SHORT COURSE KB Master Course Lyon November 2011 … 2011-2012... · 2012-01-16 · Dr. Karin Bäppler Herrenknecht AG, Germany TUNNEL BORING MACHINES: TYPES AND CRITERIA FOR TBM

05.09.2011

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TUNNEL BORING MACHINES: TYPES AND CRITERIA FOR TBM SELECTION

MASTERE SPECIALISE

TUNNELS et OUVRAGES SOUTERRAINSDe la conception à l’exploitation

FOR TBM SELECTION.

Dr. Karin Bäppler

Herrenknecht AG, Germany

TUNNEL BORING MACHINES: TYPES AND CRITERIA FOR TBM SELECTION.

Selection of Tunnelling Machine SystemsClassification scheme for tunnelling machines Geological consideration for TBM selectionOverview machine typesCase studies

GeologyGroundwater pressureGroundwater pressureComplex, changing geological conditions

DiameterThree and four-lane road tunnelsMulti-purpose tunnels

PerspectivesSupport pressure developmentInnovative directions

INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012

SELECTION OF TUNNELLING MACHINE SYSTEMS. RECOMMENDED STEPS IN THE DECISION MAKING PROCESS.

Step 1

Step 2

Step 3

Analysis of geotechnical reports and ground profiles (Basis:DIN4020)

Result: Preliminary choice of types of Tunnelling Machine

Analysis of system behavior (boreability, face stability, wear prognosis..)

Result: Basic requirements for excavation, face support, support medium. Localization of preliminary choice of TBM types

Classification of tunnel regarding feasible machine types

Result: Qualitative prognosis of suitable machine types along tunnel alignment


Step 4

Step 5

Step 6

Step 7

Analysis of muck behavior (stickiness, wear)

Result: Requirements for the muck transport system. Localization of preliminary TBM choice

Analysis of muck behavior in follow‐up systems (suitability as construction material or for landfill depositing)

Result: Requirements for further muck handling. Localization of preliminary choice

Definition of Excavation Classes: Final choice of TBM type

Division of tunnel in sections of similar behavior

Result: Tunnel profile with partitions, quantitative prognosis of excav. Classes, operational definitions, summary of characteristic ground parameters

Recommended steps by: DAUB

Geology or hydrogeology

affect the way and extent of

de‐watering workswater permeabilitysoil conditioningtunnel face supportsupport medium, increase of thrust forceshandling of bouldersoverburden, settlement & heave tunnel alignment, gradient

GEOTECHNICS. INFLUENCE OF GEOLOGY AND HYDROGEOLOGY.


Selection of machine and operation principle

Success of project

soil bearing capacity, soil stabilizationsoil disposal

Geological longitudinal profile with vertical alignment of the tunnel, groundwater table and possibly borehole locations

Horizontal alignment of the tunnel with borehole locations

Grain size distribution curve

Wet density γ, Angle of internal friction ϕ, Cohesion c, undrained cohesion cu, permeability k

Groundwater conditions

Atterberg Limits: plastic limit liquid limit natural water content (consistency and

SELECTION OF TBM TYPE TO BE USED FOR SOFT/ HARD ROCK. RELEVANT PARAMETERS FOR THE EVALUATION OF MACHINE TYPE.

Atterberg Limits: plastic limit, liquid limit, natural water content (consistency and plasticity indexes)

Modulus of elasticity Ec, Earth pressure coefficient K0

Possible existence of boulders: rock type, expected amount, expected sizes, UCS, quartz content, CAI

Unconfined Compressive Strength (UCS)

Tensile Strength

Cerchar Index (CAI, wear behaviour)

Max. Expected water inflows/ groundwater pressure


torque calculation

GEOTECHNICS

GEOLOGY + HYDROGEOLOGY


wear prognosis

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CONCEPTIONAL OVERVIEW OF THE THREE MAIN PARAMETERS

INFLUENCING EXCAVATABILITY.


TUNNELING MACHINES. CLASSIFICATION SCHEME ACCORDING TO DAUB FOR ALL TYPES OF TUNNELLING MACHINES.


OVERVIEW MACHINE TYPES.


Soft ground TBMs

TRAFFIC TUNNELLING.ALL TECHNOLOGIES ABOVE 6 m.

Soft ground TBMs

EPB-Shield (Earth Pressure Balanced Shield)

Mixshield.

Hard Rock TBMs

Shielded Hard Rock TBM (Single Shield, Double Shield)

Hard Rock Gripper TBM

Dual Mode TBMs


Single Shield TBM

Open Mode

Conversion

MOVING TOWARDS MULTIMODE.THREE BASIC SHIELDED TBM SYSTEMS.

Closed Mode

Slurry Shield EPB Shield

• integrated• modular


MODE

MIXSHIELD.


Slurry Compressed Air EPB Hard Rock

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WE OFFER THE COMPLETE RANGE IN MECHANIZED TUNNELLING.

For all Demands and every Geology.

For all Media and Traffic Systems.

All Sizes and Technologies.

All Services as a Full Service Provider.


TUNNELLING WITHOUT TUNNEL SUPPORT.


Tunnel lining

Cast-in-place PrecastImmediate ground

support

TUNNEL LINING.


Shotcrete Bolting Concrete Concrete segments

Steel segments

Block segment

Trapezoidal segment

....

Shotcrete

In-situ

Shotcrete robot

TUNNELLING WITH FINAL TUNNEL SUPPORT.

concrete

Segments


A precast concrete lining for a TBM-driven tunnel generally comprises asequence of rings placed side-by-side.One ring is divided into sectors socalled segments.

Tail Skin

Tail Skin sealing

Grouted Material

SHIELDED TBMs.GENERAL ASPECTS OF SEGMENTAL CONCRETE TUNNEL LINING.


TBM Advance

INSTALLATION OF SEGMENTS BY THE SEGMENT ERECTOR.


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Suction plate (vacuum).Segment grab (mechanical).

SEGMENT ERECTOR FOR RING BUILDING.


Mechanical erector:

SEGMENT ERECTOR. RING BUILDING.


Vacuum erector:

BACKFILLING OF THE ANNULAR GAP.


Are determined by:

The thickness of the shield shell.

The height of the shield tail seal.

The support construction of the shield tail seal.

DIMENSIONS OF ANNULAR GAP.


The conical form of the shield.

The ground displacement in curves.

The overcut.

Filing of the annular gap between the outer lining surface and the tunnel wall serves the following functions:

In the long term:

Ensures the most uniform bedding

In the short term:

Ensures effective bedding of the

PURPOSE OF ANNULAR GAP‐BACKFILLING.


gbetween the lining and the ground.

In certain special cases it provides an additional seal.

glining against the enclosing ground.

Minimizes surrounding ground deformations which can cause settlements both above and below ground.

Back-filling material must be:

Sufficiently fluid to facilitate its placement and to fill completely the annular gap.

S ffi i tl fi t id l k th h th hi ld t il l d t

REQUIREMENTS OF AN EFFECTIVE BACKFILLING MATERIAL.


Sufficiently firm to avoid leakage through the shield tail seals and segment water proofing gaskets.

Sufficiently firm to avoid seepage flows along the shield tail towards the front of the TBM.

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Through the lining by means of

holes incorporated in the

segment structure.

CONVENTIONAL BACKFILLING METHODS.


Grouting at the rear end of the

shield tail through integrated

grout pipes arranged

longitudinally within the tail.

annular gap

Shield tail

soil

GROUTING OF THE ANNULAR GAP THROUGH THE TAILSKIN IS TODAY’S STATE OF THE ART.


segment ring

BACK FILLING. GROUTING THROUGH THE TAILSKIN.


BACK FILLING. GROUTING THROUGH THE TAILSKIN.


MATERIALS FOR ANNULAR GAP‐BACKFILLING AND PHYSICAL PROPERTIES OF GROUTS IN TERMS OF HARDENING TIME.


Cohesive soil conditions (high fines content and sticky soil)

Blocks and boulders, layers of hard rock, obstacles

Mixed face conditions

Abrasive ground

Very coarse soil conditions

MACHINE DESIGN.SPECIAL ATTENTION IN RESPECT OF GROUND CONDITIONS .


High groundwater pressure

Low overburden

Underpassing of waterways, existing buildings and structures

Presence of gas

Karst formations

Swelling

Squeezing

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100

90

80

70

Sieve Size

FineClaySilt Sand Gravel

Medium MediumCoarse Fine Coarse Fine Medium Coarse

SOFT GROUND TBMs. APPLICATION RANGE OF EPB AND MIXSHIELDS.


EPB Methods Mixshield Methods

60,020.06,02,00,60,20,060,020,0060,0020,001

40

30

20

10

0

60

50

Grain diameter d (mm)

GRAVELSANDSILTCLAY

coarsemediumfinecoarsemediumfinecoarsemediumfine

ng[%

]

60

70

80

90

100

GRAVELSANDSILTCLAY


GRAVELSANDSILTCLAY


ng[%

]

60

70

80

90

100

Fluid-Supported

+ se

para

tion

+ se

para

tion

susp

ensio

n+fill

ers

susp

ensio

n+fill

ers

es, h

igh se

para

tion

effo

rt

es, h

igh se

para

tion

effo

rt

APPLICATION RANGE: FLUID‐SUPPORTED SHIELD.


Perc

entP

assi

n

Particle Size [mm]

0

10

20

30

60 10020620,60,20,060,020,0060,002

40

50

60

Perc

entP

assi

n

Particle Size [mm]

0

10

20

30

60 10020620,60,20,060,020,0060,002

40

50

60

ASt

anda

rd a

pplic

ation

+

ASt

anda

rd a

pplic

ation

+

CFa

ce su

ppor

t diffi

cult:

s

CFa

ce su

ppor

t diffi

cult:

s

BAn

ti-clo

gging

-mea

sure

s

BAn

ti-clo

gging

-mea

sure

s1. Submerged wall

2. Working chamber

3. Air cushion

4. Pressure bulkhead1

3

MIXSHIELD. GENERAL LAYOUT.


2

4

MIXSHIELDS.SUPPORT PRESSURE REGULATION.


ACCURATE FACE PRESSURE CONTROL VIA AIR BUBBLE PRINCIPLE.


slurry soil

Membrane model Penetration model

slurry soilΔP

THE 2 MODELS FOR TRANSMITTING THE CONFINEMENT PRESSURE TO THE TUNNEL FACE (SLURRY SHIELDS).


Filter cake formed Pure penetration

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Thickness of filter cake:

4% loose bedding, low compactness

MIXSHIELD. CREATION OF A FILTER CAKE.


p

5% medium dense bedding

6% loose bedding, high compactness

Support of the tunnel face by developing a filter cake for the

FUNCTION OF BENTONITE SUSPENSION IN MIXSHIELD TECHNOLOGY.


Support of the tunnel face by developing a filter cake for the transfer of the hydrostatic pressure. The air-pressure-stable filter cake enables the inspection of the tunnel face or maintenance works in the excavation chamber.

Transportation of the excavated material through powerful pumps in a slurry circuit to the separation plant on surface.

Keeping the dissolved soil in suspension, even during standstill of the shield.

FLUID‐SUPPORTED SHIELD (HYDRO SHIELD, SLURRY SHIELD).


SLURRY CIRCUIT.


SLURRY CIRCUIT – FEED LINE.


SLURRY CIRCUIT – DISCHARGE LINE.


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CLASSIFICATION OF THE DIFFERENT TYPES OF MATERIAL TRANSPORT.


V VV

homogeneous transport pseudo‐homogeneous

transportheterogeneous transport

XPreliminary sieve

Sticky soil

SiltFine sandMedium grained

sand

Coarse sand

Gravel

X X

SEPARATION TECHNOLOGY. SEPARATION STEPS.


Centrifuge/filtration

2. Hydrocyclone-StageDewatering sieve

1. Hydrocyclone-StageDewatering sieve

X X

X X X

X X

TBM diameterAverage and maximum TBM advance speedTotal quantity m³/hGrain size distribution curve up to 2µm

REQUIRED INFORMATION FOR THE DESIGN OF A SEPARATION PLANT.


to 2µmMaximum grain sizeInformation about the geologyPossibilities for disposal of excavated materialRequirement of customer (e.g. space requirement, sound proofing,…).

1 101,201,301,401,50

x I C

[-]

ry s

tiff

hard

tunnel face clay clogging at cuttingtools

cutte

rhea

drim

tunnel face clay clogging at cuttingtools

cutte

rhea

drim

Improved slurry circuit and flushing

COHESIVE SOIL CONDITIONS (HIGH FINES CONTENT, STICKY SOIL).IDENTIFICATION OF CLOGGING POTENTIAL.


0,300,400,500,600,700,800,901,001,10

0 10 20 30 40 50 60 70Plasticity Index IP [%]

Con

sist

ency

Inde

x

Low potential for clogging

Medium potential for clogging

High potential forclogging

med

ium

stiff

veso

ft

cutterhead arm

c

cutterhead arm

c

Figure by: M. Thewes

Center cutter

Flow optimization

High flushing pressure

Bypass flushing

Distribution of flushing nozzles in the working chamber

Geometric design of cutting wheel spokes

COHESIVE SOIL CONDITIONS (HIGH FINES CONTENT, STICKY SOIL).COUNTER‐MEASURES.


Geometric design of cutting wheel spokes

Geometric design of the working chamber (material flow)

Chemical additives

Agitators

Roller crushers

In case of EPB Shields eventual clogging is countered by the

conditioning with foam and/or bentonite

150150

200200

250250

158%158%

ACTIVE CENTRE CUTTER. TORQUE REDUCTION OF THE CUTTERHEAD.


00

5050

100100Without Centre CutterWithout Centre Cutter

With Centre CutterWith Centre Cutter

100%100%

Torque of the cutterhead (mto)Torque of the cutterhead (mto)

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MIXSHIELD. STONE CRUSHER TO HANDLE BLOCKS, BOULDERS OR BIG CLAY LUMPS.


Conveyor belt scale

Laser scanning

Flow meter

Density sensors

MUCK FLOW/ BULK CONTROL. COMPARING THEORETICAL AND ACTUALLY EXCAVATED AMOUNTS OF SOIL.


MASTERING NATURAL AND ARTIFICIAL OBSTACLES.SYSTEM FOR SEISMIC PROBING AHEAD.


Detection of anomalies in coarse ground conditions with low fines.

Geology

Groundwater pressure

Complex, changing geological conditions

Di t

CASE STUDIES.


Diameter

Three and four-lane road tunnels

Multi-purpose tunnels

Support pressure development

S-246 | Hallandsas | Sweden

Convertible Mixshield (Hard

Rock – Slurry)

Diameter: 10,530mm

CHALLENGES IN MECHANIZED TUNNELLING.

GROUNDWATER PRESSURE.


,

Tunnel length: 2 x 5,500m

Cutterhead power: 4,000kW

Geology: Gneiss,

Amphibolite, Diabase Dykes

Customer: Skanska/Vinci JV

Excavation of hard and abrasive rock mass

Zones of soft soil and mixed face conditions

Potential of high water inflow along the total length of the

THE HALLANDSAS RIDGE.


along the total length of the tunnel

Static water pressure above 10 bar along the majority of the alignment

Strict environmental (legal) restrictions on water inflow volume

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Open mode with dry primary muck discharge system (TBM conveyor)

Open mode with (cyclic) pre-excavation grouting

THE SOLUTION.

FULL HYBRID TBM FOR DUAL‐MODE OPERATION.


g g

Open mode with (cyclic) pre-excavation grouting in closed static conditions

Closed mode with hydraulic (slurry) muck discharge system

Test No. 1 Samson unit main drive Hallandsas 14.02.2005

2,00 Bar

4,00 Bar

6,00 Bar

8,00 Bar

10,00 Bar

12,00 Bar

14,00 Bar

16,00 Bar

10:3

7:32

10:3

9:33

10:4

1:34

10:4

3:35

10:4

5:36

10:4

7:37

10:4

9:38

10:5

1:39

10:5

3:40

10:5

5:41

10:5

7:43

10:5

9:44

11:0

1:46

11:0

3:47

11:0

5:48

11:0

7:50

11:0

9:51

11:1

1:52

11:1

3:53

11:1

5:54

11:1

7:55

11:1

9:56

11:2

1:57

11:2

3:58

11:2

5:59

11:2

8:00

11:3

0:01

11:3

2:03

11:3

4:04

11:3

6:05

11:3

8:06

11:4

0:07

11:4

2:08

11:4

4:09

11:4

6:10

11:4

8:11

11:5

0:12

time

pres

sure

(Bar

)

front pressure oil chamber leak chamber gear housing

For up to 13 bar

Original size dynamic shop test up to 15 bar pressure was performed

CUTTERHEAD DRIVE SEAL SYSTEM.


Mid-tunnel breakthrough in the Mölleback Zone at June 8, 2010.

TUNNELLING AT HALLANDSAS: PUSHING THE LIMITS.


Breakthrough 1st tube: August 25, 2010.

TUNNELLING AT HALLANDSAS: PUSHING THE LIMITS.



LAKE MEAD | INTAKE NO. 3 | LAS VEGAS.


Sedimentary and volcanic geology

Depth of the tunnel

Potential for high groundwater inflows and high hydrostatic pressures.


GROUNDWATER PRESSURE.


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LAKE MEAD | INTAKE NO. 3 | LAS VEGAS.


S-502 Lake Mead, Intake No. 3 | Las Vegas | USA

Dual-Mode TBM - Hard Rock /MixshieldDiameter: 7,180mmTunnel length: 4,800m

Cutterhead power: 2,800kWGeology: Basalt, sandstone, amphibolite, conglomerate Customer: JV VTC (Impregilo S.p.A, S.A. Healy Company)

TBM able to convert rapidly from an open-faced system to a closed pressurized system capable of withstanding potential hydrostatic pressures up to 17 bar maximum.

LAKE MEAD | INTAKE NO. 3. PROFILE OF INTAKE SYSTEM.

CHALLENGE: WATER PRESSURE.


Closed modeOpen mode

Possible drill pattern ahead of the

TBM

Three permanently installed drill rigs

P bi d d illi h d f h

LAKE MEAD | INTAKE NO. 3. PROFILE OF INTAKE SYSTEM.

PROBING AND PRE EXCAVATION GROUTING.


Probing and drilling ahead of the face can be accomplished in open mode and closed mode conditions (blow-out preventer units)

CHALLENGE: COMPLEX GEOLOGY.


Finnetunnel, Germany

Railway tunnel

2 Convertible Mixshield TBMs

closed mode

FINNETUNNEL | GERMANY.


open mode

Hydro‐Mode Conversion Open‐ModeTBM‐North

Conversion

PROJECT OVERVIEW FINNETUNNEL.SEQUENCES OF TBM TUNNELLING.


Hydro‐Mode ConversionTBM‐South

OPERATION STP (SLURRY TREATMENT PLANT)STP

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Locks Crusher

RECONSTRUCTION CLOSED MODE – OPEN MODE.DISASSEMBLY SLURRY‐SET.


Pipes

CHALLENGE: TUNNELLING UNDER THE VALLEY SCHNECKTAL.


Overburden of only 4.2m

Fissured and brittle stratum at tunnel crown along the section of low overburden

Low strength sediments

Measures to avoid collapse scenario in view of minimal overburden of only 4.5m:

Contractor grouted the rock from the surface to a point just above the tunnel roof via grouting holes



holes.

Performance of exploratory drillings and rock improvement measures

Drilled and grouted bolts and/or pipe arch from within the shield

Possibility of drilling through the



Possibility of drilling through the cutting wheel by means of a drilling platform via drilling ducts in the pressure bulkhead and/or submerged wall.

Possibility of drillings with inclinations of 8-10 degrees.

Performance of exploratory drillings and rock improvement measures

Drilled and grouted bolts and/or pipe arch from within the shield

Possibility of drilling through the



Possibility of drilling through the cutting wheel by means of a drilling platform via drilling ducts in the pressure bulkhead and/or submerged wall.

Possibility of drillings with inclinations of 8-10 degrees.

Advance performance in open mode limited due to segment production 110 rings/week

S-419: Breakthrough Sept. 09 4 months prior to schedule

S-420: Breakthrough Febr. 10 7 months prior to schedule

ANALYSIS ADVANCE PERFORMANCES, OPEN‐CLOSED MODE.


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SOCATOP, PARIS: ROAD TUNNEL FOR THE A86.

LARGE DIAMETER TUNNEL EXCAVATION IN DENSE URBAN AREA.


SOCATOP, PARIS: TUNNEL CROSS SECTION.


DIFFERENT GEOLOGICAL SOIL FORMATIONS ALONG THE TUNNEL

ALIGNMENT. CONVERTIBLE MACHINE PRINCIPLE.


OpenMode EPB Slurry EPBSlurry

Mixshield Mode

THE CONVERTIBLE MIXSHIELD.


EPB Mode

SMART, Kuala Lumpur, Malaysia Ø 13.21m, Mixshield

Silberwald, Moscow, RussiaØ 14.20m, Mixshield

Nanjing, ChinaØ 14 93m Mixshield

CHALLENGE: LARGE DIAMETER AND MULTI‐PURPOSE.


Ø 14.93m, Mixshield

M30 Madrid, Spain Ø 15.20m, EPB Shield

Shanghai Changjiang, ChinaØ 15.43m, Mixshield

Galleria Sparvo, ItalyØ 15.55m, EPB Shield

THE SMART IDEA. MULTI‐FUNCTION TUNNEL IN KUALA LUMPUR.


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S-252 and S-253 | SMART | Kuala Lumpur | Malaysia

THE SMART IDEA.


Lumpur | Malaysia

2 MixshieldsShield diameter: 13,210mmTunnel length: 9,350mGeology: Limestone, sand, marbleCustomers: MMCEG-GamudaJV; Wayss+Freytag AG

SMART TUNNEL KUALA LUMPUR. GEOLOGICAL CONDITIONS.


70 % traverses karstic limestone and sections in compact and fresh marble

30 % traverses quaternary alluvial deposits (silty, gravely sand) and mine tailings

Road tunnel section is marked red

POSSIBLE EXPLOARTION DRILLINGS FOR KARSTIC ZONES THROUGH THE

SHIELD.


EFFICIENT SOFT GROUND TUNNELLING

WITH ELECTRONIC WEAR DETECTION SYSTEM.


Actual information about cutting tool wear

Economical tool change

Limited damage on steel structure

Guide parameters from interdisciplinary processing of geotechnical, geodetic and machine data

CONTROLLED BORING PROCESS (CBP) ‐ CONTROL FOR MORE SAFETY.


and machine dataOnline visualization of tunnelling

mac

hine

(PLC

) da

tam

achi

ne(P

LC)

data

geot

echn

ical

data

geot

echn

ical

data

Nav

igat

ion

Nav

igat

ion

Mod

ule

(n)

Mod

ule

(n)

Mod

ule

(n+2

)M

odul

e (n

+2)

TUnIS CBP – TUNNEL AND UNDERGROUND INTEGRATED SOFTWARE STRUCTURE FOR CBP.


repo

rting

mod

ule

repo

rting

mod

ule

geol

ogy

geol

ogy

desi

gn d

ata

desi

gn d

ata

Mod

ule

(n+1

)M

odul

e (n

+1)

Mod

ule

(n+3

)M

odul

e (n

+3)

TUnIS data base structure with basic functions

Individual implementation of expert modules

Expandable – as and when required

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SMART TUNNEL KUALA LUMPUR.

PERFORMANCES IN METERS PER MONTH.


S-108 | 4th Tube Elbe Tunnel| Hamburg | Germany

1 Mixshield, Ø14.20mTunnel length: 2,560m

CUTTING WHEEL INTERVENTIONS. SAFETY ASPECTS.


S-317 and S-318 | Changjiang Under River Tunnel | Shanghai | China

2 Mixshields, Ø15.43mTunnel length: 7,170m each

S-349 and S-350 | Nanjing| China2 Mixshields, Ø14.93mTunnel length: 2,933m each

S-108 | 4th Elbe River Tunnel | Hamburg | Germany

Mixshield

Diameter: 14,200mmTunnel length: 2,650m


G l G l ilt d

4th ELBE RIVER TUNNEL | HAMBURG | GERMANY


Geology: Gravel, silt, sand,

boulders

Customer: Bilfinger Berger AG, Dyckerhoff & Widman AG,

Heitkamp GmbH, HOCHTIEF AG,

Philipp Holzmann AG, Wayss &

Freytag AG, Ed. Züblin AG

CONNECTION TO THE EXISTING TUNNEL TUBES.


DEMANDING GEOLOGY UNDER THE ELBE RIVER.


Access to the main arm of the cutting wheel under atmospheric pressure

Operator undertakes maintenance procedure’s

ONE OF THE MAJOR TECHNICAL INNOVATIONS.

CUTTING TOOL CHANGE IN FREE AIR.


pwithout the risk of having to work at the tunnel face

Back loading cutting tools

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S-317 and S-318 | Changjiang Under River Tunnel | Shanghai | China

2 Mixshields

Shield diameter: 15,430mm


THE WORLD’S LARGEST MIXSHIELDS.


Tunnel length: 7,170m each

Geology: Sand, clay, shell debris

End user: Shanghai ChangjiangTunnel & Bridge Construction Co., Ltd.

ACCESSIBLE CUTTING WHEEL SPOKES FOR TOOL CHANGE IN FREE AIR.


Date of contract: February 8, 2005

Start tunnelling S-317: September 2006 S-318: December 2006

BreakthroughS-317: May 2008

A CHALLENGING TIME SCHEDULE.


S 317: May 2008S-318: September 2008

In total 75,000 lining segments (16 t each) for 14,340m of tunnel.

Tunnel was opened for the traffic in time for the World Expo 2010.

SHANGHAI, CHINA. BREAKTHROUGH OF THE WORLD‘S LARGEST

MIXSHIELDS 12 AND 10 MONTH EARLIER THAN SCHEDULED.


S-317May 28, 2008

S-318September 5, 2008

THE WESTERSCHELDE ROAD TUNNEL PROJECT, THE NETHERLANDS.


GEOLOGY AT WESTERSCHELDE. PRESSURE OF UP TO 7.5 BAR.


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MACHINE FEATURES AGAINST CLOGGING BEHAVIOR.


Pressure chamber system for up to 12 divers and technicians enables divers a long-term stay under pressure

Transport shuttle:

Length: 2,500mm

Diameter: 1,300mm

WORKING IN UP TO 7.5 BAR.


Diver Capacity: 4

BREAKTHROUGH AFTER 6.6 KILOMETERS.


PERSPECTIVES. SUPPORT PRESSURE DEVELOPMENT.


SUPPORT PRESSURE DEVELOPMENT. TYPES OF DIVING APPLICATIONS DEPENDING ON REQUIRED FACE SUPPORT PRESSURE.


Atmospheric access to cutting tools

Easy access to information about wear of each cutting tool and steel structure

ACCESSIBLE CUTTING WHEEL. KEY BENEFITS.


Drastic reduction of hyperbaric interventions

Possibility to flange man lock to center

Possibility to increase pressure within the accessible cutting wheel

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05.09.2011

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EPB‐SHIELD. THROUGH SOFT GROUND WITH EARTH PRESSURE.


1. Tunnel face2. Cutting wheel

3. Excavation chamber

4. Pressure bulkhead1

8

EARTH PRESSURE BALANCED SHIELD. OPERATIONAL PRINCIPLE.


5. Thrust cylinders

6. Screw conveyor7. Erector

8. Segment lining23

4

5

6 7

EARTH PRESSURE BALANCED SHIELD. FACE PRESSURE CONTROL.


GRAVELSANDSILTCLAY


ng[%

]

60

70

80

90

100

EPB

tency, foam for stickiness

ure

GRAVELSANDSILTCLAY


ng[%

]

60

70

80

90

100

GRAVELSANDSILTCLAY


GRAVELSANDSILTCLAY


ng[%

]

60

70

80

90

100

EPB



ureure

APPLICATION RANGE: EPB SHIELD.


Perc

entP

assi

n

Particle Size [mm]

0

10

20

30

60 10020620,60,20,060,020,0060,002

40

50

60

1Water fo

r consisten

2Foam

3Foam + Polymers, water pressure < 2 bar

4Foam + Polymers + fines, no water pressure

Perc

entP

assi

n

Particle Size [mm]

0

10

20

30

60 10020620,60,20,060,020,0060,002

40

50

60

Perc

entP

assi

n

Particle Size [mm]

0

10

20

30

60 10020620,60,20,060,020,0060,002

40

50

60

1Water fo

r consisten

1Water fo

r consisten

2Foam

2Foam





Closed Mode Semi open mode or Compressed Air Mode

EPB OPERATION MODES.

CLOSED MODE, SEMI OPEN MODE, OPEN MODE.


Open Mode

To be useable as support medium, the soil has to fulfil following requirements:

Capability to extrude.Cohesive and plastic.

EPB‐SHIELD. SOIL REQUIREMENTS.


Soft to stiff consistency.Lower inner angle of friction.Low water permeability.Good elasticity.

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If the soil requirements are not existing, the soil has to be conditioned. The conditioning is dependent on following soil parameters:

Grain size distribution.

EPB‐SHIELD. CHOICE OF CONDITIONING.


Water content, w (%).Liquid limit, wL (%).Plasticity Index, IP andConsistency Index, IC.

Bentonite.Water.Polymers.Foam.

EPB‐SHIELD. INJECTION MATERIAL.


The initial state of the soil should be kept unchanged as possible; the consistency of the soil should guarantee the transport to the disposal site and should be economical.

Three main areas of conditioning:

Porous, non-cohesive soil: Conditioning required to get a plastic material to achieve a reliable earth pressure build-up in the working chamber.

EARTH PRESSURE BALANCED SHIELD. APPLICATION RANGE AND NEED FOR CONDITIONING.


Silty sands: Conditioning shows positive effects regarding the reduction of abrasion and the reduction of the torque. This enables higher advancement speed of the TBM.

Clay: Conditioning required to reduce clogging and adhesion problems

EPB‐SHIELD. FOAM INJECTION POINTS.


EPB‐SHIELD. STATORS FOR MIXING AND CONDITIONING OF EXCAVATED MATERIAL.


Stators for mixing excavated material

Low density.Optimum mixing with soil.Reduction of internal friction.Reduction of cutting wheel torque.Reduce soil adhesion to metal of

ADVANTAGES OF CONDITIONING. SOFT GROUND.


shield/ cutting wheel.Reduce soil permeability.Reduction of wear.Higher temporary face stability.

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CONDITIONING OF SOFT SOIL WITH FOAM.


Low cohesive sand

Short-term cohesion via foam

Reduction of dust.Reduction of blocked disc cutters, clean disc and faster tool change possible.Greater cooling effect with foam than with water.Lower wear, abrasion.Lower torque.

ADVANTAGES OF CONDITIONING. HARD ROCK.


Foam for structuring

BARCELONA, SPAIN: SAFE INNERCITY TUNNELLING WITH LARGE

DIAMETER TBMs IN VARIABLE SOILS.


Gorg

BARCELONA, SPAIN.


S-221 | Metro Line 9 | Barcelona |

Spain

EPB Shield

Shield diameter: 12,060mm

Cutterhead power: 4 000kW

BARCELONA, SPAIN.



Tunnel length: 8,500m

Geology: Granodiorite, Sand,

Clay, Gravel

Customer: Dragados, Necso,

ACS, Comsa, Sorigue

Tunnel profile for a double-deck metro tunnel (with platform in the station area)

Sensible structure with density f b ildi

BARCELONA: RISK CONTROL WITH LARGE DIAMETER TBMs, DENSITY OF

DEVELOPMENT, VARIABLE SOILS.


of buildings

Variable, geological conditions: Soft and hard rock, boulders, groundwater

High abrasivity due to variable geology

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MIXED TUNNEL FACE CONDITIONS. SOFT AND HARD ROCK AT TUNNEL

FACE IN BARCELONA.


60 METERS / 40 RINGS PER DAY.


S-300 | Road Tunnel M30 | Madrid | Spain

EBP ShieldDiameter: 15,200mmTunnel length: 3,600mCutterhead power:

ONE OF THE WORLD‘S LARGEST EPB SHIELD.


Cutterhead power: 12,000kW + 2,000kWGeology: Clay, gypsumCustomer: FerrovialAgroman, S.A., AccionaInfrastructuras


Required cutting wheel drive torque of 125,000,000Nm

Limitation of the shield roll due to the high installed torque

Agitating of the excavated

REQUIRED MACHINE CHARACTERISTICS.

material in order to prevent clogging in the centre area

Excavation and conditioning of 363m³ for an advance of 2m at a maximum speed of 65mm/min


Two independent drive units allowing counter clockwise rotation

32 foam generators with a max capacity of 700m³/h

Three screw conveyors with a

THE MACHINE DESIGN.

Three screw conveyors with a capacity of 2x900m³/h and 1x250m³/h


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05.09.2011

22

MUCK CONTOL. BELT WEIGHING SYSTEM.


LASER SCANNER FOR MUCK CONTROL.


3 vessels on the Rhine River to Rotterdam

1 vessel Rotterdam – Alicante

1 vessel Rotterdam - Bilbao

102 t k di tl G

FROM SCHWANAU TO MADRID IN 3 MONTHS.


102 trucks directly Germany -Madrid

Reassembly of equipment on jobsite 24h/7 days within 12 weeks

Completion of the advance in 8.5 months, 3.5 months

Cycle times for excavation of 2m length incl. ring erection

SPEED TUNNELLING IN MADRID.


0

100

200

300

400

500

50 100

150

200

250

300

350

400

450

500

550

600

650

700

750

800

850

900

950

1000

1050

1100

1150

1200

1250Ring

Zeit

Feb. 2, 2005Beginning of w

orkshop assembly

March 23, 2007

Inauguration

June 2, 2004M

achine ordered at H

errenknecht

June 6, 2005W

orkshop acceptance

Nov. 5, 2005

Start of Tunnelling

July 17, 2006Breakthrough


2005 2006 2007

EUROPE. ITALY. GALERIA SPARVO.


2 parallel road tunnels, each with 3 lanes

Extending the highway between Bologna and Florence

Challenge: Large diameter and geological conditions

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Galeria Sparvo | Italy

EPB Shield Ø:Cutterhead power: Tunnel length:

d

15,550mm

12,000kW 2 x 2,500m

THE WORLD‘S LARGEST TUNNEL BORING MACHINE.


End user: Joint venture of Toto CostruzioniGenerali, Vianini Lavoriand Profacta

S-441 | Escalator Shaft | St. Petersburg | Russia

EPB ShieldDiameter: 10,690mmCutterhead power: 1,200kW

Tunnel length: 120mGeology: Soft and hard clayCustomer: OAO Metrostroy

S‐441 |ESCALATOR SHAFT | ST. PETERSBURG | RUSSIA.


30°

S‐441 |ESCALATOR SHAFT | ST. PETERSBURG | RUSSIA.


S‐512 AND S‐514 | BRISBANE AIRPORT LINK | BRISBANE | AUSTRALIA.


S-512 and S-514 | Brisbane Airport Link | Brisbane | Australia

2 EPB ShieldsDiameter: 12,450mmTunnel length: 2,422m each

Geology: Brisbane tuff, weathered zonesCustomer: Thiess Pty. Ltd., John Holland Engineering Pty. Ltd.

Double Gripper-TBM:S-96 TBM 3000, ∅ 3.00m

Single Gripper-TBM:S-155 Tscharner, ∅ 9.53m

HARD ROCK TBMs.


Double Shield-TBM:S-153 La Réunion, ∅ 3.80m

Shielded-TBM with articulation joint:S-163 Sörenberg, ∅ 4.56m

CUTTERHEAD. EXCAVATION AND MUCKING.


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HARD ROCK CUTTING PROCESS.


HARD ROCK TBM. DISC CUTTERS.


center disc cutter

single ring disc cutters

double ring disc cutters

DiscSteel structure cutterhead

Bearing housing

HARD ROCK TBM. CUTTERHEAD DESIGN. HOUSING.


Spacing

HARD ROCK TBM. CUTTING PROCESS. CHIPPING.


Spacing

Spacing influences:

• Number of disc cutters

• Chip size

• Loads on cutters

Loads on cutterhead

HARD ROCK TBM. CUTTING PROCESS. CHIPPING.


• Loads on cutterhead

• Penetration

• Wear behavior disc cutter

HARD ROCK TBM. CUTTERHEAD DESIGN.


The cutterhead fulfills following functions:• Carrier of disc cutters

• Pick up of material at the tunnel face

• Supporting the tunnel face in case of falling rock

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Backloading cutters

Higher Cutterloads

Larger Diameters

HARD ROCK EXCAVATION.


Cutterhousing & Structure

Buckets

Cutter Handling

A1B1

D1C1

A1A2

B1

B2

C1

CUTTER GROUP ARRANGEMENT.


C2D2

A2 B2

C2

D1

D2

CUTTER HANDLING.


CUTTERHEAD DETAILS.


CUTTERHEAD ACCESS.


CUTTER HANDLING.


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BACKLOADING CUTTERHEAD. CUTTER EXCHANGE.


SINGLE SHIELDED HARD ROCK TBM.


SINGLE SHIELDED HARD ROCK TBMs.


Perschling, Austria. ∅12.98m

Wienerwald, Austria.∅10.695m

Islisberg, Switzerland. ∅11.805m

“Swiss system”: double lining

SINGLE SHIELD TBM. THRUST RING.


Double-shell Single-shell

TUNNEL LINING SYSTEM FOR TBM USE.


[Girmscheid 2000]

High quality of the precast segmentsHigh load capacity shortly after ring erectionEasy detection of leakages and easy repair work

ADVANTAGES OF THE SINGLE SHELL SEGMENT LINING.


Lower costs than for a double shell lining (no inner lining)Real loads on inner lining are not clear

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Necessary for:

Water tunnels (fresh water, headrace tunnels and sewers) with high requirements for water tightness

Water tunnels with high water pressure

DOUBLE SHELL LINING WITH SEGMENTS AND IN SITU CAST INNER LINING.


Water tunnels with high water pressure

Tunnels for the transport of dangerous materials (f.i. nuclear fluids) to protect the sealing

Special loads

Swing support roller



Thrust ring

Withdrawal of the thrust ring and placing of the bottom segments.

Placing of the left and right tunnel

Spreading of the bottom segments and placing of the key stone.

Pushing forward



and right tunnel side wall segments.

Placing of the crown segment

Pushing forward of the thrust ring and pea gravel injection in the annular gap.

S-56 | N 3 Bözberg, Aarau | Switzerland

Single Shield Hard Rock TBM

Diameter: 11,800mm

FIRST LARGE DIAMETER IN HARD ROCK.


Tunnel length: 2x 3,200m

S-60 Single Shield Hard Rock TBM

Diameter 11,740mm

Tunnel length: 3,550m

Road Tunnel

SWITZERLAND: TUNNEL DU MONT RUSSELIN.


S-287 Single Shield Hard Rock TBM

Diameter 9,900mm

Tunnel length 7,650+ 2,750m

PAJARES.


S-281 Double Shield

Diameter 10,160mm

Tunnel length 10,700+ 3,700m

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DOUBLE SHIELD TECHNOLOGY FOR HARD ROCK TUNNELLING.


S-201/202 Double Shield TBM

Diameter 9,510mm

Tunnel length 14,292 + 14,428m

GUADARRAMA.


S-373 | Cabrera | Spain

Double Shield TBM

Diameter: 9,690mm

Tunnel length: 2 x 6,200m

Geology: Limestone

S‐373 | CABRERA| SPAIN.


Geology: Limestone

Client: FCC Construcción S.A.; ConstruccionesSanchez Dominguez-Sando S.A.

Daily best performance: 105.6m / 66 rings

Weekly best performance: 435m / 290 rings

HIGH SPEED TUNNELLING IN SPAIN. S‐373 CABRERA.


Monthly best performance: 1688m / 1055 rings

NORTH‐SOUTH BYPASS TUNNEL. BRISBANE.


S-375 and S-376 | North-South Bypass Tunnel | Brisbane | Australia

2 Double Shield TBMsDiameter: 12,340mmTunnel length: 3,997m + 3,932m

Geology: Welded tuff, Arenites, Phyllites with quartz veins, faulted rockCustomer: Baulderstone Hornibrook; Bilfinger Berger AG; Leighton Contractors

NORTH‐SOUTH BYPASS TUNNEL. BRISBANE.


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APRIL 16, 2009.

BREAKTHROUGH S-376 FLORENCE IN WOOLLOONGABBA.


GRIPPER TECHNOLOGY FOR HARD ROCK TUNNELLING.


GRIPPER TBM. TUNNEL SUPPORT IN WORKING AREA L1.


Anchoring and steel arching





Fix installed probe drilling unit Pivot anchor / injection drilling unit

AnchoringExploratory drilling



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WIRE MESH ERECTOR.


WIRE MESH ERECTOR.


AUTOMATIC SHOTCRETE ROBOT L2.


ROCK SAFETY CONCEPT.


2000: S-167 Steg and S-174 Raron

9,430mm diameter, 18,850m tunnel in total

In operation since 2007

LÖTSCHBERG BASE TUNNEL.


85km of mechanized tunnelling in total

Up to approx. 2,500m overburden

Tectonically active massif (alps folding)

GOTTHARD BASE TUNNEL.


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Bodio – Faido / Faido – Sedrun

2 Gripper TBMDiameter: 8,830mm (9,430mm)Cutterhead power: 3,500kWTunnel length: 49,839mCostomer: Consorzio TAT (Implenia Industrial Construction, Alpine Bau GmbH, CSC ImpresaCostruzioni SA Hochtief AG Impregilo SpA)


Costruzioni SA, Hochtief AG, Impregilo SpA)

Amsteg – Sedrun / Erstfeld - Amsteg

2 Gripper TBMDiameter: 9,580 mmCutterhead power: 3,500kWTunnel length: 35,687mCustomer: AGN (STRABAG AG TunnelbauSchweiz (CH)/ STRABAG AG (A) )

The difference between the geologic prediction and the findings is great.The rock conditions have proven to be less favorable than expected.The relevance in terms of construction can change very quickly.

GOTTHARD BASE TUNNEL. CHALLENGES.


Strain redistributions can occur over 3x the excavation diameter in fault zones and zones with low rock strength.The tunnelling systems used are capable of mastering significantly more difficult situations than originally thought.

Enlargement of cutterhead (incl. diameter relevant parts) from 8.8m to 9.4m in respect of expected convergences and more intensive support measures.

Shifting of cutters to enlarge the cutterhead diameter to 9.5m.

Spiral arrangement of cutters.

MODIFICATIONS DUE TO EXPERIENCES MADE DURING

EXCAVATION OF SECTION BODIO.


p g

Increase number of cutters and buckets

Reinforcement of cutterhead shield and dust shield

Replacement main drive

Revision of motors, gear, hydraulic cylinders

Increasing the back-up by three wagons

S-575 | Linth Limmern | Switzerland

Gripper-TBMDiameter: 5,200mmTunnel length: 2 x 1,000m

40° INCLINE TUNNEL FOR HYDROELECTRIC POWER.


Cutterhead power: 2,205kWGeology: limestoneIncline: 85% 40°Customer: Marti Tunnelbau

S‐575 LINTH LIMMERN, SWITZERLAND.

40° INCLINE FOR HYDROELECTRIC POWER.


More complex challenges in terms of construction ground and logistics

Gotthard Base Tunnel (high rock overburden, fault zones, squeezing rock conditions), M30 Madrid (inner city tunnelling with Ø15.20m)

TENDENCIES IN MECHANIZED TUNNELLING.


Long tunnel drives with larger diameters under high groundwater pressure

Gotthard Base Tunnel (2x57km), Shanghai (Ø15.43m), Lake Mead (17bar)

Demand for well-engineered technology to produce high-capacity infrastructure systems.

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Escalators shafts

Tunnel renovation:

- Road Tunnels

- Railway tunnels

PERSPECTIVES. INNOVATIVE DIRECTIONS.


VSM – Vertical Shaft Sinking

- Offshore

- U-Park

SBS – Shaft Boring System

Now and in the future: Demand for high-efficient infrastructure

Push for innovations:

- Safety, cost effectiveness, efficiency, integrated package solutions

T h i l l ti f h ll

PERSPECTIVES.


- Technical solutions for every challenge

Large scale infrastructure schemes to benefit from economic stimulus plans

Teamwork Tunnelling to guarantee best possible project success: project owners, planers/ consultants, constructors, machine suppliers)

THANK YOU FOR YOUR ATTENTION.


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Documents

SHORT COURSE KB Master Course Lyon November 2011 … 2011-2012... · 2012-01-16 · Dr. Karin Bäppler Herrenknecht AG, Germany TUNNEL BORING MACHINES: TYPES AND CRITERIA FOR TBM