The Kielder Transfer Works

Proc. lnstn Ciu.
Engrs, Part 1, 1982,72, May, 177-208
The Kielder transfer works
D. J. COATS, BSc, FICE*

N. S. M. BERRY, BSC, F I C E ~
D. J. BANKS, BSc, MICE$
The Paper describes the various works of the Northumbrian Water Authority's Kielder
water scheme which allow transfer of water from a regulated River Tyne at Riding Mill
(56 km downstream from Kielder Water) to the rivers Wear and Tees to also furtherregulate
these rivers for the purposeof water abstraction.
Introduction
The background to the development of the Kielder water scheme is described in a
previous paper.' That part of the scheme known as the transfer works extends
from Riding Mill on the River Tyne approximately 25 km upstream of Newcastle
to the River Tees near Eggleston-a distance of about 40 km. This will allow the
transfer of up to 1,180 X 106 m3/d of water from the River Tyne to the rivers Wear
and Tees.
2. The pumping station site at Riding Mill is 13 km upstream of the tidal limit
and was the most suitable location for abstraction. At Eggleston the River Tees
starts to flow in a more southerly direction than before. The target route for the
transfer works was therefore a straight line between Riding Mill and Eggleston,
which also avoids the coal-mining areas to the east of this line. Geological and
hydraulic considerations, together with a desire to phase as much of the works as
possible, led to a pumping main for6.2 km discharging intoa gravitational
system. Most of the aqueduct length is in tunnel, with balancing storage at Airy
Holm (Fig. 1).
3. Following the execution of minor works to give access to the Tees portal in
1974, the first of the tunnelling contracts (13 km from Derwent to Wear and
14.4 km from Wear to Tees)was let in 1975. The second tunnelling contract
(4.5 km from Letch House to Derwent) was let in early 1977. Construction of the
Riding Mill pumping station and the pumping main also started in 1977. The
contract for the construction of Airy Holm dam was let towards the end of 1977.
Finally, a contract for construction of a weir on the River Tyne to improve
abstraction conditions waslet in 1980. The transfer works are expected to be
operational in 1982.
Ordinary meeting, 2.30 p.m., 18 May 1982. Written discussion closes 15 July 1982 for
publication in Proceedings, Part 1.
* Senior Partner, Babtie Shaw and Morton, Consulting Engineers.
t Partner, Babtie Shaw and Morton.
$ Associate, Babtie Shaw and Morton.
177
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COATS, BERRY AND BANKS
0 5 35 t o 30 1525 20 40
Kilometres
Fig.1 . Transfer works
Fig. 2. Riding Mill pumping station and weir
170
KIELDER TRANSFER WORKS
Scale of metres
0 40
Fig. 3. Plan of Riding Mill weir
River abstraction works

Location
4. The abstraction works (Fig. 2) are positioned just upstream of an existing
small sewage treatment works and about 400 m downstream from the nearest
dwelling, which isin the village of Riding Mill. The pumping station intake is
positioned beside a deep natura1 pool along the outside of a bend in the River
Tyne, and about 200 m upstream from a good site for a weir across the river.
Model testing’wasused to check the suitability of the site, to develop the
hydraulic design and to establish weir crest levels having an acceptable
relationship to land drainage and flooding.
Riding Mill weir

5. The 80 m long weir (Fig. 3) is divided into two sections. The right bank
section has two tilting gates (each 8 m wide) to control pond level and residual
flows during pumping, and immediately downstream a 17 m wide Crump weir for
flow measurement (Fig. 4).A machinery deck is provided above flood level to
operate the tilting gates, and a fish pass is provided in the river bank to bypass the
gates. The mid-river section comprises a concrete weir, 62 m long, with a crest level
179
ty --
180
about 2.0 m above originalriver bed level and 1.4 m above lowest weir crest level
of the right bank section.
6. When the tilting gates are r a i d the weir creates intake pond storage of
about 110000 m’ capacity above lowest weir level. In future this storage may be
increased to 214000 m3 by raising the level of the weir Crest by 0.65 m either by
increasing theheight of the concretecrest o r adding longtilting gates. This storage
provides a balancebetween natural river flows, releasesfrom Kielder Waterwhich
take time to arrive, and abstractions usingfixed speed pumps (i.e., stepped instead
of variable speed pumping). Normally the tilting gates will be kept fully lowered
and will be raised slowlyto create storagebefore pumping commences. Thereafter
they will be, adjusted so that necessary downstream flows can be maintained.
7. It was originally intended to include flow-measuringweirs and fish passes at
both sides of the river, but those beside the left bank were removed because the
model study indicated a tendency for river bed material to depositin this area (Fig.
5). During lowflows the fish can use the fish pass to bypass the tilting gates,
although at high flows the gateswill be partly or fully lowered and fish will be able
to swim over thegates. A fish counter is installed on theCrump weir.
8. The weir is of reinforced wncrete construction with a cut-off of 1.2 m din.
Secant interlocking wncrete piles extending to rockunderthe weircrest.
Sandstone lies at about 5 m below river bed level with sand, gravel and boulders
overlying. During construction of the weir not more thanone third of the normal
river channel was obstructed as the weir was constructed in four sections within
steel sheet pile cofferdams. Because of densely packed large boulders in the river
bed the sheet piling had to be driven through a preexcavated trench which had
been backfilled withgranular material.
-m-%-*;%-*- . .‘W
Fig. 5. Riding Mill model Showing leh bank bayssilted up
181
COATS,BERRYANDBANKS
z
a
1
a
U
0
S
LL
a:
W
a
a
3
182
COATS, B E R R Y A N D B A N K S
Riding Mill pumping station

9. Waterabstracted willbe normally ‘clean’ because bulk transfer for river
regulation willbe generally required during times oflow natural riverflow.
Single-lift pumping was therefore adopted. Further, it was practical to integrate
the intake andpumping station into one building, and it was decided to construct
this to accommodate an ultimate pumping capacity of 1.092 X 106 m3/d.
10. Twelve pumping units each of 91 000 m3/d capacity were chosen for
operational flexibility and taking account of electricity system restrictions, but
only six units would be installed initially. Early in the design stage of the pumping
station, tenders for pumps were obtained, and vertically suspended four-stage
shaft-driven mixed flow units were chosen. The high pumping head of 217 m at
duty point required non-standard 4000 bhp capacity totally enclosed 11 kV
water-cooled motors. These are all fixed speed-four with slip-ring induction, and
two with synchronous induction.
11. Also at an early design stage a contract was placed for six band screens,
each of 91 000 m3/d capacity, and with 6.53 mm square fine-mesh screen openings.
12. The building and plant layout (Figs 6 and 7) was developed around these
elements. The intake and wet well area comprises six modules, each containing
coarse screens, a pairof band screens, and a pair of pumps. The pumpinlet channel
enables water to be transferred between modules. The main pumps, at 5 m centres,
are individually connected to a single outlet manifold within the pump hall. The
overhead crane can traverse the length of the pump hall, including the loading bay,
which doubles as amaintenance area. The electrical annexe over the pipe manifold
enables convenient cable runs to be made from the switchgear to each item of
plant.
13. The 65 m long intake is sited to avoid obstruction to river flow. The inlet
sill is above river bed level and 1 m below lowest crest level of the weir so that the
intake velocity is kept very low and normal river intake problems with debris are
minimized. The maximum intake velocity of 0.3 m/s, which is also the maximum
velocity throughthe band screens, occurs rarely;smolts are unlikely to be
attracted into the wet well, and even if they enter, they can swim out again. The
trash screen bars, 20 mm X 65 mm section and at 75 mm centres, exclude coarse
debris and are designed to allow easy replacement; GRP plates with rubber seals
can be fitted externally to allow dewatering of a forebay chamber if necessary. An
electrically powered raking machine on rails is provided for removal of coarse
debris. The mechanical band screens are positioned in chambers which can be
readily isolated by penstock. The external band-screen area deck level is at a, flood
level with about a 1 in 80 year return period, while the concrete walls of the main
pump hall basement have no external opening below a flood level with a greater
than 1 in 500 year return period, and the pump pedestal base plate is specially
sealed to prevent ingress of water.
14. Special measures had to be taken to reduce noise because of the high
anticipated sound level of up to 104 dB(A) at 1 m radius for each motor. Noise
restrictions were part of the outline planning permission, but it was decided to
adopt the more onerous requirements of BS 4142 which gave an acoustic design
target with all twelve pumps runningof 27 dB(A) at a radius of 400 m, and a sound
level in the pump hall not exceeding 85 dB(A). To achieve this the building was
designed using reinforced concrete portal frames to support thick precast concrete
wall panels and a flat roof of solid precast concrete units. The pump hall has no
external windows, and internal surfaces are faced with noise-absorbent materials.
184
All external opnings for air circulation fans are fitted with acoustic ballles. In
addition each pumpset is reassed within an acoustic enclosure consisting of an in
situ concrete walkway at high level with a removable dome cover and curved
sound-absorbent screensat the sides.
15. The pipework mabifold which runs thefull length of the pumphall (Fig. S)
is anchored only at its downstream end and,to allow for expansion, stainless steel
bellow unitsareincorporated in thebranchpipis for eachpump. All steel
pipework was designedto BS 5500. Butterfly valves whichhave replaceable rubber
inset seals and are designed for controlled openingare provided on each71 1 mm
d i a pump deliverypipe, together with non-return valves. The manifoldis
2220 mm dia. reducing to1016 mm d i a The theoretical and measured movements
of the external buried pipework under pressure were the subjectof a study by the
ConstructionIndustry Research and InformationAssociation? The surge
suppression and protection measures adopted both at the pumping station and
elsewhere on the transfer works are described by Ellis et al.’ Horizontal s u r e
vessels are located adjacent to the pumping station in a buried chamber. Each
vessel is 100 m3 in volume and is designed to provide surge protection for three
pumps using one pumping main.
16. Theadministrationarea at theupstreamendofthepumpingstation
contains the usual facilities, including, on the groundfloor, a telemetry room and
workshop. On the first floor the supervisor’soilice, conferenceroom to
accommodate at least 50 visitors, and control room all have clear views over the
river. The station has been designed for unattended automatic operation, with
regular visits for ‘housekeeping’ duties and maintenance work, althougb initially
there will be attendance when pumps are started.
Fig. 8. Pump hall of Riding Mill pumping station

185
COATS, B E R R Y AND BANKS
17. The pumping station is founded on interlayered sequences of sand, gravel

and laminated silty clay, which are probably of glacial origin; they lie about 10 m
below the lowest foundation level and ontop of bedrock whichis mainly
mudstone, but with some siltstone and sandstone. The gravel deposits are variable
in size and permeability, and aregenerally medium dense to dense. Some silty clay
deposits indicated a tendency to swell on reduction of overburden pressure. To
avoid unacceptable differential settlements, it was decided to adopt steel universal
column bearing pileswhich would also be able to develop sufficient tensile
resistance to uplift. These piles, and also the sheet piles required for the cofferdam
around the wet well area, were driven without undue difficulty by the contractor,
although additional costswere incurred to meet noise restrictions imposed by the
temporary works planning approval.
18. The overall height of the building has been kept as low as possible for
reasons of amenity, and the architectural approach has been to give a horizontal
emphasis to the external appearance. The precast concrete wall panels have
exposed aggregate finish to reduce reflecting properties and to ensure a warm
colour, and the joints present a strong horizontal line. The surrounding area has
been landscaped to further reduce the visual impact and trees have been planted to
partially reinstate the continuous tree belt interrupted by the building and to
mitigate the visual severance inthe belt of trees made necessary by the
construction of the building. Off-site planting on the opposite side of the river will
help to screen the building from property on that side,
19. The pumping station, together with the electrical and mechanical aspects,
and operation, are described in detail by Banks et aL5
Pumping main
20. The pumping main linking the pumping station to the tunnel system is
6.2 km long and rises about 200 m. A single pipeline has been provided initially
trench depth
Imported I
compacted Imported cushlon f d
Selected backfill
level
Fig. 9. Pumping main cross-section

186
but there is provision for this to be duplicated when demand justifies it. It follows a
fairly direct route to discharge at the required level into a tank at Letch House
(Fig. 1). This point is to the east of the target route for the transfer works but is
suitably located for the start of the tunnel gravitational system ($40). The pipeline
route is mainly through agricultural land or wooded areas, but at one point it
crosses over a railway line within prestressed concrete pipes on a bridge for a new
road which wasbeing constructed by the Northumbrian County Council at about
the same time as the pipeline was being laid. Old mining activity in the area was
investigated and where the route passed over shallow abandoned workings these
were filled withgrout.
21. The pipeline is designed for a maximum working head of 263 m. The
spirally welded 50B and 43A grade steel pipes were 2 m nominal diameter with
wall thicknesses of 10 mm, 12 mm and 14 mm. With large diameter steel pipes
there is always the problem of large gaps to be welded at joints. To overcome this,
a semi-spherical joint6 was developed. The pipe itselfwas manufactured to a
circumferential tolerance of f5 mm and at the joint a tolerance of f 1.6 mm on
diameter was achieved. This meant that the maximum gap to beweldedwas
2.7 mm. The semi-spherical joint allowed a deflexion of up to 13" without
encroaching on the internal mortar lining thickness. The pipes were delivered in
12 m lengths and specials were fabricated from plate up to 18 mm thick with
reinforcing doubler plates to withstand the high stresses at the large diameter Ts.
22. To lay the pipes the contractor fenced off a 61 m wide working width and
the pipe trench and bedding arrangement were generally as shown in Fig. 9. Over
about one third of the length, rock was found at depths upto the level of the top of
the pipe and the rock was preblasted prior to the removal of overburden. The
remaining length of the pipeline is in stiff boulder clay exceptfor a 500 m length in
sand and gravel. Spiders wereleft inside the pipes until backfilling had been
virtually completed, and laying rates of up to 84 m/d were achieved.
23. The pipeline is protected externally by 6 mm thick bituminous compound
reinforced with glass cloth, with cold tape application over the joints. After laying
and backfilling the pipeline was given an internal cement mortar lining of 11 mm
nominal thickness (Fig. 10).The mortar was of equal volumes of ordinary Portland
cement and sand with enough water added to give adhesion to the pipe walls. It
was applied to its required thickness in a single pass by a lining machine with
centrifugal spraying head and circumferentially sweeping spring-loaded trowels.
Cold-applled tape
Tapped hole for testing Steel pipe, wall thlckness
\ ,l 0-1 4 mm
6 mm thick bltuminous Cement mortar l m n g

compound reinforced with 1 1 mm mln thlckness
glass tissue and glass cloth
Scale of mllllmetres
n 100
Fig. 10. Steel pipeline joint

187
The average daily output was 62 m, with 170 m lined in the best day. Some
cracking was experienced butafter filling a section of the pipeline with waterand
examining the lining after 6 weeks it became clear that the crack widths were
greatly reduced with the pipeline filledand that‘sell-healing’ wouldtake place. An
impressed currentsystem of cathodic protection has been incorporated.
24. About 100 m after leaving the pumping station the pipeline passes through
two reinforced concrete chambers,the first of which accommodates an 1800 mm
nominal diameter short Dall insert. In the s a o n d chamber there is a 1400 mm
butterfly valve, a removable section of pipe to allow a swab insert for cleaning
purposes, if necessary, and anaccess manway.The pipelineis anchored to the walls
of both chambers. Thereare no otherin-line valves. There are nine venting houses
(Fig. 1 I ) with 375 mm dia. orifice anti-vacuum valves and airvalves. There are also
eleven smaller chambers which accommodate only air valves. All the vent houses
and air valve chambers have random rubble masonry facings of local stone to
blend in withthe countryside.
25. Connection with the tunnelsystem was effectedthrough the tank andshaft
at Letch House (Fig 12) which was sizcd to ensure that large quantitiesof air do
not enter the tunnel during downsurge and that overspill does not occur during
upsurge?
26. To allow the pipeline to be drained in a reasonable time arrangements to
discharge into theRiver Tyne adjacentto the pumping station have been provided.
A 500 mm dia. drain from the main feeds two 300 mm dia. pipes in a concrete
chamber. In eachpipe. three orifice plates of increasing diameter dissipate energy
before dischargeis effectedin a submergeddischarge vertical stilling well.
Airy Holm dam

27. The Airy Holm damforms a headpond on thetunnel system to correct any
imbalance between the ratesof pumping and tunnel discharge. The storage in the
headpond also provides some protection against pump failure and could reduce
the need to pump during periods ofhigh electricity tariff.
28. The overflow crest level had to be higher than floodlevelin Denvent
Reservoir because of a possible connection between the Kielder tunnelsystem and
Fig. 11. Air venting house

188
KIELDER T R A N S F E R WORKS
that reservoir, so that flow from Derwent Reservoir could not discharge from the
headpond. There also had to be a relationship between maximum water level in
the Airy Holm headpond and the controlling level at Letch House tank. The
overflow crest at Airy Holm dam was, therefore, determined at 223 m, giving a
useful reservoir capacity below crest level of 250 OOO m3.
29. The dam’ closes the valley of the Shotleyfield Burn which has a catchment
area of 3.84 km’. The burn was, however, permanently diverted in 450 mm pipes
to bypass the reservoir to allow at least # times the average daily flow to continue
downstream.
30. At the dam site, drift deposits mainly of boulder clay but including some
sandand gravel deposits anda buried channel overlie the rocks of the
Carboniferous Durham Millstone Grit series. Rockhead was exposed in the bed of
the burn and drift cover was up to 8 m deep on the flanks. Argillaceous strata
comprising siltstones, mudstones, thin coals and associated seat-earths overlie the
moderately strong Airy Holm sandstone. Bedding is horizontal or sub-horizontal
dipping to the north-west. The axis of the dam runs from south-west to north-east.
31. Drawdown of the pond could be up to 6 m in 4 h; this circumstance,
together with the doubt as to the availability locally of suitable material for an
earth embankment, suggested a composite structure for the dam, with the central
180 m being of mass concrete gravity section 20 m high above the lowest general
foundation level, and earth embankments forming the flanks to give a dam 500 m
21 600 mm
-i
Fig. 12. Letch Housetank and shaft

189
Fig. 13. Airy Holm dam before resatvoir filling
long (Fig. 13). The a n t r a l U)m of the concretedam forms the ovcrRow which was
designed for 22.5 m3/s hut can accommodate a probable maximum flood of 37
m3/s. Fig. 14 illustrates the spillway section. The maximum inflow to the Airy
Holm pond from the tunnel system would he under 13 m’/s and it is extremely
unlikely that there will he pumping during a time of severe flood.
32. Inflowfrom and draw-off to the tunnel systemis by means of a shaft
connected to the reservoir floor, and a 600 mm d i a drain from this inlet/outlet
structure (Fig. 15) passes through the concrete dam to discharge into the stilling
basin. This allows removal of sediment which might otherwise enter the tunnel
system. A 600 mm dia. scour pipe also passes through the concretedam and each
of the pipelines is controlled by two 600 mm dia. gate valves located on the
downstream side of the dam. Shouldi t he necessary to drain the reservoir this can
he effected most readilyand very rapidly through the tunnel system.
33. Excavation for the foundationsof the concretedam c o m m e n d a tthe end
of April 1978 and a suitable foundation in the Airy Holm sandstone generally at
the predicted formationlevel was obtained, althoughat the south endof the dam,
pockets of dense but uncemented sandstone wererevealed. The upstream key
trench at that location was reduced in depth and the decomposed sandstonewas
sealed withconcrete to prevent weathering.
34. The concrete damwas constructed in blocks 15 m long with an interval of
at least 21 days between blocks. Two PVC water stops are included in all vertical
joints near to the upstream face and on the ovnflow sectionan additional water
190
225.1 m .
223 m ~ K r e c a s t concretewalkway
-
Scale of metres
n.7~ 0 5
L 1111'
m Pressure-relief
holes
\ Groutcurtain
7.5c
\
1
\
Fig. 14. Airy Holm dam overflow section
222.5
Ope
Tunnel from
-+ Derwent
Scale of metres
0 5 10
Fig. 15. Inlet/outlet and tunnel at Airy Holm
stop is provided near the sloping downstream face. A 150 mm X 50 mm X

100 mm deep recess makes a feature of the vertical joints on the sloping
downstream face, while on the vertical upstream face there are 50 mm chamfers at
the joints. Three fixed derricks were used to place the concrete and a placing rate
up to 1200 m3/week was achieved. Details of the concrete mixes used are given in
Table 1. The aggregate size for the hearting concrete was 100 mm initially but
191
COATS.BERRYANDBANKS
when this became difficult to obtain the mixwasredesignedwith a 75mm
maximum aggregate size. The PFA met sieving residual limits of 12.5% on 45 pm
and 2.5% on 150 pm, with a loss on ignition not exceeding 6.5%. Concrete was
placed in three 0.5 m layers to make 1.5 m lifts with an interval of 3 days between
lifts; the facing concrete, which was 1 m thick on the upstream face and 400 mm
thick on the sloping downstream face was placed without temporary separating
shutters. The coarse aggregate was Carboniferous limestone supplied from a
commercial quarry some 15 km distant and the fine aggregate was imported
natural sand. At horizontal construction joints a retarding agent was sprayed on
to the concrete after placing to enable the removal of surface laitance the following
day by air/water jetting.
35. Although water tanks were insulated, other methods for lowering the
temperatureof constituent materials were not economically possible, andthe
specified placing temperature of 12°C could not be achieved during the summer
months. With 120 simple thermocouples installed, the highest temperature rise of
26.5"C was recorded in the upstream facing concrete 0.2 m from the surface. The
ambient temperature during the pour was 20°C. In the same pour a temperature
rise of 23.5"C was recorded 0.5 m from the upstream surface. The lowest
temperature rise of 18°C in the facing concrete was recorded in concrete placed in
November 1978 whenthe ambient temperature was low.Some minor cracking did
occur and for a short time the PFA content was increased from 25% to 30%
cement replacement in an attempt to reduce temperature rise, but as no significant
reduction was recorded no general change was made to the mix.
36. Plasti-coated plywood formwork produced a satisfactory surface finish on
vertical faces but (as is not unusual) surface flaws caused by entrapped bubbles of
air or water were common on the sloping surfaces in spite of careful attention to
Table 1 . Concrete for Airy Holm dam
Hearting
I Facing
Dry batch quantities per m 3 :

Cement, kg 225
PFA, kg 75
Sand (zone 3 and 4), kg 555 600
100 mm aggregate, kg 765 -
75 mm aggregate, kg l005 -
40 mm aggregate, kg 340 800
20 mm aggregate, kg 220 215 300
10 mm aggregate, kg 275 285 300
Air-entraining agent, ml 360
Water/cement ratio 0.44
Test results:
28 day mean strength, MN/m2
Standard deviation, MN/m2
Mean air content, !h
Average density of 150 mm cores, kg/m3
192
vibration and mix design. By using a hardboard peg-board liner to the shutter
some improvement was achieved but this proved to be not only time-consuming
but costly and was not adopted generally. Flaws on the surface of the sloping
overflow were filled witha mortar containing asynthetic liquid rubber with better
curing properties than conventional cement mortar, but elsewhere no corrective
treatment was applied as the flaws were not considered to present a long term
durability problem.
37. Eightpneumatic disc piezometerswere installed at the concrete/rock
interface at two sections of the concrete dam to allow comparison with design
uplift assumptions which were a straight line distribution from full water head at
the upstreamface to tail waterhead at the downstream toe. Mildsteelmesh
reinforcement is included in the top 4 m of the overflow section to accommodate
ice loading.
38. Thetops of the non-overflowsections incorporatingthe walkway and
parapet walls are of precast concrete units 1.5 m long and were accurately set by a
simple levelling device cast into each unit and dowelled into the concrete of the
dam. Only thefloor sections of the 20 mm gap between precast units were filled.
39. The embankment flanks to the dam have a maximum height of 7 m above
general foundation level and Fig. 16 shows a typical cross-section. Steps between
the parapet walls of the concrete dam link the footpath on the embankmentcrest
to the walkway of the concrete dam. The clay fill was obtained from a borrow pit
upstream of and adjacent to the north side of the dam. A clay fraction of 21%,
moisture content of 13%, plasticity index of 18% and undrained shear strength of
155 kN/m2 were the average parameters obtained from tests on the fill. It was
assumed conservatively that 4' was 30". The clay was placed in 225 mm thick
layers and compacted by vibratory rollers producing average air voids of 4.5% as
measured by the sandreplacement method.
Tunnel route
40. The abrupt changein the direction of flow on the River Tees at Eggleston
(Fig. 1) determined the discharge point and level for the tunnel. The target route
for the transfer works passes through Derwent Reservoir and it was originally
thought that not only could the overall yield of the scheme have been augmented
by using that reservoir but also it could formpart of the transfer works with tunnel
portals at the north and south banks.However,because of the possibility of
eutrophication, an alternative headpond location was sought and finally located at
Footpath m
Granular 11 er
Scale of metres
5
-O
Fig. 16. Airy Holm dam embankmentsection

193
COATS, B E R R Y AND BANKS
Airy Holm. The location of this headpond influenced the starting point for the
tunnel system at Letch House. It was at first intended that tunnelling from Letch
House would start at anormalportal and would discharge into Airy Holm
headpond, with normal draw-off facilities incorporated in the dam linking to a
tunnel driven to the Derwent valley. However, there were open-cast coal
operations at Letch House and decomposed sandstone in the Airy Holm area. To
avoid these features, it was economical to drop the tunnel invert level at Letch
House to give adequate rock cover, to tunnel underneath the Airy Holm pond in
sound rock below the decomposed sandstone andto link the tunnel to the
headpond by a simple inlet/outlet shaft (Fig. 15).
41. The tunnel portal site at north Derwent had considerable cover to rock,
and a short length of tunnel using soft ground techniques was necessary before
reaching a rock portal. A 2.89 m dia. buried pipeline links the north Derwent and
south Derwent portals. The direct route from the south Derwent portal to the
crossing of the River Wear valley would have passed under Waskerley Reservoir,
designed by Thomas Hawksley,* and the line was moved slightly to theeast where
an air shaft of 765 mm lined diameter and 135 m deep could be sunk to tunnel
level. In order to allow the tunnel to be driven from both the Derwent and the
Wear valleys on a rising grade an air shaft was necessary but for hydraulic reasons
only a very flat gradient of about 1 in 1000 was possible. The tunnel portals at the
Wear and Tees valleys are conventional rock portals with the tunnel line being a
straight line between them. Again for hydraulic reasons the tunnel gradients had to
be about 1 in l o o 0 and an air shaft was required at Sharnberry. The Ordnance
Survey established co-ordinated reference pedestals near each portal of the longer
tunnels from Derwent to Tees from which the tunnels were driven to line and level.
Experimental tunnel
42. It was considered in 1970, at a very early stage of development of the
scheme, that, with over 30 km of rock tunnelling envisaged, a specially constructed
experimental tunnel with trials in the three main rock types likely to be met in the
main tunnels would be justified in addition to normal site investigations. The
Northumbrian Water Authority, the Building Research Establishment and the
Water Research Centre collaborated in carrying out the experimental work and in
financing it.
43. An inclined adit was driven from the floor of a disused quarry near to the
odrd
line the main tunnel and horizontal tunnels were driven at three levels off it. Not
only this experimental tunnel allow useful research to be c a r r i e d o ~ t ~ -but
provided contractors tendering for the main tunnelling contracts with the
~ ' it
opportunity of viewing fulltunnel faces inmudstone, limestone and sandstone, and

also of observing the effectiveness of different methods of temporary support
during the actualdriving in mudstone.
Site investigations
44. Before the start of a detailed site investigation a desk study was carried out
by the Institute of Geological Scienceswhenall relevant published data,
information from local mining activities and open-cast coal operations etc. were
examined. These indicated that the proposed line and level of the tunnels would
encounter rock suitable for tunnelling, with the Letch House to Derwent section
passing through the Lower Coal Measures and the Durham Millstone Grit with
sandstone
the predominant rock, and the Derwent-Wear-Tees tunnels
194
KlELDER T R A N S F E R WORKS
l
0 5 10 15 20 25 30
Kllornetres
(4
Limestone
Sandstone
Mudstone
Mlxed beds
Dolerlte
Fault zone
1978
1980
1981
1982
(C)
Fig. 17. (a) Longitudinal section of tunnel works; (b) geology encountered in tunnel;
(c) time-way of driving and lining
encountering rock of the Middle and Upper Limestone group comprising

sandstones, siltstones, mudstones, shales and limestones. Two dolerite dykes were
to be expected on the Wear to Tees tunnel.
45. The main site investigations comprised 30 deep boreholes on or about the
proposed tunnel line, 18 cored portal boreholes, and a large number of shallow
rotary and shell and auger boreholes at alternative portal sites and to investigate
valley crossings. When the results of these investigations and associated laboratory
testing (including Schmidt hammer testing on cores”) became available separate
reports covering the geology and the engineering geology were prepared and these
wereissued to tendering tunnelling contractors 2 months beforeissue of the
contract documents. The site investigation and geology are discussed in more
detail by Carter and Mills.22
46. A comparison of predicted and actual geology encountered in the
tunnelsz3 was made after completion of all tunnel driving and although there were
some discrepancies due to the less than ideal borehole positioning and a limit on
the number of boreholes for cost reasons, the rock encountered was much as
forecast. In addition to the main site investigation, 14 inclined boreholes had been
sunk on the Letch House to Derwent routez4 tobetter assess discontinuities, but
these failed to determine the extent of open and clay-filled fissures.On this section
195
also, the extent of weathering was underestimated fromthe borehole information
and some unexpected faulting was encountered. On the Wear to Tea tunnel an
unexpected upward transgressionof dolerite from the Little Whin Sill resultedin a
361 m length of tunnel being excavated in extremely hard dolerite, which caused
some difliculties with tunnel driving. The geology actually encountered during
driving is indicated in Fig. 17.
Fig. 18. Drill-and-blast sectionof tunnel
Protective Working Underslung

shield platform CO""ey0'
Operator's
Fresh
Services air Muhlhauser
54002400
43 000 mm
Fig, 19. Demag N M 34-38tunnellingmachine

196
K I E L D E R TRANSFER WORKS
Gripper
Rock-drilling
unit
eauimenl
11.50 m 12.15 m I 8.00m I

Fig. 20. Robbins123-133 tunnelling machine
Fig. 21. Full-face machine-driven tunnel
19000 mm
I
Fig. 22. Enlargementatairshahs
197-
COATS,BERRY A N D B A N K S
W W W W rg
I W W W W W
m
l wl
h(
a z
3
m
0
ri
a
ri
PI
CI
8
W
S
ri
W
S
m
r-
A-
i
* 0 0 0
B$ E 2 2 2 ;0
+
+
S
S
S m
0
v) +
0
198
K I E L D E R TRANSFER W O R K S
Tunnel driving
47.. The 6 m dia. by 22 m deep shaft at Letch House was sunk mainly through
competent, moderately jointed sandstone and a pre-splitting technique was used.
From Letch House to Derwent the tunnel lieslargelyin sandstone and the
contractor elected to drive by drill and blast methods to a D shaped profile before
lining to a circular profile.25The main driving equipment consisted of a Tamrock
twin-boom rail-mounted compressed air drilling jumboandan electrically
powered Hagloader together with Hagglund cars. Owing to the risk of
encountering methane from the old mine workings above the tunnel level it had
been specified that all equipment would be flame-proofed and this included the 5 t
and 10 t Clayton locomotives used for tunnel haulage. The main driving was
undertaken by the above equipment but two subsidiary drives from the shaft at
Airy Holm and a short section of the drive from north Derwent was undertaken
using conventional air legs and an Eimco loader together with small mine cars.
Progress on the highly mechanized drive averaged just under 38 m/week and on
the Eimco drives averaged 23/m week.
48. Although the general rock types encountered in the Letch House to
Derwent tunnel were very much as forecast, the degree of weathering of the rock
significantly slowed down progress, causing a large number of misfires, the need to
use relatively short pulls and continual problems with slurry in the tunnel invert.
Support where required was almost entirely colliery arches and the contractor’s
ambitious plan at the time of tender to use rock-bolting extensivelynever
materialized. However,just over 50% of the tunnel required no support at all. Fig.
18 shows a typical view of the tunnel before lining.
49. For the long tunnels between Derwent and Tees, contracts were advertised
in Europe aswell as in the UK and tenders were invited from consortia which were
required to include at least one UK firm. In preparing their tenders, tenderers were
entitled to take into account all the geological and site investigation information
provided, and excavation for tunnels wasbilled by the lineal meter with the
contractor required to cover all temporary or primary support inhis rate for
excavation. The lowest tender was submitted by a consortium of two German
firms and one UK firm and they proposed a rock classification system based on
temporary supportcriteria which isnot uncommon on the Continent.
50. Following discussion with them, a classification system26was agreed based
essentially on the type of rock encountered in the roof of the tunnel and not on the
actual support installed. The six classifications agreed can be approximately
summarized as follows :
Class 1 Good quality sandstone or limestone
Class 2 Poor quality sandstone or limestone; very good quality mudstone
or shale
Class 3 Good quality mudstone or mixed beds
Class 4 Poor quality mudstone or mixed beds; fault boundary conditions
Class 5 Fault conditions
Class 6 Rock conditions in which excavation by full-face machine was not
possible.
(Class 6 was subsequently deleted from the contract as it was agreed by both the
Contractor and the Engineer that all the forecast rock conditions could be dealt
with by the tunnelling machines and hence rock which could not be excavated by
machine would be a circumstance covered by clause 12 of the ICE conditions of
199
COATS. BERRY AND BANKS
- N m
S v ?
ov,
W
N
200
contract.) The bill rates for excavation would be adjusted by pre-agreed amounts
depending on rock classification.The system is described more fully el~ewhere~~.~*
and although it operated satisfactorily on this contract it is appreciated that its
success was largelydue to awillingness by both Engineer and Contractor tomake
the system work.
51. Thecontractor elected to use full-face
tunnelling machine^.^'*^^-^^
Initially it was intended to use two DemagTBM 34-38 full-face machines (Fig. 19)
but owing to the slower than anticipated progress with the Demag machines the
contractor brought in a Robbins 123-133 tunnelling machine (Fig. 20) and this
was eventually usedon two of the four drives. The average rate of progress on the
drivesfromthe Wear. valleyusingthe Demag machineswas just under
200 m/month whereas on the 8 km long Tees drivethe Robbins machine averaged
over
300 m/month. Even more striking, however, is the rate of nearly
600 m/month attained on the short 3 km section of the Derwent to Waskerley
drive driven bythe Robbins machine whenthe contractorused a three-shift system
instead of the two-shift system operated on the rest of the contract. An excellent
excavated profile was generally obtained with full-face tunnelling machines (Fig.
21).
52. The use of shotcrete was discussed extensively with the contractor before
the tunnel driving started, particularly in the light of the very successful trials with
shotcrete in the experimental tunnel. However,in practice shotcrete was used only
to a very limited extent and the main support system used in about 80% of the
tunnel was rock bolts and mesh. Steel arches were used extensively in the portal
area and combined with Bernold sheets were used in faults and other difficult rock
conditions. Rather surprisingly, less than 10% of the tunnel was driven without
any supportin comparison with over 50% unsupported in the drill and blast Letch
House to Derwent tunnel. The primary reason for this is of course the need to
supportthe shouldersin a circulardriventunnelwhereasinsimilarrock
conditions in a tunnel driven bydrill and blast the shoulder blocks fallout, leaving
the typical square profile.However, theinstallation of rockboltswashighly
mechanized and had little effect on progress.
53. The machinescopedwithvaryingdegrees of successwithdifficultrock
~ o n d i t i o n s . ~ The
~ , ~Demag
~ . ~ ~was
, ~ particularly
~ susceptible to roof problems
owing to the difficulty of installing early support, whereas the Robbins, with its
provision for installing bolts or steel arches a few metres from the machine head,
was able to copevery successfully withall the rock conditions encountered.
54. In order to provide capacity for air during surge conditions, enlargements
(Fig. 22) wereconstructed at the air shafts at both Waskerley and Sharnberry. The
air shafts had been excavated to 900 mm dia. by a Wirth LA drilling rig equipped
for both conventional and reverse circulation drilling and were lined to 750 mm
dia. by steel casing, with the annular space grouted from the bottom before tunnel
driving reached them.
55. The lengths of tunnels driven and lined from each portal are given in Table
2. The steel lining was at theportals.
Tunnel lining
56. The lining of the Letch House to Derwent tunnel and the Derwent to Tees
tunnel is described in detail by FawcettZ5 andMa~terton.~" The lining of tunnels
wasdesigned as a nominal200mmthickness of 30 MN/m2 concretewith a
circular profile (Fig. 23), and in all sections thecontractors elected to line
201
Precast concrete ~n'situconcrete

sub-Invert subinvert
Fig. 23. Tunnellining: (a) full-facetunnellingmachine section; (b) drill-and-blast

section
continuously, the concrete being placed using Schwing concrete pumps through a
150 mm dia. steel placer pipe. The telescopic shutters used were 60 m long in the
drill-and-blast-driven Letch House to Derwent tunnel and 54 m long in the largely
machine-driven Derwent to Tees tunnels. The specified minimum striking time for
theshutters was 12 h but on the machine-driven tunnels it was on occasion
reduced to 10 h. However, care had to be taken to avoid damage to the concrete
surface if shutters were struck too early. Table 3 shows how sensitive the volume of
concrete required for tunnel lining is to changes in the effective driven diameter
and shape of the tunnel. The increased volume of concrete required in a drill and
blast tunnel is quite significant when a comparison of costs is being made between
driving by full-face machine and driving by drill and blast. As could reasonably
have been expected, the grout take inthe drill and blast tunnel is also substantially
greater than in the machine-driven tunnel.
57. The time interval between tunnel driving and the lining varied as shown in
Fig. 17. Before lining, the rock profile either was self-supporting or appeared to
have been stabilized by temporary supports. However, in machine-driven sections
of the tunnel instrumentation was installed in the concrete lining at four locations
to try to assess rock loading on the permanent lining. Three of these locations were
at fault zones; the fourth was in a self-supporting limestone. observation^^'.^^
showed that some rock loading of the concrete lining had takenplace inthe faulted
zones but very little, if any, short term loading of the lining had taken place at the
unsupported section of tunnel. The measurements also show that grouting
operations have a significant loading effect on the tunnel lining where large voids
have beenfilled andgrouting also has the desirable effectof inducing a
compressive stress into the lining, thus reducing any tensile strains that may have
developed.
58. As is not uncommon in cast-in-situ concrete tunnel linings, circumferential
cracks developed. A detailed survey was carried out in three lengths of the tunnels,
each about l o o 0 m long. The first length was in a section excavated by drill and
blast methods where the average crack spacing was about 10 m and all cracks
went round the complete circumference of the tunnel. The other two sections
surveyed were both in machine-excavated lengths of tunnel and cracking was
observed to be less, although the pattern of cracking in these two sections was
202
KIELDER TRANSFER W O R K S
Fig. 24. Tees outlet
dissimilar. No clear conclusions cquld be reached other than that cracking is more
likely the greater the lining thickness.
Valley crossings
59. The aqueduct crosses the Derwent and Wear valleysin2.89 m nominal
diameter buried steel pipelines whichgenerally have concrete surrounds because of
the risk of flotation in the river valley sections. The steel pipe is taken into the
tunnel until the rock cover is adequate to resist the full water head. The final
section of the aqueduct at Tees is also 2.89 m dia. steel pipe. The steel pipes,
including the sections in the tunnels, were lined throughout with 12.5 mm thick
cement mortar.
Discharge works
60.An unusual feature of the Kielder transfer works is the total absence of
in-line valving, allcontrol being effected by the discharge valve at the rivers Wear
and Tees. The general arrangement of the Tees works is shown in Fig. 24 and the
works at Wear are similar. The submerged discharge valves allow both the control
of the flow and the dissipation of head through the valve and into a reinforced
concrete sump which is protected by a double coating of reinforced glass fibre.The
valves are ported to give linear discharge characteristics over their entire range of
operation and the electrical operation is arranged to ensure that the operating
time (15 min in the case of the Tees discharge works) is long enough to minimize
surge problems.
61. For security and aesthetic reasons the size of the structures was kept to a
minimum, and apart from the discharge channel the only above-ground works are
the small reinforced concrete buildings required to accommodate the telemetry.
The magnetic flowmeters and the protecting upstream butterfly valves are
accommodated in separate underground chambers.
62. In order to deal with the discharge of very small flows of water which may
be required in order to keep water in the tunnel from becoming deoxygenated,
203
C O A T S , BERRY AND BANKS
provision has also been made for 300 mm dia. in-line flow control valves capable
of discharging up to23 000 m3/d into thetunnel drain system.
Acknowledgements
63. The Authors thank MrW. F. Ridley, Chief Executiveof the Northumbrian
Water Authority for permission to publish this Paper. They also wish to thank
officers and staff of the authority and members of staff of BabtieShaw and
Morton, who havebeen most helpful in providing information and in other ways
assisting in the preparationof the Paper.
Appendix 1. Principal contractors

Riding Mill weir John Mowlem and Company Ltd
Riding Mill pumping station John Laing Construction Ltd
Pumping main Norwest Holst Civil Engineering Ltd
Byard Kenwest Engineering Ltd (pipe
manufacturer)
Airy Holm dam Gleeson Civil Engineering Ltd
Letch House to Derwent works Fairclough Civil Engineering Ltd, Tunnelling
Division
Derwent to Tees works Tyne Tees Tunnelling (a partnership of
C . Baresal AG, Stuttgart, Ed Zublin AG,
Stuttgart and A. Monk & Co. Ltd,
Warrington)
Appendix 2. Key data

Riding Mill weir
Average daily flow in River Tyne 3.6 X 106 m3/d
Lowest sill level at weir 16.85 m
Weir length 80 m
Measuring weir length 17 m
Range of tilting gates on 2.05 m (1.4 m initially)
measuring weir
Riding Mill pumping station

Sill level of draw-off 15.85 m
Station dimensions Length 95 m, width 32 m
Static pumping head 206 m
Number of pumps Six initially, twelve eventually
Pump type and capacity Four-stage vertical-spindle mixed-flow
pumps with a duty point capacity of
91 000 m3/d at 217 m pumping head
Pump motors Initially four slip-ring induction and two
synchronous induction; rated power
demand 3000 kW each
Incoming power supply Twin 66 kV reduced to 11 kV for the pumps
Total weight of each pump and 35 000 kg
motor
Surge vessels Two (initially), each 11 m long and
3500 mm i.d.
204
Pumping main
Length 6200 m
Pipe ,diameter 2.020 m o.d., spirally welded
Grade of steel 50B and 43A to BS 4360
Wall thickness 14 mm to 10 mm
Internal protection 1 1 mm thick minimum Cement mortar lining
External protection 6 mm minimum bituminous compound to
BS 4147 type 2, grade A, reinforced
with glass tissue and glass cloth;
joint protection by cold-applied tape
Cathodic protection Impressed current system
Valve control No in-line valves but 375 mm orifice dia.
anti-vacuum valves at all major summits
and Apex air valves and drain valves
elsewhere
Letch House tank

Invert level of incoming pumping 22230 m
main
Weir crest level 223.00 m
Level of suspended walkway 222.65 m
Tank dimensions Length 21.6 m, width 7.6 m, height
(tank base to underside of roof) 6.7 m
Letch House to Airy Holm tunnel

Length 2020 m
Invert level at Letch House shaft 200.13 m
Invert level at Airy Holm shaft 202.29 m
Airy Holm to Derwent tunnel

Length of tunnel 2486 m
Invert level at north Derwent 199.15 m
portal
Derwent oalley crossing

Length of pipeline 749 m
Invert level of drain at river 176.40 m
undercrossing
River bed level 180.90 m
Derwent to Wear tunnel

Length 13 374 m
Invert level at south Derwent 185.12 m
portal
Invert level at Waskerley shaft 195.38 m
Level at top of Waskerley shaft 333.26 m
Invert level at north Wear portal 182.98 m
Wear oalley crossing

Invert level at river undercrossing 176.60 m
River bed level 18010 m
205
Wear to Tees tunnel

Length 14 398 m
Invert level at south Wear portal 178.00 m
Invert level at Sharnberry shaft 183.27 m
Level at top of Sharnberry shaft 398.18 m
Invert level at Tees portal 176.60 m
Tees valley pipeline

Invert level at drain outlet 176.50 m
Wear discharge works

Weir level at outlet to valve sumps 18040 m
Invert level of valve sumps 176.20 m
Valves Two 500/450 mm dia. submerged discharge
valves, each guarded by a 500 mm dia.
butterfly valve
Discharge capacity Initial 120000 m3/d,
ultimate 170000 m3/d
Tees discharge works

Weir level at outlet to valve sumps 177.75 m
Invert level of valve sumps 170.95 m
Valves Two 1200/1100 mm dia. submerged discharge
valves, each guarded by a 1200 mm dia.
butterfly valve
Discharge capacity Initial 0.860 X 10” m3/d,
ultimate 1.370 X 10“ m3/d
Airy Holm reservoir

Catchment area 392 ha
Average annual rainfall 750 mm
Average stream flow 3000 m3/d
Usable reservoir storage 250000 m’
Surface area of reservoir 8.5 ha
Overflow crest level 223.00 m
Normal maximum operating level 222.50 m
Drawdown level 2 1640 m
Invert level of scour 210.10 m
Capacity of drain from inlet/outlet 485 000m’id
structure and reservoir scour,
with water at overflow level
Airy Holm concrete graoity dam

Length 180 m
Height above ground level 13 m
Maximum height from general 20 m
foundation to top of dam
Depth of cut-off below general 0.5 m
foundation
Volume of concrete 22 m’
Length of overflow weir 20 m
Overflow design flood 1.944 X 106 m3/d
206
KIELDER TRANSFER W O R K S
Airy Holmearth embankment damflanks

Length of north flank 150 m
Length of south flank 130 m
Maximum height from general 7m
foundation to top of dam
Total volume
fill of 33000 m’
References
1. COATSD. J. and RUFFLEN. The Kielder water scheme. Proc. Instn Civ. Engrs, Part 1,
1982,12, May, 135-147.
2. HYDRAULICS RESEARCH STATION.Water abstraction station and control weir on the River
Tyne at Riding Mill. HRS. Wallingford, 1975,report EX 702.
3. Interaction of trench materials with a buried steel pipeline containing a single mitre
bend and remote anchorages. ConstructionIndustry Research and Information
Association, London, currentresearch project 286.
4. ELLISJ. et al. Surge protection of the Kielder water scheme transfer works. Proc. Instn
Ciu. Engrs, Part 1, 1978.64, May, 227-246.
5. BANKS D.J. et al. Riding Mill pumping station. J. Instn Wat. Engrs Sci., 1981,35, Nov.,
No.6,463482.
6. Semi-sphericaljoints for large diameter steel pipes. Pipes Pipelines, 1978, Nov., 763-766.
7. PERFECT H. G. Airv Holm dam-Kielder water scheme. Wat. Serv.. 1981. AuP.. 389-392.
8 BINNIEG. M. Eahy Victorian water engineers, Thomas Telford Ltd,’ Loidon, 1981,
149-153.
9 PRIEST S . D. and HUDSONJ. A. Rock quality in the Kielder experimental tunnel. Co.
Durham. Transport and Road Research Laboratory, Crowthorne, 1975,
supplementary report 173 UC.
10. WARD W. H. et al. Performance of tunnelsupport systems in the FourFathom
Mudstone. Tunnelling 76. Institution of Mining and Metallurgy, London, 329-340.
(Also Building Research Establishment current paperCP 25/76.)
11. HILLSD.L. Sprayed concrete-site trials. Building Research Establishment, Garston,
1976 (unpublished note).
12. HILLSD.L. Sprayed concrete-interim report No. 2. Building Research Establishment,
Garston, 1976(unpublished note).
13. HILLSD. L. Sprayed concrete-interim report No. I . Building Research Establishment,
Garston, 1975(unpublished note).
14. WARDW. H. and HILLSD. L. Sprayed concrete: tunnel support requirements and the
dry mix process. Shotcrete for ground support: proc. engineeringfoundation conference,
American Society of Civil Engineers and American Concrete Institute, 1977. ASCE, New
York, publication SP-54, 475-532. (Also Building Research Establishment current
paper CP18/77.)
15. WARDW. H. and HILLSD.L. Kielder trial tunnel: sprayed concrete extension. Building
Research Establishment, Garston, 1978, current paper CP73/78.
16. LONGWORTH T. I. and TWD P.Logging of joints in Carboniferous rocks in the Kielder
experimental tunnel. Building Research Establishment, Garston, 1978 (unpublished
note).
17. FREEMAN T. J. The behaviour offully-bonded rock bolts in the Kielder experimental tunnel.
Building Research Establishment, Garston, 1978,current paperCP64/78.
18. WARDW. H. Ground supports for tunnels in weak rocks. Giotechnique, 1978,28, No. 2,
133-171.
19. TEDD P. The BRE rock extensometer. Building Research Establishment, Garston, 1979
(unpublished note).
20. WARDW. H. et al. (Building Research Establishment and Bablie Shaw & Morton).
Kielder experimental tunnel: results of five years’ work. (In preparation.)
207
21. CARTERP. G.andSNEDWN M. Comparison of Schmidt hammer, pointload and

unconfined compression tests in Carboniferous strata. Proc. Conf. Rock Engineering
( C O R E U K )Newcastle-upon-Tyne,
, 1977, 197-210. (British Geotechnical Society; and
Department of Mining Engineering, University of Newcastle-upon-Tyne.)
22. CARTERP. G. and MILLSD. A. C. Engineering geological investigations for the Kielder
tunnels. Q.J . Engng Geol. 1976,9, No. 2,12>141.
23. DAVIES T. P. et al. Kielder aqueducttunnels-predicted and actual geology. Transport and
Road Research Laboratory, Crowthorne, 1981, report SR 676.
24. COATSD. J. et al. Inclined drilling for the Kielder tunnels. Q.J . Engng Geol., 1977, 10,
195-205.
25. FAWCETT D. F. Tunnelling at Kielder with particular reference to drill and blast driving
and in-situ lining operations. Eurotunnel '80, Easel. 2980. Institution of Mining and
Metallurgy, London, 1980, 46-53.
26. CONSTRUCTION
INDUSTRY RESEARCH AND INFORMATION ASSOCIATION.
Tunnelling-improved contract practices. CIRIA, London, 1978, report 79, 62.
27. BERRYN. S. M. and FINKE. 28 km of rock tunnel for Kielder water scheme. Proc.
Tunnelling '79. Institution of Mining and Metallurgy, London, Paper 17.
28. BERRYN. S. M. Contribution to meeting on ground classification. Tunnels Tunnelling,
1980,12, NO. 6, 59-62.
29. BERRYN. S. M. and BROWN J. G. W. Performance of full facers on Kielder tunnels.
Tunnels Tunnelling, 1977, July, 35-39.
30. BROWNJ. G. W. and M I L ~ W K. Driving with fullfacers. The Kielder tunnels-NE
England. Eurotunnel '78, Paper 3.
31. BERRYN. S. M. Tunnelling machines cope with varied rock conditions at Kielder. War.
Serv.. 1978, June, 353-356.
32. BERRYN. S. M. Tunnelling by full-face machines in carboniferous strata. Proc. Instn
Mining Metall., 1980, July, A144-157.
33. O'ROURKET. D. et al. Some observations on machine tunnelling at the Kielder aqueduct.
Transport and Road Research Laboratory, Crowthorne, 1979, supplementary report
532.
34. MORGAN J. M. et al. Tunnel boring machine performance and ground properties: report on
theinitial 1) km of the North Wear Drive,KielderAqueduct. Transport and Road
Research Laboratory, Crowthorne, 1979, supplementary report 469.
35. NICHOLSON K. Coping with difficult ground on the full face mechanised tunnel drives at
Kielder. Tunnels Tunnelling, 1979, June, 55-57.
36. MASTERTON G. G. T. Concrete lining of the Kielder tunnels. Tunnels Tunnelling, 1981,
13, NOV.,NO.21-25.
37. TEDD P. and MASTERTON G. G. T. Behaviour of the concrete tunnel lining at Kielder.
Building Research Establishment, Garston, 1981, internal note.
38. TEDD P. Instrumentation of theKielderconcrete tunnel lining. Building Research
Establishment, Garston, 1980 (unpublished note).
208

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Proc. lnstn Ciu.

Engrs, Part 1, 1982,72, May, 177-208

D. J. COATS, BSc, FICE*

Fig. 2. Riding Mill pumping station and weir

Fig. 3. Plan of Riding Mill weir

River abstraction works

Riding Mill weir

Riding Mill pumping station

Fig. 8. Pump hall of Riding Mill pumping station

17. The pumping station is founded on interlayered sequences of sand, gravel

Fig. 9. Pumping main cross-section

6 mm thick bltuminous Cement mortar l m n g

Fig. 10. Steel pipeline joint

Airy Holm dam

Fig. 11. Air venting house

Fig. 12. Letch Housetank and shaft

Fig. 13. Airy Holm dam before resatvoir filling

Fig. 15. Inlet/outlet and tunnel at Airy Holm

stop is provided near the sloping downstream face. A 150 mm X 50 mm X

Table 1 . Concrete for Airy Holm dam

Dry batch quantities per m 3 :

Fig. 16. Airy Holm dam embankmentsection

opportunity of viewing fulltunnel faces inmudstone, limestone and sandstone, and

encountering rock of the Middle and Upper Limestone group comprising

Fig. 18. Drill-and-blast sectionof tunnel

Protective Working Underslung

Fig, 19. Demag N M 34-38tunnellingmachine

11.50 m 12.15 m I 8.00m I

Fig. 21. Full-face machine-driven tunnel

Fig. 22. Enlargementatairshahs

Precast concrete ~n'situconcrete

Fig. 23. Tunnellining: (a) full-facetunnellingmachine section; (b) drill-and-blast

Fig. 24. Tees outlet

Appendix 1. Principal contractors

Appendix 2. Key data

Riding Mill pumping station

Letch House tank

Letch House to Airy Holm tunnel

Airy Holm to Derwent tunnel

Derwent oalley crossing

Derwent to Wear tunnel

Wear oalley crossing

Wear to Tees tunnel

Tees valley pipeline

Wear discharge works

Tees discharge works

Airy Holm reservoir

Airy Holm concrete graoity dam

Airy Holmearth embankment damflanks

21. CARTERP. G.andSNEDWN M. Comparison of Schmidt hammer, pointload and

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