Tunnels Driven Eastward from Manhattan.
Materials and Inception of Work.—The materials encountered are shown in the profile on Plate XIII, and were similar in all the tunnels. In general, they were found to be about as indicated in the preliminary borings. The materials met in Tunnel A may be taken as typical of all.
From the Manhattan shaft eastward, in succession, there were 123 ft. of all-rock section, 87 ft. of part earth and part rock, 723 ft. of all earth, 515 ft. of part rock and part earth, 291 ft. of all rock, and 56 ft. of part rock and part earth.
The rock on the Manhattan side was Hudson schist, while that in the reef was Fordham gneiss. Here, as elsewhere, they resembled each other closely; the gneiss was slightly the harder, but both were badly seamed and fissured. Wherever it was encountered in this work, the rock surface was covered by a deposit of boulders, gravel, and sand, varying in thickness from 4 to 10 ft. and averaging about 6 ft.
The slope of the surface of the ledge on the Manhattan side averaged about 1 vertical to 4 horizontal. The rock near the surface was full of disintegrated seams, and was badly broken up. It was irregularly stratified, and dipped toward the west at an angle of about 60 degrees. Large pieces frequently broke from the face and slid into the shield, often exposing the sand. The rock surface was very irregular, and was covered with boulders and detached masses of rock embedded in coarse sand and gravel. The sand and gravel allowed the air to escape freely. By the time the shields had entirely cleared the rock, the material in the face had changed to a fine sand, stratified every few inches by very thin layers of chocolate-colored clayey material. This is the material elsewhere referred to as quicksand. As the shield advanced eastward, the number and thickness of the layers of clay increased until the clay formed at least 20% of the entire mass, and many of the layers were 2 in. thick.
At a distance of about 440 ft. beyond the Manhattan ledge, the material at the bottom of the face changed suddenly to one in which the layers of clay composed probably 98% of the whole. The sand layers were not more than 1/16 in. thick and averaged about 2 in. apart. The surface of the clay rose gradually for a distance of 40 ft. in Tunnels A and B, and 100 ft. in Tunnels C and D, when gravel and boulders appeared at the bottom of the shield. At that time the clay composed about one-half of the face.
The surfaces of both the clay and gravel were irregular, but they rose gradually. After rock was encountered, the formations of gravel and clay were roughly parallel to the rock surface.
As the surface of the rock rose they disappeared in order and were again encountered when the shields broke out of rock on the east side of the Blackwell's Island Reef. East of the reef a large quantity of coarse open sand was present in the gravel formations before the clay appeared below the top of the cutting edge. In Tunnels C and D this was especially difficult to handle. It appears to be a reasonable assumption that the layer of clay was continuous across the reef. Wherever the clay extended above the top of the shield it reduced the escape of air materially. It is doubtless largely due to this circumstance that the part-rock sections in the reef were not the most difficult portions of the work.
While sinking the lower portions of the shafts the tunnels were excavated eastward in the solid rock for a distance of about 60 ft., where the rock at the top was found to be somewhat disintegrated. This was as far as it was considered prudent to go with the full-sized section without air pressure. At about the same time top headings were excavated westward from the shafts for a distance of 100 ft., and the headings were enlarged to full size for 50 ft. The object was to avoid damage to the shaft and interference with the river tunnel when work was started by the contractor for the cross-town tunnel.
The shields were erected on timber cradles in the shaft, and were shoved forward to the face of the excavation. Concrete bulkheads, with the necessary air-locks, were then built across the tunnels behind the shields. The shields were erected before the dividing walls between the two contracts were placed. Rings of iron tunnel lining, backed by timbers spanning the openings on the west side, were erected temporarily across the shafts in order to afford a bearing for the shield jacks while shoving into the portals. The movement of the shield eastward was continued in each tunnel for a distance of about 60 ft., and the permanent cast-iron tunnel lining was erected as the shield advanced. Before breaking out of rock, it was necessary to have air pressure in the tunnels. This required the building of bulkheads with air-locks inside the cast-iron linings just east of the portals. Before erecting the bulkheads it was necessary to close the annular space between the iron tunnel lining and the rock. The space at the portal was filled with a concrete wall. After about twenty permanent rings had been erected in each tunnel, two rings were pulled apart at the tail of the shield and a second masonry wall or dam was built. The space between the two dams was then filled with grout. To avoid the possibility of pushing the iron backward after the air pressure was on, rings of segmental plates, 5/8 in. thick and 13-7/8 in. wide, were inserted in eighteen circumferential joints in each tunnel between the rings as they were erected. The plates contained slotted holes to match those in the segments. After the rings left the shield, the plates were driven outward, and projected about 5 in. When the tunnel was grouted, the plates were embedded.
The bulkheads were completed, and the tunnels were put under air pressure on the following dates:
Line D, on October 5th, 1905;
Line C, on November 6th, 1905;
Line B, on November 25th, 1905;
Line A, on December 1st, 1905.
This marked the end of the preparatory period.
In the deepest part of the river, near the pier-head line on the Manhattan side, there was only 8 ft. of natural cover over the tops of the tunnels. This cover consisted of the fine sand previously described, and it was certain that the air would escape freely from the tunnels through it. To give a greater depth of cover and to check the loss of air, the contractor prepared to cover the lines of the tunnels with blankets of clay, which, however, had been provided for in the specifications. Permits, as described later, were obtained at different times from the Secretary of War, for dumping clay in varying thicknesses over the line of work. The dumping for the blanket allowed under the first permit was completed in February, 1906. The thickness of this blanket varied considerably, but averaged 10 or 12 ft. on the Manhattan side. The original blanket was of material advantage, but the depth of clay was insufficient to stop the loss of air.
The essential parts of the shields in the four tunnels were exactly alike. Those in Tunnels B and D, however, were originally fitted with sectional sliding hoods and sliding extensions to the floors of the working chambers, as shown by [Fig. 1, Plate LXV]. The shields in Tunnels A and C were originally fitted with fixed hoods and fixed extensions to the floors, as shown in [Fig. 2, Plate LXV]. A full description of the shields will be found in Mr. Japp's paper.
The shields in each pair of tunnels were advanced through the solid rock section about abreast of each other, until test holes from the faces indicated soft ground within a few feet. As the distance between the sides of the two tunnels was only 14 ft., it was thought best to let Tunnels B and D gain a lead of about 100 ft. before Tunnels A and C opened out into soft ground, in order that a blow from one tunnel might not extend to the other. Work in Tunnel C was shut down on December 23d, 1905, after exposing sand to a depth of 3 ft. at the top, and it remained closed for seven weeks. Work in Tunnel A was suspended on September 29th, 1905. By the time Tunnel B had made the required advance, it, together with Tunnels C and D, was overtaxing the capacities of the compressor plant. Only a little work was done in Tunnel C until July, 1906, and work in Tunnel A was not resumed until October 22d, 1906.