Documents pédagogiques internes au Mastère TOS TUNNEL BORING MACHINES: TYPES AND CRITERIA FOR TBM SELECTION. FOR TBM SELECTION.

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1 MASTERE SPECIALISE TUNNELS et OUVRAGES SOUTERRAINS De la conception à l exploitation TUNNEL BORING MACHINES: TYPES AND CRITERIA FOR TBM SELECTION. Dr. Karin Bäppler Herrenknecht AG, Germany SELECTION OF TUNNELLING MACHINE SYSTEMS. RECOMMENDED STEPS IN THE DECISION MAKING PROCESS. Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 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 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 SELECTION OF TBM TYPE TO BE USED FOR SOFT/ HARD ROCK. RELEVANT PARAMETERS FOR THE EVALUATION OF MACHINE TYPE. 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 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 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 Complex, changing geological conditions Diameter Three and four-lane road tunnels Multi-purpose tunnels Perspectives Support pressure development Innovative directions GEOTECHNICS. INFLUENCE OF GEOLOGY AND HYDROGEOLOGY. 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 soil bearing capacity, soil stabilization soil disposal Selection of machine and operation principle Success of project GEOLOGY + HYDROGEOLOGY GEOTECHNICS wear prognosis torque calculation 1

2 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. Open Mode MOVING TOWARDS MULTIMODE. THREE BASIC SHIELDED TBM SYSTEMS. Single Shield TBM Soft ground TBMs TRAFFIC TUNNELLING. ALL TECHNOLOGIES ABOVE 6 m. 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 MIXSHIELD. Conversion integrated modular Closed Mode Slurry Shield EPB Shield MODE Slurry Compressed Air EPB Hard Rock 2

3 WE OFFER THE COMPLETE RANGE IN MECHANIZED TUNNELLING. TUNNELLING WITHOUT TUNNEL SUPPORT. For all Demands and every Geology. For all Media and Traffic Systems. All Sizes and Technologies. All Services as a Full Service Provider. Cast-in-place TUNNEL LINING. Tunnel lining Shotcrete Bolting Concrete Concrete segments Block segment Trapezoidal segment Precast Immediate ground support Steel segments SHIELDED TBMs. GENERAL ASPECTS OF SEGMENTAL CONCRETE TUNNEL LINING. Tail Skin Tail Skin sealing Grouted Material... A precast concrete lining for a TBMdriven tunnel generally comprises a sequence of rings placed side-by-side. One ring is divided into sectors so called segments. Shotcrete In-situ concrete Segments TUNNELLING WITH FINAL TUNNEL SUPPORT. Shotcrete robot INSTALLATION OF SEGMENTS BY THE SEGMENT ERECTOR. TBM Advance 3

4 SEGMENT ERECTOR FOR RING BUILDING. SEGMENT ERECTOR. RING BUILDING. Suction plate (vacuum). Segment grab (mechanical). Mechanical erector: BACKFILLING OF THE ANNULAR GAP. PURPOSE OF ANNULAR GAP BACKFILLING. Filing of the annular gap between the outer lining surface and the tunnel wall serves the following functions: In the short term: In the long term: Ensures effective bedding of the Ensures the most uniform bedding lining against the enclosing ground. between the lining and the ground. Minimizes surrounding ground In certain special cases it deformations which can cause provides an additional seal. settlements both above and below ground. Vacuum erector: DIMENSIONS OF 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. The conical form of the shield. The ground displacement in curves. The overcut. REQUIREMENTS OF AN EFFECTIVE BACKFILLING MATERIAL. Back-filling material must be: Sufficiently fluid to facilitate its placement and to fill completely the annular gap. Sufficiently i firm to avoid leakage through h 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. 4

5 CONVENTIONAL BACKFILLING METHODS. GROUTING OF THE ANNULAR GAP THROUGH THE TAILSKIN IS TODAY S STATE OF THE ART. Through the lining by means of holes incorporated in the segment structure. soil Shield tail annular gap Grouting at the rear end of the shield tail through integrated grout pipes arranged longitudinally within the tail. BACK FILLING. GROUTING THROUGH THE TAILSKIN. MATERIALS FOR ANNULAR GAP BACKFILLING AND PHYSICAL PROPERTIES OF GROUTS IN TERMS OF HARDENING TIME. segment ring BACK FILLING. GROUTING THROUGH THE TAILSKIN. MACHINE DESIGN. SPECIAL ATTENTION IN RESPECT OF GROUND CONDITIONS. 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 High groundwater pressure Low overburden Underpassing of waterways, existing buildings and structures Presence of gas Karst formations Swelling Squeezing 5

6 SOFT GROUND TBMs. APPLICATION RANGE OF EPB AND MIXSHIELDS. APPLICATION RANGE: FLUID SUPPORTED SHIELD. Sieve Size Silt Sand Gravel Clay Fine Medium Coarse Fine Medium Coarse Fine Medium Coarse ,001 0,002 0,006 0,02 0,06 0,2 0,6 2,0 6, ,0 Grain diameter d (mm) EPB Methods Mixshield Methods MIXSHIELD. GENERAL LAYOUT. 1. Submerged wall 3 2. Working chamber 3. Air cushion 1 4. Pressure bulkhead 2 4 ACCURATE FACE PRESSURE CONTROL VIA AIR BUBBLE PRINCIPLE. ng [%] Percent Passin Fluid-Supported CLAY SILT fine medium coarse B Anti-clogging-measures es, high separation effort 0,002 0,006 0,02 0,06 fine SAND medium coarse A Standard application + separation 0,2 Particle Size [mm] fine GRAVEL medium coarse C Face support difficult: suspension+fillers MIXSHIELDS. SUPPORT PRESSURE REGULATION. THE 2 MODELS FOR TRANSMITTING THE CONFINEMENT PRESSURE TO THE TUNNEL FACE (SLURRY SHIELDS). Membrane model 0, Penetration model slurry soil slurry soil ΔP Filter cake formed Pure penetration 6

7 MIXSHIELD. CREATION OF A FILTER CAKE. FUNCTION OF BENTONITE SUSPENSION IN MIXSHIELD TECHNOLOGY. Thickness of filter cake: 4% loose bedding, low compactness 5% medium dense bedding 6% loose bedding, high compactness FLUID SUPPORTED SHIELD (HYDRO SHIELD, SLURRY SHIELD). SLURRY CIRCUIT FEED LINE. 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. SLURRY CIRCUIT. SLURRY CIRCUIT DISCHARGE LINE. 7

8 CLASSIFICATION OF THE DIFFERENT TYPES OF MATERIAL TRANSPORT. SEPARATION TECHNOLOGY. SEPARATION STEPS. Gravel Coarse sand Medium grained sand Fine sand Silt Sticky soil Preliminary sieve X X X V homogeneous transport V pseudo homogeneous transport V heterogeneous transport REQUIRED INFORMATION FOR THE DESIGN OF A SEPARATION PLANT. TBM diameter Average and maximum TBM advance speed Total quantity m³/h Grain size distribution curve up to 2µm Maximum grain size Information about the geology Possibilities for disposal of excavated material Requirement of customer (e.g. space requirement, sound proofing, ). COHESIVE SOIL CONDITIONS (HIGH FINES CONTENT, STICKY SOIL). COUNTER MEASURES. Center cutter Flow optimization High flushing pressure Bypass flushing Distribution of flushing nozzles in the working chamber Geometric design of cutting wheel spokes Geometric design of the working chamber (material flow) Chemical additives Agitators Roller crushers 1. Hydrocyclone-Stage Dewatering sieve 2. Hydrocyclone-Stage Dewatering sieve Centrifuge/filtration x IC [-] Improved slurry circuit and flushing medium stiff ve ry stiff hard X X tunnel face X X X COHESIVE SOIL CONDITIONS (HIGH FINES CONTENT, STICKY SOIL). IDENTIFICATION OF CLOGGING POTENTIAL. Consistency Index 1,50 1,40 1,30 1, ,10 1,00 0,90 0,80 0,70 0,60 0,50 0,40 0,30 soft High potential for clogging Medium potential for clogging Low potential for clogging cutterhead arm Plasticity Index I P [%] X X clay clogging at cutting tools Figure by: M. Thewes ACTIVE CENTRE CUTTER. TORQUE REDUCTION OF THE CUTTERHEAD. 158% 100% cutterhead rim Without Centre Cutter With Centre Cutter In case of EPB Shields eventual clogging is countered by the conditioning with foam and/or bentonite 0 Torque of the cutterhead (mto) 8

9 MIXSHIELD. STONE CRUSHER TO HANDLE BLOCKS, BOULDERS OR BIG CLAY LUMPS. MUCK FLOW/ BULK CONTROL. COMPARING THEORETICAL AND ACTUALLY EXCAVATED AMOUNTS OF SOIL. Conveyor belt scale Laser scanning Flow meter Density sensors MASTERING NATURAL AND ARTIFICIAL OBSTACLES. SYSTEM FOR SEISMIC PROBING AHEAD. Detection of anomalies in coarse ground conditions with low fines. CHALLENGES IN MECHANIZED TUNNELLING. GROUNDWATER PRESSURE. S-246 Hallandsas Sweden Convertible Mixshield (Hard Rock Slurry) Diameter: 10,530mm Tunnel length: 2 x 5,500m Cutterhead power: 4,000kW Geology: Gneiss, Amphibolite, Diabase Dykes Customer: Skanska/Vinci JV CASE STUDIES. Geology Groundwater pressure Complex, changing geological conditions Diameter Three and four-lane road tunnels Multi-purpose tunnels Support pressure development 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 tunnel Static water pressure above 10 bar along the majority of the alignment Strict environmental (legal) restrictions on water inflow volume THE HALLANDSAS RIDGE. 9

10 16,00 Bar 14,00 Bar 12,00 Bar 10,00 Bar 8,00 Bar 6,00 Bar 4,00 Bar 2,00 Bar Test No. 1 Samson unit main drive Hallandsas time front pressure oil chamber leak chamber gear housing THE SOLUTION. FULL HYBRID TBM FOR DUAL MODE OPERATION. CUTTERHEAD DRIVE SEAL SYSTEM. For up to 13 bar Open mode with dry primary muck discharge system (TBM conveyor) Original size dynamic shop test up to 15 bar pressure was performed pressure (Bar) Open mode with (cyclic) pre- 10:37:32 10:39:33 10:41:34 10:43:35 10:45:36 10:47:37 10:49:38 10:51:39 10:53:40 10:55:41 10:57:43 10:59:44 11:01:46 11:03:47 11:05:48 11:07:50 11:09:51 11:11:52 11:13:53 11:15:54 11:17:55 11:19:56 11:21:57 11:23:58 11:25:59 11:28:00 11:30:01 11:32:03 11:34:04 11:36:05 11:38:06 11:40:07 11:42:08 11:44:09 11:46:10 11:48:11 11:50:12 excavation grouting g Open mode with (cyclic) preexcavation grouting in closed static conditions Closed mode with hydraulic (slurry) muck discharge system TUNNELLING AT HALLANDSAS: PUSHING THE LIMITS. Mid-tunnel breakthrough in the Mölleback Zone at June 8, CHALLENGES IN MECHANIZED TUNNELLING. LAKE MEAD INTAKE NO. 3 LAS VEGAS. TUNNELLING AT HALLANDSAS: PUSHING THE LIMITS. Breakthrough 1 st tube: August 25, CHALLENGES IN MECHANIZED TUNNELLING. GROUNDWATER PRESSURE. Sedimentary and volcanic geology Depth of the tunnel Potential for high groundwater inflows and high hydrostatic pressures. 10

11 LAKE MEAD INTAKE NO. 3 LAS VEGAS. LAKE MEAD INTAKE NO. 3. PROFILE OF INTAKE SYSTEM. CHALLENGE: WATER PRESSURE. 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. S-502 Lake Mead, Intake No. 3 Las Vegas USA Dual-Mode TBM - Hard Cutterhead power: 2,800kW Rock /Mixshield Geology: Basalt, sandstone, Diameter: 7,180mm amphibolite, conglomerate Tunnel length: 4,800m Customer: JV VTC (Impregilo S.p.A, S.A. Healy Company) LAKE MEAD INTAKE NO. 3. PROFILE OF INTAKE SYSTEM. PROBING AND PRE EXCAVATION GROUTING. Possible drill pattern ahead of the TBM Three permanently installed drill rigs Probing and drilling ahead of the face can be accomplished in open mode and closed mode conditions (blow-out preventer units) FINNETUNNEL GERMANY. closed mode Open mode Closed mode CHALLENGE: COMPLEX GEOLOGY. Finnetunnel, Germany Railway tunnel 2 Convertible Mixshield TBMs TBM North PROJECT OVERVIEW FINNETUNNEL. SEQUENCES OF TBM TUNNELLING. Hydro Mode Conversi on Conversi on Open Mode TBM South Hydro Mode Conversi on open mode STP OPERATION STP (SLURRY TREATMENT PLANT) 11

12 RECONSTRUCTION CLOSED MODE OPEN MODE. DISASSEMBLY SLURRY SET. CHALLENGE: TUNNELLING UNDER THE VALLEY SCHNECKTAL. Locks Crusher Pipes CHALLENGE: TUNNELLING UNDER THE VALLEY SCHNECKTAL. 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. 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 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. Overburden of only 4.2m Fissured and brittle stratum at tunnel crown along the section of low overburden Low strength sediments CHALLENGE: TUNNELLING UNDER THE VALLEY SCHNECKTAL. 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 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. ANALYSIS ADVANCE PERFORMANCES, OPEN CLOSED MODE. Advance performance in open mode limited due to segment production 110 rings/week S-419: Breakthrough Sept months prior to schedule S-420: Breakthrough Febr months prior to schedule 12

13 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. Open Mode EPB Slurry Slurry EPB CHALLENGE: LARGE DIAMETER AND MULTI PURPOSE. SMART, Kuala Lumpur, Malaysia Ø 13.21m, Mixshield Silberwald, Moscow, Russia Ø 14.20m, Mixshield Nanjing, China Ø 14.93m, Mixshield M30 Madrid, Spain Ø 15.20m, EPB Shield Shanghai Changjiang, China Ø 15.43m, Mixshield Galleria Sparvo, Italy Ø 15.55m, EPB Shield THE CONVERTIBLE MIXSHIELD. Mixshield Mode EPB Mode THE SMART IDEA. MULTI FUNCTION TUNNEL IN KUALA LUMPUR. 13

14 THE SMART IDEA. SMART TUNNEL KUALA LUMPUR. GEOLOGICAL CONDITIONS. S-252 and S-253 SMART Kuala Lumpur Malaysia 2 Mixshields Shield diameter: 13,210mm Tunnel length: 9,350m Geology: Limestone, sand, marble Customers: MMCEG-Gamuda JV; Wayss+Freytag AG POSSIBLE EXPLOARTION DRILLINGS FOR KARSTIC ZONES THROUGH THE SHIELD. CONTROLLED BORING PROCESS (CBP) CONTROL FOR MORE SAFETY. Guide parameters from interdisciplinary processing of geotechnical, geodetic and machine data Online visualization of tunnelling 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 EFFICIENT SOFT GROUND TUNNELLING WITH ELECTRONIC WEAR DETECTION SYSTEM. Actual information about cutting tool wear Economical tool change Limited damage on steel structure TUnIS CBP TUNNEL AND UNDERGROUND INTEGRATED SOFTWARE STRUCTURE FOR CBP. machine (PLC) data reporting module geotechnical data geology Navigation design data Module (n) Module (n+1) Module (n+2) Module (n+3) TUnIS data base structure with basic functions Individual implementation of expert modules Expandable as and when required 14

15 SMART TUNNEL KUALA LUMPUR. PERFORMANCES IN METERS PER MONTH. CUTTING WHEEL INTERVENTIONS. SAFETY ASPECTS. S th Tube Elbe Tunnel Hamburg Germany 1 Mixshield, Ø14.20m Tunnel length: 2,560m 4 th ELBE RIVER TUNNEL HAMBURG GERMANY S th Elbe River Tunnel Hamburg Germany Mixshield Diameter: 14,200mm Tunnel length: 2,650m Cutterhead power: 3,400kW 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 DEMANDING GEOLOGY UNDER THE ELBE RIVER. S-317 and S-318 Changjiang Under River Tunnel Shanghai China 2 Mixshields, Ø15.43m Tunnel length: 7,170m each S-349 and S-350 Nanjing China 2 Mixshields, Ø14.93m Tunnel length: 2,933m each CONNECTION TO THE EXISTING TUNNEL TUBES. ONE OF THE MAJOR TECHNICAL INNOVATIONS. CUTTING TOOL CHANGE IN FREE AIR. Access to the main arm of the cutting wheel under atmospheric pressure Operator undertakes maintenance procedure s without the risk of having to work at the tunnel face Back loading cutting tools 15

16 THE WORLD S LARGEST MIXSHIELDS. ACCESSIBLE CUTTING WHEEL SPOKES FOR TOOL CHANGE IN FREE AIR. S-317 and S-318 Changjiang Under River Tunnel Shanghai China 2 Mixshields Shield diameter: 15,430mm Cutterhead power: 3,500kW Tunnel length: 7,170m each Geology: Sand, clay, shell debris End user: Shanghai Changjiang Tunnel & Bridge Construction Co., Ltd. A CHALLENGING TIME SCHEDULE. Date of contract: February 8, 2005 Start tunnelling S-317: September 2006 S-318: December 2006 Breakthrough S-317: May 2008 S-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 THE WESTERSCHELDE ROAD TUNNEL PROJECT, THE NETHERLANDS. SHANGHAI, CHINA. BREAKTHROUGH OF THE WORLD S LARGEST MIXSHIELDS 12 AND 10 MONTH EARLIER THAN SCHEDULED. S-317 May 28, 2008 S-318 September 5, 2008 GEOLOGY AT WESTERSCHELDE. PRESSURE OF UP TO 7.5 BAR. 16

17 MACHINE FEATURES AGAINST CLOGGING BEHAVIOR. WORKING IN UP TO 7.5 BAR. 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 Diver Capacity: 4 BREAKTHROUGH AFTER 6.6 KILOMETERS. SUPPORT PRESSURE DEVELOPMENT. TYPES OF DIVING APPLICATIONS DEPENDING ON REQUIRED FACE SUPPORT PRESSURE. PERSPECTIVES. SUPPORT PRESSURE DEVELOPMENT. ACCESSIBLE CUTTING WHEEL. KEY BENEFITS. Atmospheric access to cutting tools Easy access to information about wear of each cutting tool and steel structure Drastic reduction of hyperbaric interventions Possibility to flange man lock to center Possibility to increase pressure within the accessible cutting wheel 17

18 EPB SHIELD. THROUGH SOFT GROUND WITH EARTH PRESSURE. EARTH PRESSURE BALANCED SHIELD. OPERATIONAL PRINCIPLE. EARTH PRESSURE BALANCED SHIELD. FACE PRESSURE CONTROL. Closed Mode EPB OPERATION MODES. CLOSED MODE, SEMI OPEN MODE, OPEN MODE. Semi open mode or Compressed Air Mode 1. Tunnel face 8 2. Cutting wheel 1 3. Excavation chamber 4. Pressure bulkhead 4 5. Thrust cylinders 6. Screw conveyor Erector Segment lining 5 EPB CLAY SILT SAND GRAVEL fine medium coarse fine medium coarse fine medium coarse ng [%] Percent Passin ,002 0,006 APPLICATION RANGE: EPB SHIELD. 1 Water for consisten tency, foam for stickiness 0,02 2 Foam 3 Foam + Polymers, water pressure < 2 bar 4 Foam + Polymers + fines, no water pressure 0,06 0,2 0, Particle Size [mm] EPB SHIELD. SOIL REQUIREMENTS. To be useable as support medium, the soil has to fulfil following requirements: Open Mode Capability to extrude. Cohesive and plastic. Soft to stiff consistency. Lower inner angle of friction. Low water permeability. Good elasticity. 18

19 EPB SHIELD. CHOICE OF CONDITIONING. EPB SHIELD. INJECTION MATERIAL. If the soil requirements are not existing, the soil has to be conditioned. The conditioning is dependent on following soil parameters: Grain size distribution. Water content, w (%). Liquid limit, w L (%). Plasticity Index, I P and Consistency Index, I C. EARTH PRESSURE BALANCED SHIELD. APPLICATION RANGE AND NEED FOR CONDITIONING. 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. 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. STATORS FOR MIXING AND CONDITIONING OF EXCAVATED MATERIAL. Stators for mixing excavated material Bentonite. Water. Polymers. Foam. 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. EPB SHIELD. FOAM INJECTION POINTS. ADVANTAGES OF CONDITIONING. SOFT GROUND. Low density. Optimum mixing with soil. Reduction of internal friction. Reduction of cutting wheel torque. Reduce soil adhesion to metal of shield/ cutting wheel. Reduce soil permeability. Reduction of wear. Higher temporary face stability. 19

20 CONDITIONING OF SOFT SOIL WITH FOAM. ADVANTAGES OF CONDITIONING. HARD ROCK. 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. Low cohesive sand Short-term cohesion via foam BARCELONA, SPAIN: SAFE INNERCITY TUNNELLING WITH LARGE DIAMETER TBMs IN VARIABLE SOILS. BARCELONA, SPAIN. S-221 Metro Line 9 Barcelona Spain EPB Shield Shield diameter: 12,060mm Cutterhead power: 4,000kW Tunnel length: 8,500m Geology: Granodiorite, Sand, Clay, Gravel Customer: Dragados, Necso, ACS, Comsa, Sorigue Foam for structuring BARCELONA, SPAIN. BARCELONA: RISK CONTROL WITH LARGE DIAMETER TBMs, DENSITY OF DEVELOPMENT, VARIABLE SOILS. Tunnel profile for a doubledeck metro tunnel (with platform in the station area) Sensible structure with density of fbuildings Variable, geological conditions: Soft and hard rock, boulders, groundwater High abrasivity due to variable geology Gorg 20

21 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 ONE OF THE WORLD S LARGEST EPB SHIELD. EBP Shield Diameter: 15,200mm Tunnel length: 3,600m Cutterhead power: 12,000kW + 2,000kW Geology: Clay, gypsum Customer: Ferrovial Agroman, S.A., Acciona Infrastructuras REQUIRED MACHINE CHARACTERISTICS. Required cutting wheel drive torque of 125,000,000Nm Limitation of the shield roll due to the high installed torque Agitating of the excavated 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 THE MACHINE DESIGN. Two independent drive units allowing counter clockwise rotation 32 foam generators with a max capacity of 700m³/h Three screw conveyors with a capacity of 2x900m³/h and 1x250m³/h 21

22 MUCK CONTOL. BELT WEIGHING SYSTEM. LASER SCANNER FOR MUCK CONTROL. FROM SCHWANAU TO MADRID IN 3 MONTHS. 3 vessels on the Rhine River to Rotterdam 1 vessel Rotterdam Alicante 1 vessel Rotterdam - Bilbao 102 trucks directly Germany - Madrid Reassembly of equipment on jobsite 24h/7 days within 12 weeks June 2, 2004 Machine ordered at Herrenknecht Feb. 2, 2005 Beginning of workshop assembly June 6, 2005 Workshop acceptance Nov. 5, 2005 Start of Tunnelling July 17, 2006 Breakthrough March 23, 2007 Inauguration Zeit Ring 50 SPEED TUNNELLING IN MADRID. Completion of the advance in 8.5 months, 3.5 months Cycle times for excavation of 2m length incl. ring erection EUROPE. ITALY. GALERIA SPARVO parallel road tunnels, each with 3 lanes Extending the highway between Bologna and Florence Challenge: Large diameter and geological conditions 22

23 THE WORLD S LARGEST TUNNEL BORING MACHINE. S 441 ESCALATOR SHAFT ST. PETERSBURG RUSSIA. Galeria Sparvo Italy EPB Shield Ø: 15,550mm Cutterhead power: 12,000kW Tunnel length: 2 x 2,500m End user: Joint venture of Toto Costruzioni Generali, Vianini Lavori and Profacta S 441 ESCALATOR SHAFT ST. PETERSBURG RUSSIA. Single Gripper-TBM: S-155 Tscharner, 9.53m HARD ROCK TBMs. S-441 Escalator Shaft St. Petersburg Russia EPB Shield Tunnel length: 120m Diameter: 10,690mm Geology: Soft and hard clay Cutterhead power: 1,200kW Customer: OAO Metrostroy 30 S 512 AND S 514 BRISBANE AIRPORT LINK BRISBANE AUSTRALIA. S-512 and S-514 Brisbane Airport Link Brisbane Australia 2 EPB Shields Diameter: 12,450mm Tunnel length: 2,422m each Geology: Brisbane tuff, weathered zones Customer: Thiess Pty. Ltd., John Holland Engineering Pty. Ltd. CUTTERHEAD. EXCAVATION AND MUCKING. Double Gripper-TBM: S-96 TBM 3000, 3.00m Shielded-TBM with articulation joint: S-163 Sörenberg, 4.56m Double Shield-TBM: S-153 La Réunion, 3.80m 23

24 HARD ROCK CUTTING PROCESS. HARD ROCK TBM. DISC CUTTERS. center disc cutter double ring disc cutters HARD ROCK TBM. CUTTERHEAD DESIGN. HOUSING. Disc Steel structure Bearing cutterhead housing HARD ROCK TBM. CUTTING PROCESS. CHIPPING. Spacing influences: Number of disc cutters Chip size Loads on cutters Spacing Loads on cutterhead Penetration Wear behavior disc cutter single ring disc cutters HARD ROCK TBM. CUTTING PROCESS. CHIPPING. Spacing 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 24

25 HARD ROCK EXCAVATION. CUTTER GROUP ARRANGEMENT. Backloading cutters B1 A1 A2 A1 Higher Cutterloads B1 Larger Diameters B2 C1 D1 C1 Cutterhousing & Structure Buckets Cutter Handling CUTTER HANDLING. CUTTERHEAD ACCESS. D2 C2 C2 D1 D2 A2 B2 CUTTERHEAD DETAILS. CUTTER HANDLING. 25

26 BACKLOADING CUTTERHEAD. CUTTER EXCHANGE. INSA Lyon ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS SINGLE SHIELDED HARD ROCK TBM INSA Lyon ENTPE SINGLE SHIELDED HARD ROCK TBMs. MS TUNNELS ET OUVRAGES SOUTERRAINS SINGLE SHIELD TBM. THRUST RING. Swiss system : double lining Perschling, Austria m Wienerwald, Austria m Islisberg, Switzerland m INSA Lyon ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS INSA Lyon ENTPE TUNNEL LINING SYSTEM FOR TBM USE. Double-shell MS TUNNELS ET OUVRAGES SOUTERRAINS ADVANTAGES OF THE SINGLE SHELL SEGMENT LINING. Single-shell High quality of the precast segments High load capacity shortly after ring erection Easy detection of leakages and easy repair work Lower costs than for a double shell lining (no inner lining) Real loads on inner lining are not clear [Girmscheid 2000] INSA Lyon ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS INSA Lyon ENTPE MS TUNNELS ET OUVRAGES SOUTERRAINS

27 DOUBLE SHELL LINING WITH SEGMENTS AND IN SITU CAST INNER LINING. SINGLE SHIELD TBM. THRUST RING. Necessary for: Swing support roller Water tunnels (fresh water, headrace tunnels and sewers) with high requirements for water tightness Water tunnels with high water pressure Tunnels for the transport of dangerous materials (f.i. nuclear fluids) to protect the sealing Special loads SINGLE SHIELD TBM. THRUST RING. Withdrawal of the thrust ring and placing of the bottom segments. Placing of the left and right tunnel side wall segments. Placing of the crown segment Spreading of the bottom segments and placing of the key stone. Pushing forward of the thrust ring and pea gravel injection in the annular gap. SWITZERLAND: TUNNEL DU MONT RUSSELIN. S-60 Single Shield Hard Rock TBM Diameter 11,740mm Tunnel length: 3,550m Road Tunnel Thrust ring FIRST LARGE DIAMETER IN HARD ROCK. S-56 N 3 Bözberg, Aarau Switzerland Single Shield Hard Rock TBM Diameter: 11,800mm Tunnel length: 2x 3,200m PAJARES. S-287 Single Shield Hard Rock TBM Diameter 9,900mm Tunnel length 7,650+ 2,750m S-281 Double Shield Diameter 10,160mm Tunnel length 10,700+ 3,700m 27

28 DOUBLE SHIELD TECHNOLOGY FOR HARD ROCK TUNNELLING. GUADARRAMA. S-201/202 Double Shield TBM Diameter 9,510mm Tunnel length 14, ,428m S 373 CABRERA SPAIN. S-373 Cabrera Spain Double Shield TBM Diameter: 9,690mm Tunnel length: 2 x 6,200m Geology: Limestone Client: FCC Construcción S.A.; Construcciones Sanchez Dominguez- Sando S.A. NORTH SOUTH BYPASS TUNNEL. BRISBANE. HIGH SPEED TUNNELLING IN SPAIN. S 373 CABRERA. Daily best performance: 105.6m / 66 rings Weekly best performance: 435m / 290 rings 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 TBMs Diameter: 12,340mm Tunnel length: 3,997m + 3,932m Geology: Welded tuff, Arenites, Phyllites with quartz veins, faulted rock Customer: Baulderstone Hornibrook; Bilfinger Berger AG; Leighton Contractors 28

29 GRIPPER TECHNOLOGY FOR HARD ROCK TUNNELLING. APRIL 16, BREAKTHROUGH S-376 FLORENCE IN WOOLLOONGABBA. GRIPPER TBM. TUNNEL SUPPORT IN WORKING AREA L1. GRIPPER TBM. TUNNEL SUPPORT IN WORKING AREA L1. GRIPPER TBM. TUNNEL SUPPORT IN WORKING AREA L1. Anchoring and steel arching GRIPPER TBM. TUNNEL SUPPORT IN WORKING AREA L1. Exploratory Anchoring drilling Fix installed probe drilling unit Pivot anchor / injection drilling unit 29

30 GRIPPER TBM. TUNNEL SUPPORT IN WORKING AREA L1. WIRE MESH ERECTOR. WIRE MESH ERECTOR. AUTOMATIC SHOTCRETE ROBOT L2. LÖTSCHBERG BASE TUNNEL. 2000: S-167 Steg and S-174 Raron 9,430mm diameter, 18,850m tunnel in total In operation since 2007 ROCK SAFETY CONCEPT. GOTTHARD BASE TUNNEL. 85km of mechanized tunnelling in total Up to approx. 2,500m overburden Tectonically active massif (alps folding) 30

31 GOTTHARD BASE TUNNEL. CHALLENGES. Bodio Faido / Faido Sedrun 2 Gripper TBM Diameter: 8,830mm (9,430mm) Cutterhead power: 3,500kW Tunnel length: 49,839m Costomer: Consorzio TAT (Implenia Industrial Construction, Alpine Bau GmbH, CSC Impresa Costruzioni SA, Hochtief AG, Impregilo SpA) Amsteg Sedrun / Erstfeld - Amsteg 2 Gripper TBM Diameter: 9,580 mm Cutterhead power: 3,500kW Tunnel length: 35,687m Customer: AGN (STRABAG AG Tunnelbau Schweiz (CH)/ STRABAG AG (A)) MODIFICATIONS DUE TO EXPERIENCES MADE DURING EXCAVATION OF SECTION BODIO. 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. 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. 40 INCLINE FOR HYDROELECTRIC POWER. 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. 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. 40 INCLINE TUNNEL FOR HYDROELECTRIC POWER. S-575 Linth Limmern Switzerland Gripper-TBM Diameter: 5,200mm Tunnel length: 2 x 1,000m Cutterhead power: 2,205kW Geology: limestone Incline: 85% 40 Customer: Marti Tunnelbau TENDENCIES IN MECHANIZED TUNNELLING. 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) 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. 31

32 PERSPECTIVES. INNOVATIVE DIRECTIONS. PERSPECTIVES. Escalators shafts Tunnel renovation: - Road Tunnels - Railway tunnels VSM Vertical Shaft Sinking - Offshore - U-Park SBS Shaft Boring System THANK YOU FOR YOUR ATTENTION. Now and in the future: Demand for high-efficient infrastructure Push for innovations: - Safety, cost effectiveness, efficiency, integrated package solutions - 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) 32