2 Support of the cavity and settlement Support of the face Natural support Mechanical support...

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1 Table of Contents The authors... VII Foreword to the 2nd Edition... IX 1 Introduction Basic principles and terms Types of tunnel boring machine according to DAUB Categories of tunnelling machines German association for underground construction (TVM) Tunnel boring machines (TBM) Tunnel boring machines without shield (gripper TBM) Reamer tunnel boring machines (ETBM) Tunnel boring machines with single shield (TBM-S) Double shield machines (DSM) Shield machines (SM) Shield machines with full-face excavation (SM-V) Shield machines with partial face excavation (SM-T) Adaptable shield machines with combined process technology (KSM) Special types Blade shields Shields with multiple circular cross-sections Articulated shields Remarks about the individual types of tunnelling machines with diagrams Tunnel boring machines (TBM) Double shield machines (DSM) Face without support (SM-V1) Face with mechanical support (SM-V2) Face with compressed air (SM-V3) Face with slurry support (SM-V4) Face with earth pressure support (SM-V5) Face without support (SM-T1) Face with partial support (SM-T2) Face with compressed air support (SM-T3) Face with slurry support (SM-T4) Adaptable machines (KSM) Origins and historical developments Support of the cavity and settlement Support of the face Natural support Mechanical support Mechanised Shield Tunnelling, 2nd Edition B. Maidl, M. Herrenknecht, U. Maidl, G. Wehrmeyer Copyright 2011 Ernst & Sohn, Berlin Buch 1.indb :14:19

2 XII Table of Contents Compressed air support Slurry support Earth support Calculation models Support of the cavity at the shield Support of the cavity behind the shield Settlement and damage classifications Empirical determination of the settlement Numerical models for the calculation of settlement Heave and compaction Design and calculation methods Constructional parts of the shield Loading on the shield Loading on the shield skin Loading on the pressure bulkhead Loading from the thrust cylinders Calculation of the necessary thrust force Resistance to advance through friction on the shield skin Resistance to advance at the front shield Resistance to advance at the face through platforms and excavation tools Resistance to advance with slurry support, earth support and compressed air support Resistance to advance from steering the shield Summary Empirical values for the dimensioning of the shield and the thrust cylinders Calculation and dimensioning basics Regulations and recommendations for the design of shields Excavation tools and excavation process Excavation tools Hand-held tools Cutting edges Scrapers Drag picks, flat chisels, round chisels, rippers Disc cutters, discs Buckets Excavation process Tunnelling without cutting wheel Manual digging Partial-face mechanical excavation Mechanical full-face excavation Hydraulic excavation Alternative excavation processes Buch 1.indb :14:19

3 Table of Contents XIII 5 Muck removal Preparation for transport Removal from the face Open shield machines Shield machines with pressure chamber Transport along the tunnel and up shafts Open transport Piped transport Quantity determination and measuring equipment Separation Separating process Separating devices Suitability of the muck for landfill The tunnel lining General Construction principles for the tunnel lining Single-layer and Double-layer construction Watertight and water draining construction Segmental lining General Constructional variants Block segments with rectangular plan Hexagonal segments Rhomboidal and trapezoidal segment systems Expanding segments Yielding lining systems Joint details Longitudinal joints Ring joints Steel fibre concrete segments Filling of the annular gap Filling with gravel Mortar grouting Measures to waterproof tunnels with segment linings Gaskets Grouting Production Damage Damage during ring building Damage while advancing the machine Damage in the shield tail seal Damage after leaving the shield Repair of damage Buch 1.indb :14:19

4 XIV Table of Contents 6.4 In-situ concrete lining General Construction Concreting Injected concrete, Extruded concrete Shotcrete layers as the final lining Structural calculations Shield tail sealing, grouting works Shield tail seals Plastic seals Steel brush seals Outer shield tail seals Elastically supported face formwork for the extrusion process Grouting process Requirements Conception Grouting systems Grout Grouting for ground improvement Machinery and equipment Grout Grouting work at the Channel Tunnel Open shields Shield construction Hand shields Part-face excavation Full-face excavation Projects Example: Eurotunnel under the English Channel, 1988 to Arrowhead Tunnel Double shields [203] Development Functional principle Special features Shield skin and bentonite lubrication Telescopic shield Examples Compressed air shields Functional principle Compressed air facilities Air locks Compressed air supply Compressed air regulations Buch 1.indb :14:20

5 Table of Contents XV 9.3 Air requirement Determination of air requirement Verification of safety (blowout safety) Special processes Further developments Compressed air shield with unpressurised working space and full-face excavation Compressed air shield with unpressurised working spaces and part face excavation Membrane shield The use of compressed air with other types of shield Examples Old Elbe Tunnel next to the St. Pauli landing stage, 1907 to Energy supply tunnel under the Kiel Fjord, 1989/ Slurry shields Development history Functional principle Scope of application Machine types Full-face machines with fluid support Part face machines with slurry support Machine and process technology Soil excavation Muck transport Examples Westerschelde Lower Inn Valley railway, Münster/Wiesing Tunnel, main contract H3-4; Jenbach/Wiesing Tunnel, main contract H8, 2007 to Fourth bore of the Elbe Tunnel Chongming Earth pressure balance shields Development history Functional principle Support pressure measurement and control Soil conditioning Mass-volume control Areas of application Operating modes and muck transport Open mode (screw conveyor conveyor belt) Semi open mode (screw conveyor conveyor belt) Closed mode (hydraulic mucking circuit) EPB mode (screw conveyor conveyor belt or screw conveyor piston pump) Open mode (conveyor belt) Buch 1.indb :14:20

6 XVI Table of Contents 11.5 Components Cutting wheel Bearing and drive construction Excavation chamber Screw conveyor Foam conditioning Examples Katzenberg Tunnel on the new railway line Karlsruhe Basel, 2005 to Madrid M-30 (Bypass Sur Tunnel Nord) Heathrow DTSS Singapore Convertible shields or multi mode machines Development strategies Convertible shield with integrated components for multiple operating modes Building block systems Machine concepts Mixshield Polyshield Examples Grauholz Tunnel, 1990 to Zürich Thalwil contract Socatop Special shields and special processes Blade shields Face support with blade shields Support types with blade shields Multi-face shields Arrangement of the cutting wheels in multi-face shields Tunnel support with multi-face shields Enlargement of shield tunnels Pipe jacking Pipe jacking Box jacking New concepts in mechanised shield tunnelling Shield machines for flexible cross-sections Ultra-flexible shield Horizontal and vertical shield machines Enlargement shields Rotation shields Shield docking method Buch 1.indb :14:20

7 Table of Contents XVII 14 Guided microtunnelling processes Pilot tube process Auger microtunnelling Shield microtunnelling English Mini Tunnel system New developments Surveying and steering Surveying Navigation with tunnel laser and automatic target unit Navigation with gyroscope system and hose water level Navigation with total station and automatic target unit Navigation with total station and prisms Ring design and calculation of the ring installation sequence Ring convergence measurement Steering Further surveying and data logging tasks Workplace safety General safety requirements Control stations Electrical cut-out and safety devices Control devices and control systems Towing connections Laser guidance Ventilation and the control of dust and gas Fire protection Storage of safety equipment for the personnel Maintenance Content of handbook Evaluation of risk in mechanised tunnelling [26] Partnering contract models and construction Introduction Requirements for the contract model Contract model according to VOB Time and cost drivers Under-pricing as a performance killer Chances and risks of partnering Partnering contractual implementation Partnering mutual process optimisation Process controlling and data management Introduction Procedure Data management Buch 1.indb :14:20

8 XVIII Table of Contents 18.4 Target-actual comparison Target process structure Analysis of the actual process DAUB recommendations for the selection of tunnelling machines Preliminary notes Regulatory works National regulations International standards Standards and other regulatory works Definitions and abbreviations Definitions Abbreviations Application and structure of the recommendations Categorisation of tunnelling machines Types of tunnelling machine (TVM) Tunnel boring machines (TBM) Tunnel boring machines without shield (Gripper TBM) Enlargement tunnel boring machines (ETBM) Tunnel boring machine with shield (TBM-S) Double shield machines (DSM) Shield machines (SM) Shield machines for full-face excavation (SM-V) Shield machines with partial face excavation (SM-T) Adaptable shield machines with convertible process technology (KSM) Special types Blade shields Shields with multiple circular cross-sections Articulated shields Support and lining Tunnel boring machines (TBM) Tunnel boring machines with shield (TBM-S), Shield machines (SM, DSM, KSM) Advance support Support next to the tunnelling machine Ground and system behaviour Preliminary remarks Ground stability and face support Excavation Sticking Wear Soil conditioning Soil separation Soil transport and tipping Environmental aspects Buch 1.indb :14:20

9 Table of Contents XIX 19.8 Other project conditions Scope of application and selection criteria General notes about the use of the tables Core area of application Possible areas of application Critical areas of application Classification in soft ground Classification in rock Notes about each type of tunnelling machine TBM (Tunnel boring machine) DSM (Double shield machines) SM-V1 (full-face excavation, face without support) SM-V2 (full-face excavation, face with mechanical support) SM-V3 (Full-face excavation, face with compressed air application) SM-V4 (full-face excavation, face with slurry support) SM-V5 (full-face excavation, face with earth pressure balance support) SM-T1 (partial excavation, face without support) SM-T2 (partial excavation, face with mechanical support) SM-T3 (partial excavation, face with compressed air application) SM-T4 (Partial excavation, face with slurry support) KSM (Convertible shield machines) Appendices Bibliography Index Buch 1.indb :14:20

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