05.09.2011 1 TUNNEL BORING MACHINES: TYPES AND CRITERIA FOR TBM SELECTION MASTERE SPECIALISE TUNNELS et OUVRAGES SOUTERRAINS De 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 Systems Classification scheme for tunnelling machines Geological consideration for TBM selection Overview machine types Case studies Geology Groundwater pressure Groundwater pressure Complex, changing geological conditions Diameter Three and four-lane road tunnels Multi-purpose tunnels Perspectives Support pressure development Innovative 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 INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012 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 works water permeability soil conditioning tunnel face support support medium, increase of thrust forces handling of boulders overburden, settlement & heave tunnel alignment, gradient GEOTECHNICS. INFLUENCE OF GEOLOGY AND HYDROGEOLOGY. INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012 Selection of machine and operation principle Success of project soil bearing capacity, soil stabilization soil 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 c u , 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 E c , Earth pressure coefficient K 0 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 INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012 torque calculation GEOTECHNICS GEOLOGY + HYDROGEOLOGY INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012 wear prognosis Documents pédagogiques internes au Mastère TOS
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05.09.2011
1
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
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
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
torque calculation
GEOTECHNICS
GEOLOGY + HYDROGEOLOGY
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
wear prognosis
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CONCEPTIONAL OVERVIEW OF THE THREE MAIN PARAMETERS
INFLUENCING EXCAVATABILITY.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
TUNNELING MACHINES. CLASSIFICATION SCHEME ACCORDING TO DAUB FOR ALL TYPES OF TUNNELLING MACHINES.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
OVERVIEW MACHINE TYPES.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Single Shield TBM
Open Mode
Conversion
MOVING TOWARDS MULTIMODE.THREE BASIC SHIELDED TBM SYSTEMS.
Closed Mode
Slurry Shield EPB Shield
• integrated• modular
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
MODE
MIXSHIELD.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Slurry Compressed Air EPB Hard Rock
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3
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
TUNNELLING WITHOUT TUNNEL SUPPORT.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Tunnel lining
Cast-in-place PrecastImmediate ground
support
TUNNEL LINING.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Shotcrete Bolting Concrete Concrete segments
Steel segments
Block segment
Trapezoidal segment
....
Shotcrete
In-situ
Shotcrete robot
TUNNELLING WITH FINAL TUNNEL SUPPORT.
concrete
Segments
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
TBM Advance
INSTALLATION OF SEGMENTS BY THE SEGMENT ERECTOR.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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Suction plate (vacuum).Segment grab (mechanical).
SEGMENT ERECTOR FOR RING BUILDING.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Mechanical erector:
SEGMENT ERECTOR. RING BUILDING.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Vacuum erector:
BACKFILLING OF THE ANNULAR GAP.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
segment ring
BACK FILLING. GROUTING THROUGH THE TAILSKIN.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
BACK FILLING. GROUTING THROUGH THE TAILSKIN.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
MATERIALS FOR ANNULAR GAP‐BACKFILLING AND PHYSICAL PROPERTIES OF GROUTS IN TERMS OF HARDENING TIME.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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 .
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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
coarsemediumfinecoarsemediumfinecoarsemediumfine
GRAVELSANDSILTCLAY
coarsemediumfinecoarsemediumfinecoarsemediumfine
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
2
4
MIXSHIELDS.SUPPORT PRESSURE REGULATION.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
ACCURATE FACE PRESSURE CONTROL VIA AIR BUBBLE PRINCIPLE.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
slurry soil
Membrane model Penetration model
slurry soilΔP
THE 2 MODELS FOR TRANSMITTING THE CONFINEMENT PRESSURE TO THE TUNNEL FACE (SLURRY SHIELDS).
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Filter cake formed Pure penetration
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Thickness of filter cake:
4% loose bedding, low compactness
MIXSHIELD. CREATION OF A FILTER CAKE.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
SLURRY CIRCUIT.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
SLURRY CIRCUIT – FEED LINE.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
SLURRY CIRCUIT – DISCHARGE LINE.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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CLASSIFICATION OF THE DIFFERENT TYPES OF MATERIAL TRANSPORT.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Conveyor belt scale
Laser scanning
Flow meter
Density sensors
MUCK FLOW/ BULK CONTROL. COMPARING THEORETICAL AND ACTUALLY EXCAVATED AMOUNTS OF SOIL.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
MASTERING NATURAL AND ARTIFICIAL OBSTACLES.SYSTEM FOR SEISMIC PROBING AHEAD.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Detection of anomalies in coarse ground conditions with low fines.
Geology
Groundwater pressure
Complex, changing geological conditions
Di t
CASE STUDIES.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
,
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Mid-tunnel breakthrough in the Mölleback Zone at June 8, 2010.
TUNNELLING AT HALLANDSAS: PUSHING THE LIMITS.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Breakthrough 1st tube: August 25, 2010.
TUNNELLING AT HALLANDSAS: PUSHING THE LIMITS.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
CHALLENGES IN MECHANIZED TUNNELLING.
LAKE MEAD | INTAKE NO. 3 | LAS VEGAS.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Sedimentary and volcanic geology
Depth of the tunnel
Potential for high groundwater inflows and high hydrostatic pressures.
CHALLENGES IN MECHANIZED TUNNELLING.
GROUNDWATER PRESSURE.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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LAKE MEAD | INTAKE NO. 3 | LAS VEGAS.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
S-502 Lake Mead, Intake No. 3 | Las Vegas | USA
Dual-Mode TBM - Hard Rock /MixshieldDiameter: 7,180mmTunnel length: 4,800m
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Probing and drilling ahead of the face can be accomplished in open mode and closed mode conditions (blow-out preventer units)
CHALLENGE: COMPLEX GEOLOGY.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Finnetunnel, Germany
Railway tunnel
2 Convertible Mixshield TBMs
closed mode
FINNETUNNEL | GERMANY.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
open mode
Hydro‐Mode Conversion Open‐ModeTBM‐North
Conversion
PROJECT OVERVIEW FINNETUNNEL.SEQUENCES OF TBM TUNNELLING.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Hydro‐Mode ConversionTBM‐South
OPERATION STP (SLURRY TREATMENT PLANT)STP
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Locks Crusher
RECONSTRUCTION CLOSED MODE – OPEN MODE.DISASSEMBLY SLURRY‐SET.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Pipes
CHALLENGE: TUNNELLING UNDER THE VALLEY SCHNECKTAL.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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
CHALLENGE: TUNNELLING UNDER THE VALLEY SCHNECKTAL.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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
CHALLENGE: TUNNELLING UNDER THE VALLEY SCHNECKTAL.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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
CHALLENGE: TUNNELLING UNDER THE VALLEY SCHNECKTAL.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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SOCATOP, PARIS: ROAD TUNNEL FOR THE A86.
LARGE DIAMETER TUNNEL EXCAVATION IN DENSE URBAN AREA.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
SOCATOP, PARIS: TUNNEL CROSS SECTION.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
DIFFERENT GEOLOGICAL SOIL FORMATIONS ALONG THE TUNNEL
ALIGNMENT. CONVERTIBLE MACHINE PRINCIPLE.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
OpenMode EPB Slurry EPBSlurry
Mixshield Mode
THE CONVERTIBLE MIXSHIELD.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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S-252 and S-253 | SMART | Kuala Lumpur | Malaysia
THE SMART IDEA.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
5. Thrust cylinders
6. Screw conveyor7. Erector
8. Segment lining23
4
5
6 7
EARTH PRESSURE BALANCED SHIELD. FACE PRESSURE CONTROL.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
GRAVELSANDSILTCLAY
coarsemediumfinecoarsemediumfinecoarsemediumfine
ng[%
]
60
70
80
90
100
EPB
tency, foam for stickiness
ure
GRAVELSANDSILTCLAY
coarsemediumfinecoarsemediumfinecoarsemediumfine
ng[%
]
60
70
80
90
100
GRAVELSANDSILTCLAY
coarsemediumfinecoarsemediumfinecoarsemediumfine
GRAVELSANDSILTCLAY
coarsemediumfinecoarsemediumfinecoarsemediumfine
ng[%
]
60
70
80
90
100
EPB
tency, foam for stickiness
tency, foam for stickiness
ureure
APPLICATION RANGE: EPB SHIELD.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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
3Foam + Polymers, water pressure < 2 bar
3Foam + Polymers, water pressure < 2 bar
4Foam + Polymers + fines, no water pressure
4Foam + Polymers + fines, no water pressure
Closed Mode Semi open mode or Compressed Air Mode
EPB OPERATION MODES.
CLOSED MODE, SEMI OPEN MODE, OPEN MODE.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Water content, w (%).Liquid limit, wL (%).Plasticity Index, IP andConsistency Index, IC.
Bentonite.Water.Polymers.Foam.
EPB‐SHIELD. INJECTION MATERIAL.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
EPB‐SHIELD. STATORS FOR MIXING AND CONDITIONING OF EXCAVATED MATERIAL.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
shield/ cutting wheel.Reduce soil permeability.Reduction of wear.Higher temporary face stability.
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CONDITIONING OF SOFT SOIL WITH FOAM.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Foam for structuring
BARCELONA, SPAIN: SAFE INNERCITY TUNNELLING WITH LARGE
DIAMETER TBMs IN VARIABLE SOILS.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Gorg
BARCELONA, SPAIN.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
S-221 | Metro Line 9 | Barcelona |
Spain
EPB Shield
Shield diameter: 12,060mm
Cutterhead power: 4 000kW
BARCELONA, SPAIN.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Cutterhead power: 4,000kW
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
60 METERS / 40 RINGS PER DAY.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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APRIL 16, 2009.
BREAKTHROUGH S-376 FLORENCE IN WOOLLOONGABBA.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
GRIPPER TECHNOLOGY FOR HARD ROCK TUNNELLING.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
GRIPPER TBM. TUNNEL SUPPORT IN WORKING AREA L1.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Anchoring and steel arching
GRIPPER TBM. TUNNEL SUPPORT IN WORKING AREA L1.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
GRIPPER TBM. TUNNEL SUPPORT IN WORKING AREA L1.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
Fix installed probe drilling unit Pivot anchor / injection drilling unit
AnchoringExploratory drilling
GRIPPER TBM. TUNNEL SUPPORT IN WORKING AREA L1.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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GRIPPER TBM. TUNNEL SUPPORT IN WORKING AREA L1.
WIRE MESH ERECTOR.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
WIRE MESH ERECTOR.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
AUTOMATIC SHOTCRETE ROBOT L2.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
ROCK SAFETY CONCEPT.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
2000: S-167 Steg and S-174 Raron
9,430mm diameter, 18,850m tunnel in total
In operation since 2007
LÖTSCHBERG BASE TUNNEL.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
85km of mechanized tunnelling in total
Up to approx. 2,500m overburden
Tectonically active massif (alps folding)
GOTTHARD BASE TUNNEL.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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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)
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012
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.
INSA Lyon ‐ ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS 2011‐2012