellation on 7 October 2001. For its entire existence, it
4662-487: The Fréjus Rail Tunnel, by using less ambitious methods). Wilson's machine anticipated modern TBMs in the sense that it employed cutting discs, like those of a disc harrow , which were attached to the rotating head of the machine. In contrast to traditional chiseling or drilling and blasting, this innovative method of removing rock relied on simple metal wheels to apply a transient high pressure that fractured
4788-527: The Northern Explorer and Coastal Pacific ended their services in December 2021. On April 12, 2022, KiwiRail announced the return of the Northern Explorer and Coastal Pacific services in September, alongside new multi day excursion trains at a later date. Horizons Regional Council 's 2021-2031 Regional Land Transport Plan noted that KiwiRail is considering a "connector service" which would link
4914-500: The Railways Corporation continued to dispose of surplus land. The central government renationalised first the Auckland metro railway network in 2001, then the rest of the network in 2004, and finally the rail and ferry operations in 2008, creating another SOE, KiwiRail . Today, services are primarily provided by KiwiRail and focused on bulk freight, with a small number of tourist orientated passenger services, such as
5040-574: The Railways Department, now branded The Interislander . In 1982, the Railways Department was corporatised into a new entity at the same time land transport was deregulated. The Railways Department became the New Zealand Railways Corporation . The Corporation embarked on a major restructuring, laying off thousands of staff and cutting unprofitable services. After the 1983 land transport deregulation, there
5166-535: The Tuen Mun Chek Lap Kok link in Hong Kong. TBMs typically consist of a rotating cutting wheel in front, called a cutter head, followed by a main bearing, a thrust system, a system to remove excavated material (muck), and support mechanisms. Machines vary with site geology, amount of ground water present, and other factors. Rock boring machines differ from earth boring machines in the way they cut
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5292-533: The United States, the first boring machine to have been built was used in 1853 during the construction of the Hoosac Tunnel in northwest Massachusetts. Made of cast iron, it was known as Wilson's Patented Stone-Cutting Machine , after inventor Charles Wilson. It drilled 3 meters (10 ft) into the rock before breaking down (the tunnel was eventually completed more than 20 years later, and as with
5418-702: The Wellington and Manawatu Railway Company, nationalised in 1908, achieved any measure of success, with the rest being purchased by the Government before completion of their intended railway lines. One exception to this rule was the Ohai Railway Board in Southland, which was owned by the State Mines department and a local county council until its dissolution in 1990. The first major route
5544-1060: The Wellington suburban services revenue met only 26% of operating costs (Dunedin was 28%, Auckland 46%). Tunnel Boring Machine Tunnel boring machines are an alternative to drilling and blasting (D&B) methods and "hand mining". TBMs limit the disturbance to the surrounding ground and produce a smooth tunnel wall. This reduces the cost of lining the tunnel, and is suitable for use in urban areas. TBMs are expensive to construct, and larger ones are challenging to transport. These fixed costs become less significant for longer tunnels. TBM-bored tunnel cross-sections range from 1 to 17.6 meters (3.3 to 57.7 ft) to date. Narrower tunnels are typically bored using trenchless construction methods or horizontal directional drilling rather than TBMs. TBM tunnels are typically circular in cross-section although they may be u-shaped, horseshoes, square or rectangular. Tunneling speeds increase over time. The first TBM peaked at 4 meters per week. This increased to 16 meters per week four decades later. By
5670-862: The abolition of the provinces in 1876, railway lines were controlled by the central government, originally under the Public Works Department , and from 1880 under the New Zealand Railways Department. A Minister of Railways was responsible for the department and was a member of the New Zealand Cabinet . A few private companies built railways in New Zealand, including the New Zealand Midland Railway Company , Wellington and Manawatu Railway Company , Waimea Plains Railway , and Thames Valley and Rotorua Railway Company. Only
5796-433: The broad gauge network had been converted to narrow gauge. From 1870, the central government of Sir Julius Vogel proposed infrastructure including a national railway network to be funded by overseas loans of £10 million, under the guise of the "Great Public Works Policy". Settlement and land sales to immigrants from Britain resulting from this infrastructure investment would pay for the scheme. The first narrow-gauge line
5922-472: The caisson, requiring workers to be medically cleared as "fit to dive" and able to operate pressure locks. Open face soft ground TBMs rely on the excavated ground to briefly stand without support. They are suitable for use in ground with a strength of up to about 10 MPa (1,500 psi) with low water inflows. They can bore tunnels with cross-section in excess of 10 m (30 ft). A backactor arm or cutter head bore to within 150 mm (6 in) of
6048-436: The commission postulated that freight traffic to the Bay of Plenty would double by 1982, a feat that was actually attained in 1966. It also made the following recommendations: Following the publication of this report in 1963, the government authorised a survey of the whole deviation route. However, it was not until September 1964 that the project was actually approved at an estimated cost of $ 11,434,000. In November, construction
6174-426: The company's total revenue. Freight is mostly bulk traffic geared towards export industries, with general freight being largely restricted to containerised and palletised products on the trunk route. Major bulk freight includes coal, lime, steel, wood and wood products, paper pulp, dry and liquid milk, cars, fertiliser, grain and shipping containers . Freight levels have returned to the level that they were at when
6300-543: The construction of a tunnel under the English Channel and the British Parliament supported a trial run using English's TBM. Its cutting head consisted of a conical drill bit behind which were a pair of opposing arms on which were mounted cutting discs. From June 1882 to March 1883, the machine tunneled, through chalk, a total of 1,840 m (6,036 ft). A French engineer, Alexandre Lavalley , who
6426-490: The core rail operations of the Corporation were transferred to New Zealand Rail Limited, another state-owned enterprise, with the Corporation retaining non-core assets which were gradually disposed of, including a significant land portfolio. In many cases, the Corporation did not dispose of land due to Treaty of Waitangi claims and has continued to manage land. New Zealand Rail Limited was privatised in 1993. The company
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#17327973234926552-487: The country, but did recommend narrow gauge if that were to happen, stating "narrow gauge appears calculated to carry all the traffic for many years, and would possess the advantage of greater cheapness in construction; for this reason railways of this character should be encouraged." By 1869, 78 kilometres (48 mi) of provincial railways were open, with another 30 kilometres (19 mi) under construction, mainly in Southland and Canterbury. Parliamentary debate focused on
6678-534: The creation of the "super-city" Auckland Council in 2010, ARTA was dissolved and its role was taken over by Auckland Transport , a new council-controlled organisation . In 2003, the share price of Tranz Rail dropped to a record low on the New Zealand sharemarket , dropping 88% in value in 12 months as a result of its poor financial state and credit downgrading. The government then considered various schemes for bailing it out in return for regaining control of
6804-439: The cutter head and extraction screw to ensure that the muck is sufficiently cohesive to maintain pressure and restrict water flow. Like some other TBM types, EPB's use thrust cylinders to advance by pushing against concrete segments. The cutter head uses a combination of tungsten carbide cutting bits, carbide disc cutters, drag picks and/or hard rock disc cutters. EPB has allowed soft, wet, or unstable ground to be tunneled with
6930-437: The cutter head of a TBM can be unpressurized, as the exposed rock face can support itself. In weaker soil, or when there is significant ground water, pressure must be applied to the face of the tunnel to prevent collapse and/or the infiltration of ground water into the machine. Earth pressure balance (EPB) machines are used in soft ground with less than 7 bar (100 psi) of pressure. It uses muck to maintain pressure at
7056-434: The cutter head to support the walls until permanent tunnel support is constructed further along the machine. The stability of the walls also influences the method by which the TBM anchors itself in place so that it can apply force to the cutting head. This in turn determines whether the machine can bore and advance simultaneously, or whether these are done in alternating modes. Gripper TBMs are used in rock tunnels. They forgo
7182-499: The cutting discs would travel over almost all of the rock face that was to be removed. The first TBM that tunneled a substantial distance was invented in 1863 and improved in 1875 by British Army officer Major Frederick Edward Blackett Beaumont (1833–1895); Beaumont's machine was further improved in 1880 by British Army officer Major Thomas English (1843–1935). In 1875, the French National Assembly approved
7308-431: The deregulation of land transport in 1983. The Corporation became a state-owned enterprise (SOE) in 1987, required to run at a profit. In 1991, the rail, inter-island ferry and infrastructure businesses of the Railways Corporation were split off into a new SOE, New Zealand Rail Limited , which was in turn privatised in 1993, and renamed Tranz Rail in 1995. The parcels and bus service business units were also privatised, and
7434-495: The districts' populations to urban services. It also noted that rail service between Whanganui and Palmerston North could be established. The Plan proposes to replace the Capital Connection, a long-range commuter train, with a modern and larger train fleet that could operate at a higher frequency. Currently, Auckland and Wellington have suburban passenger services. In both cities, the respective local governments own
7560-506: The edge of the shield. After a boring cycle, the shield is jacked forward to begin a new cycle. Ground support is provided by precast concrete, or occasionally spheroidal graphite iron (SGI) segments that are bolted or supported until a support ring has been added. The final segment, called the key, is wedge-shaped, and expands the ring until it is tight against the ground. TBMs range diameter from 1 to 17 meters (3 to 56 ft). Micro tunnel shield TBMs are used to construct small tunnels, and
7686-478: The electric trains on behalf of Auckland Transport (AT). In recent years the mothballed Onehunga Branch was reopened (2010) and a new line was built ( Manukau Branch , opened April 2012). Recent major projects include electrification of the Auckland suburban network and the building of the City Rail Link . Most Auckland rolling stock is owned by AT, which funds and coordinates all services. In 2017,
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#17327973234927812-467: The end of the 19th century, speeds had reached over 30 meters per week. 21st century rock TBMs can excavate over 700 meters per week, while soil tunneling machines can exceed 200 meters per week. Speed generally declines as tunnel size increases. The first successful tunnelling shield was developed by Sir Marc Isambard Brunel to excavate the Thames Tunnel in 1825. However, this
7938-411: The ferry service to Wellington ran in 1976. The 10.5 km line to Lyttelton was electrified from 1929 to 1970. There were worker's trains north to Rangiora; two in the morning and two in the afternoon. Dunedin had suburban trains to Port Chalmers and Mosgiel, withdrawn on 3 December 1982. The Invercargill to Bluff service stopped in 1967; in 1929 the sole Clayton steam railcar had been used. Trains ran
8064-530: The formation of the Kaimai Tunnel Committee. Hopes for a timely start on such a line were dashed, when on 14 August 1958 it was announced that the project was to be deferred. A report that had been prepared on the subject stated that there was an insufficient volume of guaranteed traffic then or in the near future to justify the project at that time. Alternatives were mentioned, including a preferred 24 km route between Waharoa and Apata with
8190-429: The four workers who had lost their lives. Finally, he cut a ribbon and declared the tunnel to be open. The train proceeded to Tauranga with the official party and minus the school children where several civic functions were held. The project ended up running eight years over time, and over budget. The final cost was $ 43 million for the tunnel and $ 13 million for the deviation, a total of $ 56 million. The Kaimai Deviation
8316-492: The government announced funding for a number of rail-related infrastructure projects, mainly in the Auckland region. A business case is progressing for a branch railway to be built from the North Auckland Line to Northport at Marsden Point . Freight is carried by KiwiRail and provides the majority of its revenue traffic. In the 2017–2018 financial year, freight contributed $ 350.7 million in revenue or 57% of
8442-472: The government launched the New Zealand Rail Plan, with funding for rail projects to come from National Land Transport Fund (NLTF), with KiwiRail remaining an SOE but paying Track Access Charges (TACs) to use the network. Railway lines were initially constructed by the provincial governments of New Zealand from 1863 onwards. New Zealand's first public railway was opened in that year, running
8568-441: The major freight terminals. One of the reasons often cited for these policies was that the cost of using road transport to Tranz Rail was less than that of using rail because the road infrastructure is provided as a public good , whereas the rail network was a private good . The government purchased the Auckland metropolitan rail network from Tranz Rail for $ 81 million in 2002. Tranz Rail retained time slots for freight trains, and
8694-509: The national railway network and were often moved as the forest was cleared. The last bush tramway for logging native bush closed in 1974. Bush tramways should not be confused with urban street-cars , known in New Zealand as trams. In the 20th century, New Zealand cities had extensive tram networks. Most of these networks closed mid-century, being replaced by buses. There are now proposals in Auckland and Wellington for new light rail networks, New Zealand has no rapid transit metros. Following
8820-816: The number had decreased to 11.7 million. A number of services came to an end in the early 2000s, including the Waikato Connection between Hamilton and Auckland, the Kaimai Express between Auckland and Tauranga, the Geyserland Express between Auckland and Rotorua, the Bay Express between Wellington and Napier, the Southerner between Christchurch and Invercargill and the Northerner night service between Auckland and Wellington. Two further long distance scheduled passenger services,
8946-436: The number of tonnes of traffic gained in 2008–2009 compared to the amount of traffic hauled in the 2006–2007 year). In recent years, the amount of freight moved by rail has increased substantially and has started to gain market share in non-bulk areas as well. Freight on the North Island Main Trunk line between Auckland and Palmerston North saw an increase of 39% in freight volumes between 2006 and 2007. The five daily trains on
9072-504: The old line at Apata. Today, there are up to 22-weekday freight train movements per day through the Kaimai Tunnel, and up to 19 movements per day during the weekends. Freight transported over this route includes inter-port container traffic, timber and timber products, coal, manufactured goods, and petroleum. Traffic on the Kaimai Deviation has been dominated by freight trains for its entire working life. Regular passenger trains to
9198-468: The opening up and development of the hinterland outside of New Zealand's predominantly dispersed and coastal settlements. Starting with the Ferrymead Railway in 1863, most public railway lines were short, built by provincial governments and connected major centres to their nearest seaport (such as Christchurch and its port at Lyttelton Harbour ). From the 1870s, the focus shifted to building
9324-458: The other side to check the alignment. Though the official hole-through ceremony had been planned for 17 June, the dignitaries had to be content with shovelling some of the rubble as the TBM had again jammed with loose rock. Mr. L. Dillon, a project supervisor, became the first person to walk the tunnel end-to-end on 21 June. The project plan had called for lining to be done once all excavations had been completed, but deteriorating rock, especially at
9450-425: The portal, is 123 ft (37 m) and bridge 43, 106.7 m (350 ft) long. The latter cost about $ 24,000 and rests on 4 piers. A 126 ft (38 m) cutting follows, then about a mile from the tunnel portal, Works Road crosses the line, followed by a 747 ft (228 m) long Wainui River bridge 45, 110 ft (34 m) above the river. Then Wainui South Road goes over the track, before it rejoins
9576-605: The provincial railways expanded. In 1867, the House of Representatives formed a select committee to investigate the issue, composed of members of parliament from all across New Zealand. The select committee heard evidence from railway engineers who proposed a number of options, including building main trunk lines at standard gauge, while using narrow gauge for branch lines. Engineers cited the experience of Queenland's railways , which had adopted narrow gauge in 1864. The select committee did not recommend making railway gauge uniform across
9702-560: The question of whether the provincial railways could keep their wider gauges, while narrow gauge railways were to be built. Member of the House of Representatives (MHR) James Crowe Richmond , who had worked on the Great Western Railway and in railways in Belgium, became the most prominent advocate for a uniform narrow gauge nationwide. In late 1869 Francis Dillon Bell MHR and Issac Featherston MHR (also superintendent of
9828-633: The rail infrastructure. Cited reasons included a "level playing field" for freight movements on road and rail, and ensuring access to the tracks for all interested parties. Toll Holdings of Australia made a successful takeover bid for Tranz Rail, subject to an agreement to sell back the infrastructure to the government for $ 1. In exchange, Toll was granted exclusive use of the rail network subject to minimum freight and passenger volumes, payment of track access charges and its own investment in new rolling stock. This transaction took place in July 2004, and Tranz Rail
9954-406: The railway had a virtual monopoly on land transport, prior to 1983. In 1980 11.8 million tonnes of freight was moved by rail, in 1994 this had decreased to 9.4 million tonnes. By 1999, tonnes carried had increased to 12.9 million tonnes, slightly more than the 1975 peak. In the 2006–2007 financial year, 13.7 million tonnes of freight were carried. This equated to 3.96 million net tonne kilometres (or
10080-538: The recently elected Labour -led Coalition government proposed to provide commuter rail in Christchurch and to provide long-distance commuter services from Auckland to Hamilton and Tauranga. Other cities (Christchurch, Dunedin, Invercargill and Napier-Hastings) once had suburban services, but they were withdrawn due to a lack of patronage. The Christchurch-Lyttelton suburban service was stopped in 1972 when passengers were down to "a busload". The last "boat train" for
10206-407: The relative particle sizes of the muck. Slurry TBMs are not suitable for silts and clays as the particle sizes of the spoil are less than that of the bentonite. In this case, water is removed from the slurry leaving a clay cake, which may be polluted. A caisson system is sometimes placed at the cutting head to allow workers to operate the machine, although air pressure may reach elevated levels in
10332-428: The required diesel locomotives. Auckland's network consists of four lines: Southern , Eastern , Western and Onehunga . All services on these lines are provided by AM class electric trains , the conversion from diesel being completed by the end of 2015 with the exception of the non-electrified section of track between Papakura and Pukekohe, where a diesel train shuttle service operates. Auckland One Rail operates
10458-481: The rock. In 1853, the American Ebenezer Talbot also patented a TBM that employed Wilson's cutting discs, although they were mounted on rotating arms, which in turn were mounted on a rotating plate. In the 1870s, John D. Brunton of England built a machine employing cutting discs that were mounted eccentrically on rotating plates, which in turn were mounted eccentrically on a rotating plate, so that
10584-710: The rocks, have caused maintenance problems. Rail transport in New Zealand Rail transport in New Zealand is an integral part of New Zealand's transport network , with a nationwide network of 4,375.5 km (2,718.8 mi) of track linking most major cities in the North and South Islands, connected by inter-island rail and road ferries. Rail transport in New Zealand has a particular focus on bulk freight exports and imports, with 19 million net tonnes moved by rail annually, accounting for more than half of rail revenue. Rail transport played an important role in
10710-539: The second select committee to investigate whether a law was required for gauge uniformity met from that month. By majority the select committee reported back to the house in favour of narrow gauge being adopted as the uniform gauge nationwide, and allowing Canterbury Provincial Railways to continue to expand its broad-gauge network, with dual-gauge track where narrow gauge met broad gauge. William Sefton Moorhouse MHR, former superintendent of Canterbury Province and advocate for broad gauge, and William Rolleston MHR, at
10836-556: The services have been operated by Transdev Wellington . Prior to Transdev, KiwiRail's Tranz Metro division held the contract. Wellington's suburban rolling stock consists of electric multiple units , with diesel locomotive-hauled carriage trains used on the Wairarapa service. All of the rolling stock (except the diesel locomotives) is owned by Greater Wellington Rail Limited, a subsidiary of Greater Wellington Regional Council. Transdev Wellington contracts KiwiRail to provide and operate
10962-606: The short distance between Christchurch and the wharf at Ferrymead and built by the Canterbury Provincial Railways . The Canterbury Provincial Railways were built to the broad gauge of 5 ft 3 in ( 1,600 mm ). In February 1867, Southland Province opened a branch from Invercargill to Bluff to the international standard gauge of 4 ft 8 + 1 ⁄ 2 in ( 1,435 mm ). 3 ft 6 in ( 1,067 mm ) gauge (internationally known as narrow gauge)
11088-587: The special requirement that the surface remain undisturbed, and that ground subsidence be avoided. The normal method of doing this in soft ground is to maintain soil pressures during and after construction. TBMs with positive face control, such as earth pressure balance (EPB) and slurry shield (SS), are used in such situations. Both types (EPB and SS) are capable of reducing the risk of surface subsidence and voids if ground conditions are well documented. When tunnelling in urban environments, other tunnels, existing utility lines and deep foundations must be considered, and
11214-618: The start of 2008. Instead of concluding a final track access agreement with Toll, in 2008 the government purchased the rail and ferry assets for $ 690 million, effective 1 July 2008. The new organisation created to operate services on the rail network was named KiwiRail . Ownership of the national rail network is vested in KiwiRail Holdings Limited, with land owned by the New Zealand Railways Corporation. KiwiRail Network (formerly ONTRACK)
11340-431: The suburban passenger rolling stock and contract the operation of services to a third-party, in both cases Transdev . The Wellington suburban network has five lines: Johnsonville , Kapiti , Melling , Hutt Valley and Wairarapa . In 1938, Wellington became the second city (after the Christchurch service to Lyttelton) to have electric suburban trains, and from 1970 to 2014 was the only city with them. From July 2016,
11466-418: The suitability of the TBM for work at the western portal. It soon became apparent that the nature of the rock at this end of the tunnel was too fractured for efficient operation of the TBM, resulting in the cutters and fill extraction systems of the machine being continually blocked by rock. By the end of the trial period, the TBM had only advanced 106 metres (348 ft) and was wearing out far more quickly than
11592-715: The time superintendent of Canterbury Province, were in the minority on the select committee opposing the legislation. Despite this opposition, Parliament passed the Railways Act 1870 in September 1870, requiring all railways to be built or converted to narrow gauge, with an exemption of the Christchurch-Rakaia section of Canterbury Provincial Railways. Sections of the Canterbury railway network were converted to dual-gauge, including Rakaia to Lyttleton, with new branch lines built to narrow gauge. By 1878, all of
11718-409: The time that the deviation would be an advantage to the whole North Island railway system, shortening the rail distance between Tauranga and Hamilton by 51.5 kilometres (32.0 mi), and the rail distance between Rotorua and Tauranga by 100 kilometres (62 mi). He expected that the construction costs could be recovered through savings on operational costs once the deviation was completed. The work
11844-497: The traditional ballast and sleepers to reduce maintenance costs for the track inside the tunnel. The slab track extends about 70 m (230 ft) beyond each end of the tunnel. The first official train through the tunnel was the Silver Fern railcar RM 3 , which departed Hamilton railway station for Tauranga on 12 September 1978. On board were various railway officials and a party of 50 disabled Waikato school children. After
11970-592: The tunnel face. Main Beam machines do not install concrete segments behind the cutter head. Instead, the rock is held up using ground support methods such as ring beams, rock bolts, shotcrete , steel straps, ring steel and wire mesh. Depending on the stability of the local geology, the newly formed walls of the tunnel often need to be supported immediately after being dug to avoid collapse, before any permanent support or lining has been constructed. Many TBMs are equipped with one or more cylindrical shields following behind
12096-401: The tunnel face. The muck (or spoil ) is admitted into the TBM via a screw conveyor . By adjusting the rate of extraction of muck and the advance rate of the TBM, the pressure at the face of the TBM can be controlled without the use of slurry . Additives such as bentonite , polymers and foam can be injected ahead of the face to stabilize the ground. Such additives can separately be injected in
12222-411: The tunnel, the way they provide traction to support the boring activity, and in the way they support the newly formed tunnels walls. Shielded TBMs are typically used to excavate tunnels in soil. They erect concrete segments behind the TBM to support the tunnel walls. The machine stabilizes itself in the tunnel with hydraulic cylinders that press against the shield, allowing the TBM to apply pressure at
12348-411: The use of a shield and instead push directly against the unreinforced sides of the tunnel. Machines such as a Wirth machine can be moved only while ungripped. Other machines can move continuously. At the end of a Wirth boring cycle, legs drop to the ground, the grippers are retracted, and the machine advances. The grippers then reengage and the rear legs lift for the next cycle. A single-shield TBM has
12474-476: The use of the more powerful diesel locomotives. It was also an unreliable route, with frequent disruptions caused by slips. Easing of the ruling gradient to 1:300 allowed train weights to be increased from 530 to 900 tons for a single engine. Proposals to shorten the distance between Auckland and Tauranga were made as far back as the early 20th century. A line over the Kaimai Range was suggested in 1911 but
12600-464: The western end, meant that the plan had to change. The problem was solved by pumping concrete under high pressure behind steel liners. Once this was finished, the concrete track bed was laid by the private contractor Robert McGregor and Sons of the United Kingdom . Together with British Rail, they had developed a technique for laying paved concrete track (PACT). This method was chosen rather than
12726-414: Was a substantial rationalisation of freight facilities; many stations and smaller yards were closed and freight train services were sped up, increased in length and made heavier, with the removal of guard's vans in 1987 and the gradual elimination of older rolling stock, particularly four-wheeled wagons. In 1987, the Railways Corporation became a state-owned enterprise , required to make a profit. In 1990,
12852-679: Was about 62 GWh. It is owned and operated by the Italian construction company Toto S.p.A. Costruzioni Generali (Toto Group) for the Sparvo gallery of the Italian Motorway Pass A1 ("Variante di Valico A1"), near Florence. The same company built the world's largest-diameter slurry TBM , excavation diameter of 17.6 meters (58 ft), owned and operated by the French construction company Dragages Hong Kong (Bouygues' subsidiary) for
12978-684: Was accused of deliberately running down some lines through lack of maintenance. The Midland Line for example, which mostly carries coal from the West Coast to Lyttelton, was assessed to be in a safe but poor state by the LTSA government safety body in 2003, and has needed major repairs. Tranz Rail was accused of forcing freight onto the roads, and in 2002 introduced a containerisation scheme that assumed that most freight would be carried in containers on unit trains made up of fixed consists of flat deck wagons. Container loading depots were constructed at
13104-592: Was also a Suez Canal contractor , used a similar machine to drill 1,669 m (5,476 ft) from Sangatte on the French side. However, despite this success, the cross-Channel tunnel project was abandoned in 1883 after the British military raised fears that the tunnel might be used as an invasion route. Nevertheless, in 1883, this TBM was used to bore a railway ventilation tunnel — 2 m (7 ft) in diameter and 2.06 km (6,750 ft) long — between Birkenhead and Liverpool , England, through sandstone under
13230-619: Was carried out primarily by the Ministry of Works , who were responsible for the drilling of the tunnel. Various other related jobs were handled by private contractors, including the tunnel approaches and the laying of the track bed in the tunnel. In planning for the construction of the tunnel, the possibility of using a Tunnel Boring Machine (TBM) was considered in 1966. Discussions were held in Australia with those that had experience with them, or had previously investigated using them, and as
13356-402: Was chosen due to the need to cross mountainous terrain in the country's interior and the lower cost of construction. Due to multiple rail gauges being used by railways built by provincial governments, the prospect of a similar break of gauge problem to Australia (where narrow, standard and broad gauge railways were built by different colonial governments) became a major political issue as
13482-467: Was completed between Christchurch and Dunedin in 1878, later extended to Invercargill the following year. The North Island Main Trunk , linking capital city Wellington with the largest city Auckland , opened in 1908 after 23 years of construction. At the network's peak in 1952, about 100 branch lines were operating. Large-scale closures of branch railway lines began in the 1960s and 1970s. The network
13608-403: Was expected to dig 380,000 cu yd (290,000 m) of rock. The western approach begins at Waharoa, where new marshalling yards were built, then crosses a flat area, goes under SH 27 , over two 240 ft (73 m) 240 ft bridges (No.37, Hardings Drain and No.38, Turanga-O-Moana Stream), under Tower Road and then a 600 ft (180 m) long reinforced concrete bridge (No.41) over
13734-425: Was further delayed by six months until funding of $ 710,000 was finally approved in the following years budget for the 1965-1966 financial year. It was expected at the time that the project could be completed by October 1970. At the turning-of-the-first-sod ceremony on 2 October 1965, the Minister of Works the Hon. Percy Allen (who was also the MP for the Bay of Plenty) officiated. The Chief Civil Engineer remarked at
13860-481: Was heavily regulated from 1931 onwards. NZR eventually expanded into other transport modes, especially with the Railways Road Services , inter-island ferries and Rail Air service. NZR also had an extensive network of workshops. By 1981, NZR employed 22,000 staff. In the early 1980s, NZR was corporatised as the New Zealand Railways Corporation and drastically restructured, especially following
13986-472: Was hoped, so it was decided to dismantle it and move it to the eastern portal. Work at the western end of the tunnel continued with traditional drill and blast methods. The profile of the western end, which had been round to accommodate the TBM, was changed to a horseshoe shape to better suit conventional tunnelling procedure. By the time the tunnel was finished, around 48% of the length of the tunnel had been bored using conventional methods. Reasonable progress
14112-533: Was initially protected from road transport competition under the Transport Licensing Act 1931 , but this protection was gradually eased until its total abolition in 1983, along with the deregulation of the land transport industry. The networks of the North and South Islands were independent of one another until the introduction of the inter-island roll-on roll-off rail ferry service in 1962 by
14238-503: Was launched in April 2021, confirming funding for rail projects from the NLTF, and the use of Track Access Charges (TACs) for users of the rail network, including KiwiRail. Some specific projects were also outlined as possibilities: The City Rail Link is an underground rail line currently under construction linking Waitematā railway station to Maungawhau railway station in Auckland and
14364-402: Was made from the eastern end of the tunnel once the TBM had been reassembled there in April 1972. Though the wear on the machine caused by its use at the western end caused some mechanical problems, progress of up to 15 metres (49 ft) per 8-hour shift was achieved, though this was considerably reduced in wet areas. With up to 600 m³ of water flowing through the tunnel walls, continuous pumping
14490-480: Was manufactured by The Robbins Company for Canada's Niagara Tunnel Project . The machine was used to bore a hydroelectric tunnel beneath Niagara Falls . The machine was named "Big Becky" in reference to the Sir Adam Beck hydroelectric dams to which it tunnelled to provide an additional hydroelectric tunnel. An earth pressure balance TBM known as Bertha with a bore diameter of 17.45 meters (57.3 ft)
14616-540: Was mothballed in the wake of the COVID-19 pandemic, but has since restarted with a reduced timetable. Mixed trains were "once the backbone of the New Zealand railway passenger system" on branch and even main lines, but the last scheduled mixed train ran between Whangarei and Opua on 6 June 1977. With a "rake of assorted wagons" and one or two passenger carriages, often listed as "goods with car" in timetables, they were slow, often stopping and shunting wagons en route. In
14742-491: Was named Stokes Peak in 2010 in honour of geographer Evelyn Stokes . In 2012 the name of the mountain peak reverted to being unnamed. The tunnel runs through pumice , breccia , andesite and ignimbrite , interbedded with soft tuff . The rocks are about 3 to 5 million years old. Soft geology and groundwater have resulted in voids under the tunnel floor. Repairs with resin were made in 2013 and 2018. Water contamination with sulphur and arsenic , leached out of
14868-585: Was only the invention of the shield concept and did not involve the construction of a complete tunnel boring machine, the digging still having to be accomplished by the then standard excavation methods. The first boring machine reported to have been built was Henri Maus 's Mountain Slicer . Commissioned by the King of Sardinia in 1845 to dig the Fréjus Rail Tunnel between France and Italy through
14994-659: Was opened on 1 January 1873 in the Otago Province , the Port Chalmers Branch under the auspices of the Dunedin and Port Chalmers Railway Company Limited. Auckland's first railway, between Auckland and Onehunga , opened in December 1873. Vogel also arranged for Brogdens of England to undertake several rail construction contracts, to be built by "Brogden's Navvies" recruited in England. Vogel's vision of
15120-480: Was operated with Silver Fern railcars. Since the Railways Corporation relaxed its policy on private use of the national rail network in the 1980s, there have been occasional passenger excursions run on the deviation by organisations such as Mainline Steam and the Railway Enthusiasts Society . A 814 m (2,671 ft) peak of the Kaimai Range directly above the tunnel, previously unnamed,
15246-430: Was produced by Hitachi Zosen Corporation in 2013. It was delivered to Seattle , Washington , for its Highway 99 tunnel project . The machine began operating in July 2013, but stalled in December 2013 and required substantial repairs that halted the machine until January 2016. Bertha completed boring the tunnel on April 4, 2017. Two TBMs supplied by CREG excavated two tunnels for Kuala Lumpur 's Rapid Transit with
15372-482: Was purchased and imported from the United States in 1970 at a cost of $ 1.4 million, a decision considered adventurous at the time as a TBM had not been used on this type of geology before. The boring head of up to 78 cutters, was driven at 6 rpm by eight 125 hp (93 kW) 440 volt motors, plus a 75 hp (56 kW) motor for the hydraulics and smaller motors for conveyors and other services. The TBM cut
15498-507: Was quickly dismissed as being impractical. In 1913, a 3.2 km tunnel was suggested, and in 1920 a survey was requested for a Kaimai rail route, though it would be many years before this happened. In 1955, an investigation was made of the possibility of road and rail access to Mt. Maunganui from the Waikato including a 4 km tunnel, an idea that was enthusiastically supported by Federated Farmers, and later local news media. This led to
15624-435: Was renamed Toll New Zealand . The government committed $ 200 million of taxpayer funding for deferred maintenance and capital improvements via a new subsidiary of the New Zealand Railways Corporation, ONTRACK. An interim agreement was signed by Toll NZ for track access; Toll paid a nominal track access charge while negotiating a final agreement with ONTRACK. These negotiations did not progress and eventually went to arbitration at
15750-479: Was required to avoid flooding. Ducted ventilation was initially sufficient for the machine and the workers in the tunnel, but the closer the excavation got to the midway point, the more the temperature increased. To combat this, the shifts were shortened, though eventually three refrigeration plants had to be installed for the western end and one at the eastern end. The two headings of the tunnel workings met on 4 June 1976 when two pilot tunnels were drilled through to
15876-462: Was sold for $ 328.3 million to a consortium named Pylorus Investments Limited. In 1995 the new owners adopted the name Tranz Rail and listed the company on the New Zealand stock market and NASDAQ . Rail freight volumes increased between 1993 and 2000 from 8.5m net tonnes to 14.99m net tonnes carried annually, and then gradually fell until 2003 to 13.7m tonnes. Freight volumes then increased again to 16.1m tonnes carried annually in 2012. Tranz Rail
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